阅读说明：本技术 一种不规则形状部件的自动计数系统 (Automatic counting system for irregular-shaped components ) 是由 廖帮全 白家伟 于 2019-10-15 设计创作，主要内容包括：本发明涉及一种不规则形状部件的自动计数系统,其特征在于,包括光电转换系统、电压比较器、信号处理系统和显示系统,其中,光电转换系统包括红外光发射器、红外光接收器；红外光发射器作为照射光源；红外光接收器将照射到其上的红外光信号变成电信号；电压比较器用于将红外光接收器输出的电信号进行比较后变成高电平信号和低电平信号两种信号；信号处理系统用于将电压比较器输出的高电平信号或者低电平信号的出现次数进行处理,根据一定时间内电信号的高电平或者低电平的出现次数在单片机上增加一定的次数；单片机将总的计数值转化为字符串,传送给显示系统；显示系统用于显示计数值；本发明可广泛用于制造类企业自动化控制技术领域中。(The invention relates to an automatic counting system of an irregular-shaped component, which is characterized by comprising a photoelectric conversion system, a voltage comparator, a signal processing system and a display system, wherein the photoelectric conversion system comprises an infrared light emitter and an infrared light receiver; the infrared light emitter is used as an irradiation light source; the infrared light receiver changes the infrared light signal irradiated on the infrared light receiver into an electric signal; the voltage comparator is used for comparing the electric signals output by the infrared light receiver and then converting the electric signals into high-level signals and low-level signals; the signal processing system is used for processing the occurrence frequency of the high level signal or the low level signal output by the voltage comparator, and increasing a certain frequency on the singlechip according to the occurrence frequency of the high level or the low level of the electric signal within a certain time; the singlechip converts the total count value into a character string and transmits the character string to the display system; the display system is used for displaying the count value; the invention can be widely applied to the technical field of automatic control of manufacturing enterprises.)

1. The automatic counting system for the irregular-shaped parts is characterized by comprising a photoelectric conversion system, a voltage comparator, a signal processing system and a display system, wherein the photoelectric conversion system comprises an infrared light emitter and an infrared light receiver;

the infrared light emitter is used for emitting infrared light as a light source for irradiating the part to be counted;

the infrared light receiver is used for receiving infrared light and converting an infrared light signal irradiated on the infrared light receiver into an electric signal;

the voltage comparator is used for comparing the electric signals output by the infrared light receiver and then converting the electric signals into two signals, namely a high-level signal and a low-level signal;

the signal processing system is used for processing the occurrence frequency of the high level signal or the low level signal output by the voltage comparator, and increasing a certain frequency on the singlechip according to the occurrence frequency of the high level or the low level of the electric signal within a certain time; the singlechip converts the total count value into a character string and transmits the character string to the display system;

and the display system is used for displaying the count value transmitted by the signal processing system in real time.

2. The automatic counting system for irregular-shaped parts according to claim 1, wherein the relative positions of the parts to be counted in the photoelectric conversion system with respect to the infrared light emitter and the infrared light receiver include two positional relationships, one positional relationship is that the infrared light emitted from the infrared light emitter is directly irradiated onto the infrared light receiver in a normal state where the parts to be counted do not appear, and the infrared light emitted from the infrared light emitter is shielded from being irradiated onto the infrared light receiver when the parts to be counted appear; the other position relation is that the infrared light emitted by the infrared light emitter in the normal state that the part to be counted does not appear can not be irradiated on the infrared light receiver, and the infrared light emitted by the infrared light emitter is reflected to the infrared light receiver when the part to be counted appears;

the two position relations cause that the light intensity received by the infrared light receiver is different under the normal state that the irregular-shaped component to be counted does not appear and when the irregular-shaped component to be counted appears, and on the basis, the electric signal generated by the infrared light receiver also has two states;

the electric signals in the two states are compared by a voltage comparator and then two electric signals of a high level signal and a low level signal are output.

