The precise sorting control of a swing wheel sorter relies on a highly integrated intelligent control system. Its core lies in the real-time sensing of item status by sensors, the rapid data processing by a PLC (Programmable Logic Controller), and the precise execution of actions by servo motors, ultimately achieving stable sorting of items along a preset path. This process involves multi-stage collaboration, from item identification to path planning and dynamic adjustment of the swing wheel's movement, each step based on high-precision control.
Item identification is the starting point of sorting. When an item enters the sorting area, laser sensors, photoelectric sensors, or a vision recognition system quickly capture its location, size, weight, and other key information. For example, a barcode reader or RFID reader can identify the item's unique identifier, and combined with preset rules in a database, the system can immediately determine its target sorting port. The accuracy of this step directly affects the rationality of subsequent actions; therefore, sensors must have millisecond-level response capabilities and high resolution to handle the identification needs of items with different shapes and materials.
The PLC, as the "brain" of the control system, is responsible for integrating sensor data and generating control commands. Based on item information and sorting rules, it calculates the optimal path using complex algorithms and breaks it down into specific pendulum wheel motion parameters, such as rotation angle, speed, and timing. For example, when an item approaches the target pendulum wheel, the PLC sends a command to the corresponding servo motor in advance to ensure the pendulum wheel completes its turn the instant the item arrives. This process must balance efficiency and safety, avoiding item collisions or sorting errors due to delayed or excessive movements.
The servo motor is the key hardware for precise sorting. Its high-precision encoder and closed-loop control technology enable the pendulum wheel to adjust its angle with sub-millimeter precision and maintain stability during high-speed operation. For example, when sorting large items, the servo motor needs to provide greater torque to overcome inertia; while for fragile items, acceleration needs to be reduced to minimize impact. Furthermore, real-time communication between the motor driver and the PLC ensures zero-delay transmission of motion commands, further improving sorting reliability.
Dynamic path optimization is the core technology for improving sorting efficiency. The system continuously monitors variables such as item spacing and flow fluctuations and adjusts the pendulum wheel motion using adaptive algorithms. For example, when the system detects that the spacing between items is too small, it temporarily reduces the rotation speed of subsequent swing wheels to avoid sorting failures due to overlapping actions. During peak periods, it optimizes path planning to allow multiple swing wheels to work together, maximizing the utilization of the sorting aisle. This flexibility allows the swing wheel sorter to handle both small soft packages and large, heavy loads, adapting to different scenario requirements.
Modular design provides the hardware foundation for precise control. The swing wheel components use independent drive units, each swing wheel can be controlled individually, and the modules are connected via standardized interfaces for easy replacement and maintenance. For example, if a module fails, the system can automatically isolate that unit and adjust the load on other swing wheels to ensure overall operation is unaffected. This design not only reduces the failure rate but also improves equipment availability by simplifying maintenance processes.
The human-machine interface uses visualization technology, allowing operators to monitor the sorting status in real time, adjust parameters, or intervene in anomalies. For example, administrators can modify sorting rules, view equipment logs, or manually control the actions of specific swing wheels via a touchscreen. This transparent management tool further enhances the system's flexibility and controllability. From sensor recognition to servo motor execution, from dynamic path optimization to modular hardware support, the precise sorting control of the swing wheel sorter is the result of deep collaboration between hardware and software. Its core lies in using real-time data feedback and intelligent algorithms to ensure that the movement of each swing wheel is precisely matched to the state of the items, ultimately achieving efficient, stable, and flexible sorting operations.
