鸡蛋电子称量分级包装生产线自动控制系统设计与试验
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摘要
鸡蛋质量分级是鸡蛋生产加工和销售前处理的重要工序之一,为了提高鸡蛋分级的生产效率和准确率,该文研究了一种用于鸡蛋电子称量、分级包装的同步跟踪自动控制系统,由称量部分、分级部分、装盘部分和自动送盘部分组成。利用一种32位嵌入式RISC处理器ARM同时采集多个通道传感器的鸡蛋质量信号并进行处理,将处理后的信息通过并行口送到可编程逻辑控制器PLC的寄存器,PLC对鸡蛋质量进行等级判断。利用限位开关脉冲作为数据传递的触发信号,然后利用编码器产生的高速脉冲实现对鸡蛋运动的位置精确定位,并控制相应的执行元件,配合机械装置的运动,解决了鸡蛋6排称量转单排线后的位置同步跟踪、对应电磁铁的准时动作和复位及分级之后鸡蛋自动装盘的难点,完成质量采集、分级卸料、装盘、送盘等动作,实现对不同质量等级范围鸡蛋的精确分级包装。试验结果表明,该控制系统测量误差在±1 g以内的鸡蛋占85.6%,分级准确率达到98%,生产效率为30 000枚/h,该研究结果有助于提高鸡蛋分级的生产效率,可为鸡蛋分级技术国产化提供参考。
It is generally known that egg weight classification is one of the most important processes of egg production,processing and sales.In order to improve the production efficiency and accuracy of egg grading,this paper introduces a synchronous tracking automatic control system,which is used for electronic weighing and grading packaging of eggs.This new system is based on the task group design of egg grading packaging machine,and composed of 4 parts,namely,a weighing part,a grading part,a loading plate part and an automatic feeding part.The egg grading packaging process includes egg weight detection,data processing,data communication,egg position synchronous tracking and quick boot and reset of electromagnet.Advanced RISC machines(ARM)are used to process egg weight signals collected by multiple-channel sensors,and the weight signal is intercepted in a stable period of time for about 70 ms after the simulation of filter,nonlinear correction,and frequency compensation.Then the system uses the average value to perform filter processing.Firstly the processing of information is through the free port communication protocol,which is sent to the programmable logic controller(PLC)of the register;secondly,the PLC controls to start the corresponding discharge electromagnet by judging the grade of egg weights.Then,as the reference signal frequency of external pulse,the high-speed pulse produced by the encoder precisely is applied to locate the position of the movement of the egg by using the method of data location transmission.Then the corresponding actuators are controlled together with the movement of the mechanical device,and the links of weight acquisition,classification of unloading,traying and sending the disc are completed to achieve accurate grading and packing for the eggs in different weight level range.Three hundred eggs are randomly selected as the experimental samples,and electronic scale weighs actual weight and records data.After using ARM to measure the weight of the egg,the weight information is sent to PLC,which is then real-time displayed in the upper computer and compared with the actual weight.At the same time,PLC controls the corresponding discharge solenoid action,so that the eggs of different weights can fall into the egg transfer tray of corresponding level.After we finish the measurement and grading of 300 eggs,each egg is tested continuously for 10 times and the data are recorded.The experimental results show that the weighing error of this control system is between-1 and 1g,which accounts for 85.6%;the weighing error of this control system is between-1.5 and 1.5 g,which accounts for 95.3%;and the classification accuracy rate reaches 98%.When the egg weight is at the boundary value of 2 levels,it is likely to be assigned to the wrong class because of the measurement error,which greatly affects the accuracy.The research results can help to improve the production efficiency of egg grading,which provides a reference for the localization of egg grading technology.
