Automated Factory Upgrade: How Ljxy Rolling Lines Integrate Intelligent Sortation Systems

​Opening question.​
“Ljxy in your workshop.platen lineIs it just a silly way of moving goods forward? Watching the factory next doorSorting systemsAnxious to swish and split your goods? Don't panic! Let's get this straight today--Putting ’eyes' and 'brains' on the drum lineJust how easy is it!”

​One,Intelligent Sorting SystemWhat's that? Open the eye of heaven for the rolling line!​

To put it bluntly, it's a three-piece suit.Visual recognition as eyes, PLC controller as brain, robot arm as handThe Ljxy roller line is responsible for delivering the goods to the designated location, and the system does the rest.

To cite a chestnut: an auto parts factory in Ljxy line with cameras and robotic arms, and now every 60 seconds automatically sorting 28 parts, 3 times faster than manual and not sleepy!

​Second, Ljxy roll line + visual system: how to team up this CP?​

​1. Hardware Building Blocks - Eye to Hand​

• ​Where's the camera?​
  Racked directly above the roller line at 1.2 meters (do not be afraid of dust! Just add a protective cover), special photo of the bottom side of the goods features
  → A courier warehouse test: oblique 45 ° installation recognition rate than vertical 15% high

• ​Is the roller line going to be remodeled?​
  ✅ Must do three things:

  1. ​emergency stop: 2-meter buffer zone in front of the sorting gate (photoelectric sensor-controlled start/stop)
  2. ​Replacement of rubberized rollers: Anti-slip! Otherwise the box is crooked and the camera is just confused
  3. ​open signal interface: Leave communication slot for PLC controller (RJ45 or 485 interface is fine).

​2. Software in love - data to pass on love​

​I'm afraid to go my own way.! I'll teach you two tricks to open up the Renju chakra:

Tested and recommended: using industrial Ethernet group LAN, transmission delay <0.1 seconds within 20 meters, the milk tea is not yet finished the data run out!

​Third, PLC controller - the invisible big brother of intelligent sorting​

​You think it's just a steel box? It's actually the soul commander of the sorting system!​

• ​How fierce is the new school PLC?​
  Like Sai Fang Technology's RISC-V PLC (JH-7110 chip), the 1.5GHz main frequency can do five things at the same time:

  1. Receive image signals from vision systems
  2. Counting goods to the left or to the right
  3. Control roller line emergency stop/acceleration
  4. Commanding robotic arm gripping angle
  5. It also sends sorting reports to the owner's cell phone!

• ​Programming is not for the faint of heart.​
  They all use it now.graphical programming(Ladder LD/Function Block FBD), drag and drop modules and you're screwed:

  plaintextmake a copy of
  [Camera recognizes red box] → [Trigger roller line pause] → [Robotic arm grabs and puts left channel] → [Resume operation]
  A food factory big sister training 3 days to get started to change the process
  

​Four,Guide to avoiding the pit--Blood and Tears for Experience Package​

​Pit 1: Light deceives the camera​

• ​scene of an overturned vehicle: Glass reflections allow the system to treat empty boxes as if they were full.
• ​break (a bond, constraint etc)::
  ✅ UseRing LED fill light(Color temperature 5000K most accurate)
  ✅ Pluspolarizing filterreflective
  → Cost increase ￥800, false positive rate straight down 90%

​Pit 2: Robotic arm and roller line fights​

• ​bloodbath: Before the robotic arm is retracted, the roller line suddenly starts → parts fly all over the place!
• ​life-saving device::
  1. Add in PLCinterlocking program(Locking roller line during arm movement)
  2. ​Dual Sensor Confirmation: Infrared + ultrasonic detection of robot arm position

​Pit 3: The more you use the system, the slower it gets​

• ​the actual facts: The image cache is crowding the memory!
• ​eradication program::
  ✅ Automatically clear the cache every day (set a timed task for 3am)
  ✅ QuarterlyCompression Algorithm Thinning(Compresses image data to its original value of 30%)

​V. Real cases - see how others eat crabs​

​Case 1: Express Warehouse Against the Odds​

• ​pre-remodeling: Manual sorting error rate of 5%, peak season backlog of 3 days
• ​after remodeling::
  • Ljxy roller line + visual sorting (investment ￥1.2 million)
  • ​Sorting speed: 12,000 pieces/hour
  • ​accuracy: 99.2% (reflective stickers are fully recognizable)
  • ​payback period:: 14 months

​Case 2: God's operation in a small parts factory​

• ​flirty trick: Use ofUsed Robotic Arm + Raspberry PiRetrofit Ljxy Old Rolling Line
• ​(manufacturing, production etc) costs: ¥80,000 (including the money for the master's milk tea)
• ​effect::
  ✅ Mixed Screw Sorting Accuracy 98%
  ✅ Compatible with 20 sizes from M3 to M12
  → The boss's exact words, ”It works better than recruiting two college students!”

​Personal opinion on the blackboard​

After ten years of automation, I want to yell three truths the most:

1. ​Don't be greedy!Smaller factories are taken care of first.Single-category sorting(e.g., cartons only), saving half a million dollars over hard-on full automation.
2. ​Don't throw away the old roll line!Ljxy 10 years old retrofitSignal Interface Module(¥ 2000 / unit), as usual, can access the intelligent system.
3. ​Maintenance is more important than installation!I've seen too many factories drop millions on installing systems and end up with a lot of money because of theNot clearing the cache / not changing the filterParalyzed into scrap metal - remember.The system is like a car, maintenance is the life renewing elixir!​

Finally dump a storm theory.Intelligent sorting is not a matter of choice, it's a matter of survival. When the workshop next door with Ljxy roller line + vision system in the middle of the night no one to separate goods - your workers are still staying up late to move boxes, the gap which is technology? It'sgenerational differenceAh!