3. The automatic counting system for irregular-shaped parts according to claims 1 to 2, characterized in that the signal processing system comprises a single chip microcomputer and a signal processing algorithm;

the single chip microcomputer judges and counts the signal level transmitted from the voltage comparator in two modes, wherein one mode is that the single chip microcomputer counts when the signal level is judged to be high level within a certain time; the other mode is that when the signal level is judged to be low level within a certain time, the single chip microcomputer counts;

the signal processing algorithm comprises two modes, wherein one mode is that the initial time when the single chip microcomputer judges that the signal level is high level is used as a timing starting point, and no matter whether the signal level transmitted by the voltage comparator is high level or low level is uniformly used as high level within a certain duration after the time, and 1 count is added to a count value; the other mode is that the single chip microcomputer judges the initial time of low level as the starting point of timing, and no matter the signal level transmitted by the voltage comparator is high level or low level in a certain duration after the time, the signal level is uniformly taken as low level and 1 count is added to the count value;

in the signal processing algorithm, the duration of the level which is uniformly used as the timing starting point when the signal level transmitted by the voltage comparator is high level or low level after the timing starting point is started can be freely set according to the speed of the actual production process, and the setting range is 0.1 second to 9999 seconds; the duration may be set to remain the same for a given part production run, and different durations may be set for different part production runs.

4. The automatic counting system for irregular-shaped parts according to claims 1 to 3, characterized in that the light emitting part of the infrared light emitter is externally wrapped with a light limiting cylinder for limiting the range of the propagation direction of the emitted infrared light, and the length of the light limiting cylinder is in the range of 0.5 mm to 20 mm;

the light receiving front part of the infrared light receiver is provided with a light limiting cylinder for limiting the direction range of the received infrared light, and the length range of the light limiting cylinder is between 0.5 millimeter and 20 millimeters.

5. The automatic counting system for irregular-shaped parts according to claims 1 to 4, wherein the voltage comparator is used for comparing the electric signal output by the infrared light receiver with an adjustable threshold voltage to become a high-level signal and a low-level signal;

the voltage comparator can adopt a single limit comparator or a monostable circuit;

the threshold voltage is adjustable by a variable resistor;

the relative azimuth angle and the relative distance between the infrared light emitter, the irregular-shaped component to be counted and the infrared light receiver can be adjusted according to the surface area and the moving track of the irregular-shaped component to be counted, the power of the infrared light emitter and the photoelectric conversion efficiency of the infrared light receiver, and the adjustment standard is as follows: the output signal of the infrared light receiver can output two distinguishable difference levels of a high level and a low level after passing through the voltage comparator under two states of the existence of the irregular-shaped component to be counted and the nonexistence of the irregular-shaped component to be counted.

6. The automatic counting system for irregular-shaped parts as claimed in claims 1 to 5, wherein the single chip microcomputer converts the total count value into a character string and transmits the character string to the display system;

the display system can adopt a liquid crystal display screen or a digital tube to display the counting value.

Technical Field

The invention relates to an automatic counting system for irregular-shaped components, and belongs to the technical field of automatic control of manufacturing enterprises.

Background

The manufacturing enterprises need to effectively master the actual production quantity of the enterprises in each day or even each time period, and the counting problem is involved. The products produced by the manufacturing enterprise include regularly shaped parts and irregularly shaped parts. For regularly shaped parts, there are currently well established automatic counting systems. For example, a camera can be used to take a picture to obtain an image, and analysis software such as MATLAB is applied to perform analysis processing, so as to realize automatic counting of components. The photoelectric sensor can be combined with the PLC, the photoelectric sensor converts a non-electrical quantity signal into an electrical quantity signal, and further converts the electrical quantity signal into a standard signal to be transmitted to the PLC; the master control device PLC processes various data according to a designed program, sends the data to the upper computer for display and processing, and can receive parameters set by the upper computer for corresponding adjustment, thereby realizing the automatic counting of the components. The eddy current type proximity switch capable of detecting the metal object can be used, the oscillator of the proximity switch generates an alternating magnetic field, when the metal part to be detected passes through the proximity switch through the transmission belt, if the metal part enters the induction range of the proximity switch, eddy current is generated in the metal of the metal part, so that oscillation is attenuated to stop oscillation, and automatic counting is realized by using the change of the sensing signal. For some metal parts, it is also possible to use their conductive properties to automatically count them by measuring resistance.