It is generally known that egg weight classification is one of the most important processes of egg production,processing and sales.In order to improve the production efficiency and accuracy of egg grading,this paper introduces a synchronous tracking automatic control system,which is used for electronic weighing and grading packaging of eggs.This new system is based on the task group design of egg grading packaging machine,and composed of 4 parts,namely,a weighing part,a grading part,a loading plate part and an automatic feeding part.The egg grading packaging process includes egg weight detection,data processing,data communication,egg position synchronous tracking and quick boot and reset of electromagnet.Advanced RISC machines(ARM)are used to process egg weight signals collected by multiple-channel sensors,and the weight signal is intercepted in a stable period of time for about 70 ms after the simulation of filter,nonlinear correction,and frequency compensation.Then the system uses the average value to perform filter processing.Firstly the processing of information is through the free port communication protocol,which is sent to the programmable logic controller(PLC)of the register;secondly,the PLC controls to start the corresponding discharge electromagnet by judging the grade of egg weights.Then,as the reference signal frequency of external pulse,the high-speed pulse produced by the encoder precisely is applied to locate the position of the movement of the egg by using the method of data location transmission.Then the corresponding actuators are controlled together with the movement of the mechanical device,and the links of weight acquisition,classification of unloading,traying and sending the disc are completed to achieve accurate grading and packing for the eggs in different weight level range.Three hundred eggs are randomly selected as the experimental samples,and electronic scale weighs actual weight and records data.After using ARM to measure the weight of the egg,the weight information is sent to PLC,which is then real-time displayed in the upper computer and compared with the actual weight.At the same time,PLC controls the corresponding discharge solenoid action,so that the eggs of different weights can fall into the egg transfer tray of corresponding level.After we finish the measurement and grading of 300 eggs,each egg is tested continuously for 10 times and the data are recorded.The experimental results show that the weighing error of this control system is between-1 and 1g,which accounts for 85.6%;the weighing error of this control system is between-1.5 and 1.5 g,which accounts for 95.3%;and the classification accuracy rate reaches 98%.When the egg weight is at the boundary value of 2 levels,it is likely to be assigned to the wrong class because of the measurement error,which greatly affects the accuracy.The research results can help to improve the production efficiency of egg grading,which provides a reference for the localization of egg grading technology.
引文
[1]江应红.国内外洁蛋生产装备对比分析与展望[J].中国禽业导刊,2009(14):44-45Jiang Yinghong.Analysis and prospect of domestic and international comparison of clean egg production equipment[J].Guide To Chinese Poultry,2009(14):44-45.(in Chinese with English abstract)
[2]王树才.我国蛋品加工装备制造业的发展之路[J].中国禽业导刊,2009,26(12):11-13.Wang Shucai.Egg processing equipment manufacturing industry development in China[J].Guide To Chinese Poultry,2009,26(12):11-13.(in Chinese with English abstract)
[3]范梅华,张建华.中国洁蛋生产和消费状况及对策[J].中国禽业导刊,2009,26(14):40-42.Fan Meihua,Zhang Jianhua.The status of clean egg production and consumption China and Countermeasures[J].Guide To Chinese Poultry,2009,26(14):40-42.(in Chinese with English abstract)