However, for irregularly shaped parts, a large deviation is likely to occur when performing automatic counting using a conventional automatic counting method, and even a counting failure occurs, so that a failure of the automatic counting system occurs. For example, if an irregular part is a grab-shaped palm-shaped part which comprises a dome-shaped palm and five fingers with different lengths in a curved shape, and the automatic counting of such parts is performed, the counting results obtained when different parts are detected by the automatic counting system are different due to the random arrangement of the parts when the conventional counting method of regular parts is adopted. Conventional automatic counting systems count only 1 part when the palm is detected, 5 parts when all fingers are detected, 3 parts when a longer 3 fingers are detected, and so on.

Thus, many businesses still employ manual counting of counts for irregular parts. However, the manual counting method not only needs a lot of manpower and time, but also has the problems of low counting accuracy, incapability of reflecting the production quantity of parts in real time, no contribution to production management and the like.

Disclosure of Invention

In view of the above problems, it is an object of the present invention to provide an automatic counting system capable of real-time counting and accurate counting in the production process of irregularly shaped parts.

In order to achieve the purpose, the invention adopts the following technical scheme: the automatic counting system for the irregular-shaped parts is characterized by comprising a photoelectric conversion system, a voltage comparator, a signal processing system and a display system, wherein the photoelectric conversion system comprises an infrared light emitter and an infrared light receiver; the infrared light emitter is used for emitting infrared light as a light source for irradiating the part to be counted; the infrared light receiver is used for receiving infrared light and converting an infrared light signal irradiated on the infrared light receiver into an electric signal; the voltage comparator is used for comparing the electric signals output by the infrared light receiver and then converting the electric signals into two signals, namely a high-level signal and a low-level signal; the signal processing system is used for processing the occurrence frequency of the high level signal or the low level signal output by the voltage comparator, increasing a certain frequency on an internal counter according to the occurrence frequency of the high level or the low level of the electric signal within a certain time, converting the total count value into a character string and transmitting the character string to the display system; and the display system is used for displaying the count value transmitted by the signal processing system in real time.

Furthermore, the relative positions of the component to be counted in the photoelectric conversion system, the infrared light emitter and the infrared light receiver comprise two position relations, wherein one position relation is that infrared light emitted by the infrared light emitter directly irradiates the infrared light receiver under a normal state that the component to be counted does not appear, and when the component to be counted appears, the infrared light emitted by the infrared light emitter is shielded so that the infrared light cannot irradiate the infrared light receiver; the other position relationship is that the infrared light emitted by the infrared light emitter in the normal state that the component to be counted does not appear can not be irradiated on the infrared light receiver, and the infrared light emitted by the infrared light emitter is reflected to the infrared light receiver when the component to be counted appears. For the two position relations, the light received by the infrared light receiver is different in the normal state when the part to be counted does not appear and when the part to be counted appears, and on the basis, the electric signal generated by the infrared light receiver also has two states; the electric signals in two states are compared by a voltage comparator and then two electric signals of a high level signal and a low level signal are output.

Furthermore, an infrared light emitter light limiting cylinder is wrapped outside a light emitting part of the infrared light emitter in the photoelectric conversion system and is used for limiting the range of the transmission direction of the emitted infrared light; the light receiving front part of the infrared light receiver is wrapped with an infrared light receiver light limiting cylinder which is used for limiting the direction range of the received infrared light.

Further, the signal processing system comprises a single chip microcomputer and a signal processing algorithm; the single chip microcomputer judges and counts the signal level transmitted from the voltage comparator in two modes, wherein one mode is that the single chip microcomputer counts when the signal level is judged to be high level within a certain time; the other mode is that when the signal level is judged to be low level within a certain time, the single chip microcomputer counts; correspondingly, the signal processing algorithm comprises two modes, wherein one mode is that the initial time when the single chip microcomputer judges that the signal level is high is used as a timing starting point, and no matter whether the signal level transmitted by the voltage comparator is high or low is uniformly used as the high level within a certain duration after the time, and the count value on the single chip microcomputer is increased by 1 count; the other mode is that the initial time when the single chip microcomputer judges to be the low level is taken as a timing starting point, no matter the signal level transmitted by the voltage comparator is the high level or the low level in a certain duration after the time, the signal level is taken as the low level in a unified way, and the count value on the single chip microcomputer is increased by 1 count; in the signal processing algorithm, the duration of the level which is uniformly used as the timing starting point whether the signal level transmitted by the voltage comparator is high level or low level after the timing starting point is started can be freely set according to the speed of the actual production process; the duration may be set to remain the same for a given part production run, and different durations may be set for different part production runs.

Due to the adoption of the technical scheme, the invention has the following advantages: 1. the invention sets the duration time that the signal level transmitted by the voltage comparator is uniformly used as the level of the timing starting point no matter the signal level is high level or low level after the timing starting point of the counter starts, the duration time can ensure that a certain part of the irregular-shaped component can ensure that the numerical value of the singlechip does not change even if the rest part of the irregular-shaped component can enable the output signal of the voltage comparator to change between high level and low level after the singlechip starts counting; therefore, even if a certain irregular-shaped component can cause the optical signal received by the infrared light receiver to change for many times, the final singlechip is only 1 component, and automatic counting of the irregular-shaped component can be realized. 2. The duration of the level which is uniformly used as the timing starting point when the signal level transmitted by the voltage comparator is high level or low level after the timing starting point is started can be adjusted in a signal processing algorithm, so that the automatic counting system for the irregular-shaped components can be used in the production process of different irregular-shaped components, has the characteristic of strong adaptability, and can be widely applied to the field of counting the irregular-shaped components.

Drawings

FIG. 1 is a schematic structural diagram of an irregular-shaped component to be measured reflecting infrared light according to the present invention;

FIG. 2 is a schematic diagram of the structure of the irregular-shaped component to be measured for blocking infrared light according to the present invention.

Detailed Description

The present invention is described in detail below with reference to the attached drawings. It is to be understood, however, that the drawings are provided solely for the purposes of promoting an understanding of the invention and that they are not to be construed as limiting the invention.

As shown in fig. 1, the automatic counting system for irregular-shaped components reflecting infrared light by irregular-shaped components to be measured provided by the invention comprises a photoelectric conversion system 1, irregular-shaped components to be counted 2, a voltage comparator 3, a signal processing system 4 and a display system 5, wherein the photoelectric conversion system 1 comprises an infrared light emitter 11, an infrared light emitter light limiting cylinder 12, an infrared light receiver 13 and an infrared light receiver light limiting cylinder 14.

As shown in fig. 2, the automatic counting system for irregular-shaped components to be detected, which block infrared light, includes a photoelectric conversion system 1, an irregular-shaped component to be counted 2, a voltage comparator 3, a signal processing system 4, and a display system 5, where the photoelectric conversion system 1 includes an infrared light emitter 11, an infrared light emitter light limiting cylinder 12, an infrared light receiver 13, and an infrared light receiver light limiting cylinder 14.

Taking fig. 1 as an example of an automatic counting system for irregularly-shaped components to be counted, which reflect infrared light, an infrared light emitter 11 is an infrared light emitting device, and an infrared light emitter light limiting cylinder 12 is wrapped outside a light emitting part of the infrared light emitting device and used for limiting the range of the propagation direction of the emitted infrared light. The irregularly shaped parts to be counted 2 serve to reflect infrared light emitted by the infrared light emitter 1. The infrared light receiver 13 is for receiving infrared light reflected from the irregularly shaped component 2 to be counted; the light-receiving front part of the infrared light receiver 13 is covered with an infrared light receiver light limiting cylinder 14 for limiting the direction range of the received infrared light. The infrared light receiver 13 receives the infrared light signal, converts the infrared light signal into an electrical signal, and transmits the electrical signal to the input end of the voltage comparator 3 through a wire. The relative azimuth angle and the relative distance between the infrared light emitter 11, the irregular-shaped component 2 to be counted and the infrared light receiver 13 can be adjusted according to the surface area size and the moving track of the irregular-shaped component 2 to be counted, the power size of the infrared light emitter 11 and the photoelectric conversion efficiency of the infrared light receiver 13.