[4]张晨.基于单片机的禽蛋检测分级与包装控制系统研究[D].呼和浩特:内蒙古农业大学,2013.Zhang Chen.Control System of Egg-Quality Detecting and Grading Based on Single-Chip Microcomputer[D].Hohhot:Inner Mongolia Agricultural University,2013.(in Chinese with English abstract)
[5]武智慧,郁超,温鹿,等.禽蛋品质检测与分级中PLC控制系统的研究[J].内蒙古农业大学学报(自然科学版),2013(4):123-126.Wu Zhihui,Yu Chao,Wen Lu,et al.Development on the PLC control system for the egg quality inspection and grading[J].Journal of Inner Mongolia Agricultural University2013(4):123-126.(in Chinese with English abstract)
[6]黄永林,应义斌.用于水果实时分级系统的同步跟踪自动控制装置[J].农业工程学报,2002,18(4):163-166.Huang Yonglin,Ying Yibin.Controller for fruit synchronous tracking and auto-classification used in real-time fruit grading system[J].Transactions of the Chinese Society of Agricultural Engineering(Transactions of the CSAE),2002,18(4):163-166.(in Chinese with English abstract)
[7]应义斌,饶秀勤,黄永林,等.水果高速实时分级机构控制系统[J].农业机械学报,2004,35(5):117-121.Ying Yibin,Rao Xiuqin,Huang Yonglin,et al.Controller for real-time sorting mechanism of fruits[J].Chinese Journal of Mechanical Engineering,2004,35(5):117-121.(in Chinese with English abstract)
[8]蔡文.水果动态称量与自动化分选控制系统的研究与开发[D].杭州:浙江大学,2011.Cai Wen.Research and Development of the Control System for Fruit Dynamic Weighing and Automatic Sorting Lines[D].Hangzhou:Zhejiang University,2011.(in Chinese with English abstract)
[9]杨春伟.基于DSP的多通道禽蛋动态称量及分级控制研究与开发[D].杭州:浙江大学,2016.Yang Chunwei.Research and Development of Multichannel Egg Dynamic Weighing and Grading Control System Based on DSP[D].Hangzhou:Zhejiang University,2016.(in Chinese with English abstract)
[10]王松磊,刘民法,何建国,等.红枣自动快速无损检测分级机研究[J].农业机械学报,2014,45(9):79-83.Wang Songlei,Liu Minfa,He Jianguo,et al.Study of rapid and automatic non-destructive testing[J].Chinese Journal of Mechanical Engineering,2014,45(9):79-83.(in Chinese with English abstract)
[11]左兴建,武广伟.猕猴桃自动分级设备设计与试验[J].农业机械学报,2014,45(11):287-293.Zuo Xingjian,Wu Guangwei.Design and experiment on automatic grading machine for kiwi[J].Chinese Journal of Mechanical Engineering,2014,45(11):287-293.(in Chinese with English abstract)
[12]王树才,夏高兵,周雨程,等.禽蛋分级生产线零速电子称量装置中国专利,201420296069.9[P].2014-06-05.
[13]王树才,周雨程,夏高兵,等.禽蛋分级生产线接蛋翻转的装置中国专利,201420612801.9[P].2014-10-22.
[14]白修云,刘旭明,龚海岩.我国与欧美鲜禽蛋质量分级及检验标准比较解析[J].中国家禽,2014,36(1):51-53.Bai Xiuyun,Liu Xuming,Gong Haiyan.Fresh egg quality grading and inspection standards of comparative analysis between China and Europe[J].China Poultry,2014,36(1):51-53.(in Chinese with English abstract)
[15]孙贺欣.动态称重装置的研究[D].黑龙江:哈尔滨理工大学,2005.Sun Hexin.A Dissertation for the Degree of Master in Engineering[D].Heilongjiang:Harbin University of Science and Technology,2005.(in Chinese with English abstract)
[16]白仁刚.基于嵌入式系统的动态称重系统[D].杭州:浙江大学,2008.Bai Rengang.Dynamie Weighing System Based on Embedded System[D].Hangzhou:Zhejiang University,2008.(in Chinese with English abstract)
[17]黄奕安.基于嵌入式的称重系统的设计与研究[D].北京:北京交通大学,2011.Huang Yian.Design and Researeh of Weighing System Based on Embedded System[D].Beijing:Beijing Jiaotong University,2011.(in Chinese with English abstract)
[18]Frances V J,Calpe J,Martinez M,et al.Application of ARMA modeling to the improvement of weight estimations in fruit sorting and grading machinery[C]//.IEEE International Conference on Acoustics,Speech and Signal ProcessingProceedings,2000.
[19]He H,Huang P,Hou D,et al.An intelligent signal processing method for high-speed weighting system[J].International Journal of Food Engineering,2013,9(4):179-186.
[20]Umemoto T,Sasamoto Y,Adachi M,et al.Improvement of accuracy for continuous mass measurement in checkweighers with an adaptive notch filter[J].Transactions of the Society of Instrument&Control Engineers,2012,47(10):477-484.
[21]Gong Y,Cowan CFN.An LMS style variable tap-length algorithm for structure adaptation[J].IEEE Transactions on Signal Processing,2005,53(7):2400-2407.