The voltage comparator 3 is used for comparing the electric signal output by the infrared light receiver 13 with an adjustable threshold value and then converting the electric signal into two signals, namely a high-level signal and a low-level signal. The voltage comparator 3 outputs a high level signal when the infrared light receiver 13 receives the voltage value of the electrical signal converted from the infrared light reflected from the irregularly shaped parts 2 to be counted is higher than the threshold value, and the voltage comparator 3 outputs a low level signal when the infrared light receiver 13 receives the voltage value of the electrical signal converted from the infrared light reflected from the irregularly shaped parts 2 to be counted is lower than the threshold value. The threshold voltage may be adjusted by a variable resistor.

The signal processing system 4 includes a single chip 41 and a signal processing algorithm 42. The one-chip microcomputer 41 judges and counts the level of the signal transmitted from the voltage comparator 3. When the signal level transmitted from the voltage comparator 3 is judged to be high, the single chip 41 counts. The initial time at which the single chip microcomputer 41 determines that the signal level is high in the signal processing algorithm 42 is used as the starting point of timing, and the signal level transmitted from the voltage comparator 3 is uniformly used as the high level and the count value is increased by 1 count in the single chip microcomputer within a certain duration after the initial time. The duration of the signal level transmitted from the voltage comparator 3 after the start of timing, whether the signal level is high or low, which is uniformly regarded as high, can be freely set according to the speed of the actual production process; the duration may be set to remain the same for a given part production run, and different durations may be set for different part production runs. The single chip 41 converts the total count value into a character string and transmits the character string to the display system 5.

The display system 5 is used for displaying the count value transmitted by the signal processing system 4 in real time.

In a preferred embodiment, the included angle between the infrared light emitter 11 and the infrared light receiver 13 is in a range of 40 degrees to 150 degrees, and the distance between the irregular-shaped component 2 to be counted and the infrared light emitter 11 and the infrared light receiver 13 is in a range of 100 millimeters to 300 millimeters. The length of the infrared light transmitter light limiting cylinder 12 and the infrared light receiver light limiting cylinder 14 ranges from 0.5 mm to 20 mm.

In a preferred embodiment, the voltage comparator 3 adopts a single limit comparator or a monostable circuit, and has a simple structure and high reliability.

In a preferred embodiment, the initial time when the single chip 41 in the signal processing algorithm 42 determines the high level is used as the timing starting point, and the duration of the signal level transmitted from the voltage comparator 3 after the timing starting point is uniformly regarded as the high level no matter the high level or the low level is set to be in the range of 1 second to 200 seconds, so that the counting requirement of the actual production process can be met from a slower production process to a faster production process.

In a preferred embodiment, the display system 5 uses a liquid crystal display or a digital tube to display the count value.

The automatic counting system of irregularly shaped parts of the invention is described in detail below by means of a specific embodiment:

the included angle between the infrared light emitter 11 and the infrared light receiver 13 is 100 degrees, the distance between the irregular-shaped component 2 to be counted and the infrared light emitter 11 and the infrared light receiver 13 is 200 millimeters, and the lengths of the infrared light emitter light limiting cylinder 12 and the infrared light receiver light limiting cylinder 14 are 1 millimeter; the signal processing algorithm 42 sets the initial time at which the single chip microcomputer 41 determines that the signal level is high as the timing start point, and sets the duration of the signal level transmitted from the voltage comparator 3 as the high level at all times as 3 seconds after the timing start point starts; 5 fingers of the palm are completely separated and straightened, 5 fingers and the palm sweep from the adjacent area of the irregular-shaped part 2 to be counted in the triangle formed by the infrared light emitter 11, the infrared light receiver 13 and the irregular-shaped part 2 to be counted, and the counting value of the display system 5 is increased by 1 when the hand sweeps 1 time no matter how the gesture formed by the fingers and the palm changes. This shows that the automatic counting system for irregularly shaped parts of the present invention can be used to automatically count irregularly shaped parts.

The above embodiments are only used for illustrating the present invention, and the structure, connection mode, manufacturing process, etc. of the components may be changed, and all equivalent changes and modifications performed on the basis of the technical solution of the present invention should not be excluded from the protection scope of the present invention.