[22]魏新华,周杏鹏,王金星,等.水果动态位置同步跟踪自动控制系统的设计与实现[C]//2007仪表自动化及先进集成技术大会论文集(二).重庆.2007.Wei Xinhua,Zhou Xingpeng,Wang Jinxing,et al.Design of a synchronous tracking and automatic control system of dynamic positions of fruits on conveyor of fruit machine vision grader[C]//Advanced instrument automation and integration technology conference proceedings(2),Chongqing.2007.(in Chinese with English abstract)
[23]景婧.应变式称重传感器的非线性校正[J].计算机应用研究,2013,30(1):189-191.Jing Jing.Nonlinear compensation of strain-type weighing sensor[J].Computer Application Research,2013,30(1):189-191.(in Chinese with English abstract)
[24]程亮,林斌,查凌志.PLC与单片机串口通信的实现[J].电气自动化,2006,28(3):35-37.Cheng Liang,Lin Bin,Zha Lingzhi.Realization of serial communication between PLC and single chip microcomputer[J].Electrical Automation,2006,28(3):35-37.(in Chinese with English abstract)
[25]王珍珠,刘伟,刘占清.基于ARM的PLC的CAN通信协议设计与实现术[J].组合机床与自动化加工技术,2011(8):60-63.Wang Zhenzhu,Liu Wei,Liu Zhanqing.Design and development of the CAN communication protocol in programmable controller based ARM[J].Modular Machine Tool&Automatic Manufacturing Technique,2011(8):60-63.(in Chinese with English abstract)
[26]胡惠玉.16位CRC校验原理与基于PLC的算法程序设计[J].常熟理工学院学报(自然科学),2009,23(10):80-88.Hu Huiyu.16-bit CRC checksum principle and programming based on PLC[J].Journal of Changshu Institute Of Technology,2009,23(10):80-88.(in Chinese with English abstract)
[27]王映龙,徐辉辉,刘道金.球形水果实时分级PLC控制系统[J].农业机械学报,2007,38(12):229-231.Wang Yinglong,Xu Huihui,Liu Daojin.The spherical fruit grading of PLC control system in real time[J].Chinese Journal of Mechanical Engineering,2007,38(12):229-231.(in Chinese with English abstract)
[28]Bin Rao.Design and implementation of remote data acquisition system based on embedded system[C]//.Computer Science in Industrial Application,Information Engineering Research Institute,2014.
[29]朱春凤.多工位自动生产线的PLC控制系统设计[D].北京:华北电力大学,2013.Zhu Chunfeng.PLC Control System Design of The Multistation Automatic Production Line[D].Beijing:North China Electric Power University,2013.
[30]荀群德,杨超君,王宏睿,等.基于PLC的六工位组合机床的控制系统设计[J].组合机床与自动化加工技术,2009(7):53-56.Xun Dequn,Yang Chaojun,Wang Hongrui,et al.Design of control system of six position combined machine tool based on PLC[J].Modular Machine Tool&Automatic Manufacturing Technique,2009(7):53-56.(in Chinese with English abstract)
[31]王博东.基于PLC和组态软件的水冷监控系统的设计实现[D].北京:中国科学院大学,2014.Wang Bodong.Design and Implementation on System of Cooling Water Monitoring Based on PLC and Configuration Software[D].Beijing:University of the Chinese Academy of Sciences,2014.
[2]王树才.我国蛋品加工装备制造业的发展之路[J].中国禽业导刊,2009,26(12):11-13.Wang Shucai.Egg processing equipment manufacturing industry development in China[J].Guide To Chinese Poultry,2009,26(12):11-13.(in Chinese with English abstract)
[3]范梅华,张建华.中国洁蛋生产和消费状况及对策[J].中国禽业导刊,2009,26(14):40-42.Fan Meihua,Zhang Jianhua.The status of clean egg production and consumption China and Countermeasures[J].Guide To Chinese Poultry,2009,26(14):40-42.(in Chinese with English abstract)
[4]张晨.基于单片机的禽蛋检测分级与包装控制系统研究[D].呼和浩特:内蒙古农业大学,2013.Zhang Chen.Control System of Egg-Quality Detecting and Grading Based on Single-Chip Microcomputer[D].Hohhot:Inner Mongolia Agricultural University,2013.(in Chinese with English abstract)
[5]武智慧,郁超,温鹿,等.禽蛋品质检测与分级中PLC控制系统的研究[J].内蒙古农业大学学报(自然科学版),2013(4):123-126.Wu Zhihui,Yu Chao,Wen Lu,et al.Development on the PLC control system for the egg quality inspection and grading[J].Journal of Inner Mongolia Agricultural University2013(4):123-126.(in Chinese with English abstract)
[6]黄永林,应义斌.用于水果实时分级系统的同步跟踪自动控制装置[J].农业工程学报,2002,18(4):163-166.Huang Yonglin,Ying Yibin.Controller for fruit synchronous tracking and auto-classification used in real-time fruit grading system[J].Transactions of the Chinese Society of Agricultural Engineering(Transactions of the CSAE),2002,18(4):163-166.(in Chinese with English abstract)
[7]应义斌,饶秀勤,黄永林,等.水果高速实时分级机构控制系统[J].农业机械学报,2004,35(5):117-121.Ying Yibin,Rao Xiuqin,Huang Yonglin,et al.Controller for real-time sorting mechanism of fruits[J].Chinese Journal of Mechanical Engineering,2004,35(5):117-121.(in Chinese with English abstract)
[8]蔡文.水果动态称量与自动化分选控制系统的研究与开发[D].杭州:浙江大学,2011.Cai Wen.Research and Development of the Control System for Fruit Dynamic Weighing and Automatic Sorting Lines[D].Hangzhou:Zhejiang University,2011.(in Chinese with English abstract)
[9]杨春伟.基于DSP的多通道禽蛋动态称量及分级控制研究与开发[D].杭州:浙江大学,2016.Yang Chunwei.Research and Development of Multichannel Egg Dynamic Weighing and Grading Control System Based on DSP[D].Hangzhou:Zhejiang University,2016.(in Chinese with English abstract)
[10]王松磊,刘民法,何建国,等.红枣自动快速无损检测分级机研究[J].农业机械学报,2014,45(9):79-83.Wang Songlei,Liu Minfa,He Jianguo,et al.Study of rapid and automatic non-destructive testing[J].Chinese Journal of Mechanical Engineering,2014,45(9):79-83.(in Chinese with English abstract)
[11]左兴建,武广伟.猕猴桃自动分级设备设计与试验[J].农业机械学报,2014,45(11):287-293.Zuo Xingjian,Wu Guangwei.Design and experiment on automatic grading machine for kiwi[J].Chinese Journal of Mechanical Engineering,2014,45(11):287-293.(in Chinese with English abstract)
[12]王树才,夏高兵,周雨程,等.禽蛋分级生产线零速电子称量装置中国专利,201420296069.9[P].2014-06-05.
[13]王树才,周雨程,夏高兵,等.禽蛋分级生产线接蛋翻转的装置中国专利,201420612801.9[P].2014-10-22.
[14]白修云,刘旭明,龚海岩.我国与欧美鲜禽蛋质量分级及检验标准比较解析[J].中国家禽,2014,36(1):51-53.Bai Xiuyun,Liu Xuming,Gong Haiyan.Fresh egg quality grading and inspection standards of comparative analysis between China and Europe[J].China Poultry,2014,36(1):51-53.(in Chinese with English abstract)
[15]孙贺欣.动态称重装置的研究[D].黑龙江:哈尔滨理工大学,2005.Sun Hexin.A Dissertation for the Degree of Master in Engineering[D].Heilongjiang:Harbin University of Science and Technology,2005.(in Chinese with English abstract)
[16]白仁刚.基于嵌入式系统的动态称重系统[D].杭州:浙江大学,2008.Bai Rengang.Dynamie Weighing System Based on Embedded System[D].Hangzhou:Zhejiang University,2008.(in Chinese with English abstract)
[17]黄奕安.基于嵌入式的称重系统的设计与研究[D].北京:北京交通大学,2011.Huang Yian.Design and Researeh of Weighing System Based on Embedded System[D].Beijing:Beijing Jiaotong University,2011.(in Chinese with English abstract)
[18]Frances V J,Calpe J,Martinez M,et al.Application of ARMA modeling to the improvement of weight estimations in fruit sorting and grading machinery[C]//.IEEE International Conference on Acoustics,Speech and Signal ProcessingProceedings,2000.
[19]He H,Huang P,Hou D,et al.An intelligent signal processing method for high-speed weighting system[J].International Journal of Food Engineering,2013,9(4):179-186.
[20]Umemoto T,Sasamoto Y,Adachi M,et al.Improvement of accuracy for continuous mass measurement in checkweighers with an adaptive notch filter[J].Transactions of the Society of Instrument&Control Engineers,2012,47(10):477-484.
[21]Gong Y,Cowan CFN.An LMS style variable tap-length algorithm for structure adaptation[J].IEEE Transactions on Signal Processing,2005,53(7):2400-2407.
[22]魏新华,周杏鹏,王金星,等.水果动态位置同步跟踪自动控制系统的设计与实现[C]//2007仪表自动化及先进集成技术大会论文集(二).重庆.2007.Wei Xinhua,Zhou Xingpeng,Wang Jinxing,et al.Design of a synchronous tracking and automatic control system of dynamic positions of fruits on conveyor of fruit machine vision grader[C]//Advanced instrument automation and integration technology conference proceedings(2),Chongqing.2007.(in Chinese with English abstract)
[23]景婧.应变式称重传感器的非线性校正[J].计算机应用研究,2013,30(1):189-191.Jing Jing.Nonlinear compensation of strain-type weighing sensor[J].Computer Application Research,2013,30(1):189-191.(in Chinese with English abstract)
[24]程亮,林斌,查凌志.PLC与单片机串口通信的实现[J].电气自动化,2006,28(3):35-37.Cheng Liang,Lin Bin,Zha Lingzhi.Realization of serial communication between PLC and single chip microcomputer[J].Electrical Automation,2006,28(3):35-37.(in Chinese with English abstract)
[25]王珍珠,刘伟,刘占清.基于ARM的PLC的CAN通信协议设计与实现术[J].组合机床与自动化加工技术,2011(8):60-63.Wang Zhenzhu,Liu Wei,Liu Zhanqing.Design and development of the CAN communication protocol in programmable controller based ARM[J].Modular Machine Tool&Automatic Manufacturing Technique,2011(8):60-63.(in Chinese with English abstract)
[26]胡惠玉.16位CRC校验原理与基于PLC的算法程序设计[J].常熟理工学院学报(自然科学),2009,23(10):80-88.Hu Huiyu.16-bit CRC checksum principle and programming based on PLC[J].Journal of Changshu Institute Of Technology,2009,23(10):80-88.(in Chinese with English abstract)
[27]王映龙,徐辉辉,刘道金.球形水果实时分级PLC控制系统[J].农业机械学报,2007,38(12):229-231.Wang Yinglong,Xu Huihui,Liu Daojin.The spherical fruit grading of PLC control system in real time[J].Chinese Journal of Mechanical Engineering,2007,38(12):229-231.(in Chinese with English abstract)
[28]Bin Rao.Design and implementation of remote data acquisition system based on embedded system[C]//.Computer Science in Industrial Application,Information Engineering Research Institute,2014.
[29]朱春凤.多工位自动生产线的PLC控制系统设计[D].北京:华北电力大学,2013.Zhu Chunfeng.PLC Control System Design of The Multistation Automatic Production Line[D].Beijing:North China Electric Power University,2013.
[30]荀群德,杨超君,王宏睿,等.基于PLC的六工位组合机床的控制系统设计[J].组合机床与自动化加工技术,2009(7):53-56.Xun Dequn,Yang Chaojun,Wang Hongrui,et al.Design of control system of six position combined machine tool based on PLC[J].Modular Machine Tool&Automatic Manufacturing Technique,2009(7):53-56.(in Chinese with English abstract)
[31]王博东.基于PLC和组态软件的水冷监控系统的设计实现[D].北京:中国科学院大学,2014.Wang Bodong.Design and Implementation on System of Cooling Water Monitoring Based on PLC and Configuration Software[D].Beijing:University of the Chinese Academy of Sciences,2014.