Continuous material detection system, material defect detection system

Abstract

The present invention discloses a continuous material detection system and a material defect detection system, wherein the material defect detection system comprises a processing table, a detection table, and a discharge roller placed on the processing table and close to the material entrance, a first encoder installed on the first roller closest to the discharge roller, and used to obtain the material conveying speed of the data acquisition surface; a material data collector, comprising: an A-side CCD camera installed on the second roller, and used to collect the material image on the data acquisition surface facing the A-side within the image acquisition time; a B-side CCD camera installed between the discharge roller and the first roller, and arranged below the processing table, and used to collect the material image on the data acquisition surface facing the B-side within the image acquisition time. The present invention also discloses a continuous material detection system. The technical solution of the present invention can realize real-time detection, marking, and recording of material defect information of material defects during the production process.

Description

Technical Field

[0001] The present invention relates to the field of material detection, and in particular to a continuous material detection system and a material defect detection system. Background Art

[0002] In the production process of certain specific industries, it involves coating a layer of surface material such as glue, coating or ink with specific functions on rolled substrates, such as paper, cloth, leather, aluminum foil, plastic film, etc., and then drying and rolling them up.

[0003] Taking the coating of new energy battery pole pieces (pole cloth for short) as an example, a single roll of pole pieces is tens of thousands of meters long and has a high unit price. During the continuous conveying and coating process, the pole pieces may produce various types of defects (NG) due to various production failures, such as breakage, wrinkles, uneven coating, bubbles, etc. If the defective materials are not detected in time during the continuous conveying process, some defective materials will cause production accidents such as interruption of the conveying process, and defective materials that do not affect normal production are difficult to check after rewinding, which seriously affects product quality. Summary of the invention

[0004] The main technical problem solved by the present invention is to provide a continuous material detection system and a material defect detection system, which can collect real-time material data of the continuous material being transported for defect identification.

[0005] In order to solve the above technical problems, a technical solution adopted by the present invention is:

[0006] A material defect detection system is provided, comprising a processing table, a detection table, and a discharge roller placed on the processing table and close to a material entrance, wherein a plurality of rollers for guiding the material when it moves are arranged on the processing table and the detection table; the material defect detection system is arranged in a material detection section of a material conveying system, and the material conveying system comprises a plurality of rollers arranged at a certain conveying interval; the material defect detection system comprises: a first encoder, installed on a first roller closest to the discharge roller, for obtaining a material conveying speed on a data acquisition surface; a material data collector, comprising: an A-side CCD camera, installed on a second roller, for acquiring a material image on a data acquisition surface facing the A-side within an image acquisition time; wherein the second roller is closest to the first roller and is arranged behind the first roller; a B-side CCD camera, installed between the discharge roller and the first roller, and arranged below the processing table, for acquiring a material image on a data acquisition surface facing the B-side within an image acquisition time.

[0007] It also includes a cantilever, one end of which is fixedly mounted on the second roller, and the A-surface CCD camera is mounted on the other end, so that the A-surface CCD camera forms a predetermined distance with the processing table.

[0008] Among them, it also includes: a translation mechanism, which is arranged on one side of the detection; an inkjet printer, which is fixed on the translation mechanism; wherein the inkjet printer's inkjet working surface is arranged corresponding to a inkjet working surface roller, and the inkjet working surface roller is arranged on the detection table; a line sensor or a corresponding optical fiber is installed on the left and right sides of the inkjet printer to obtain the edge coordinates of both sides of the material; a second encoder is installed on the inkjet working surface roller to obtain the material conveying speed of the inkjet printer working surface.

[0009] Wherein, the material defect detection system also includes a color sensor, and the color sensor includes a second color sensor installed on the translation mechanism corresponding to the position of the inkjet printer, which is used to identify the color information of the NG identification code.

[0010] Wherein, the material defect detection system also includes an A-side light source and a B-side light source for illuminating an A-side data collection surface and a B-side data collection surface respectively; wherein the A-side data collection surface and the B-side data collection surface are separated by a preset collection interval.

[0011] It also includes a processing unit, and an input unit, a storage unit and a display unit respectively connected to the processing unit; the processing unit is used to control the display unit to display a material detection control interface, and the input unit is used to input control instructions or the coding parameters in the material detection control interface.

[0012] Wherein, the material defect detection system also includes an alarm device connected to the processing unit.

[0013] Wherein, the processing unit is connected to the first encoder and the physical data collector.

[0014] Wherein, the processing unit is deployed as a PLC or an industrial computer.

[0015] Another technical solution adopted by the present invention is:

[0016] A continuous material detection system is provided, comprising any one of the material defect detection systems described above, wherein the continuous material detection system further comprises an MES system and a material conveying system which are communicatively connected to the material defect detection system; the material conveying system comprises a plurality of rollers arranged at a certain conveying interval, the material conveying section of the material conveying system comprises a conventional material conveying section and a material detection section entering and exiting the material defect detection system, and the material defect detection system is used to detect and collect material conveying speed and material images on a data collection surface.

[0017] The beneficial effects of the embodiments of the present invention are: different from the prior art, the technical solution disclosed in the embodiments of the present invention can collect real-time material data of continuous materials in transportation for defect identification, and can spray NG identification codes for marking material defects, thereby realizing real-time detection, marking, and recording of material defect information of material data during the production process. BRIEF DESCRIPTION OF THE DRAWINGS

[0018] Figure 1 This is a structural block diagram of a continuous material detection system in one embodiment of the present invention;

[0019] Figure 2 It is a structural schematic diagram of a continuous material detection system in one embodiment of the present invention;

[0020] Figure 3 It is a schematic diagram of the CCD camera collecting images of continuous materials;

[0021] Figure 4 is the kth defect G k Corresponding NG identification code NG k Schematic diagram of the spraying area. DETAILED DESCRIPTION

[0022] In order to explain the technical content, structural features, achieved objectives and effects of the present invention in detail, the present invention is described in detail below with reference to the accompanying drawings and embodiments.

[0023] First of all, NG in this article refers to material defects, such as broken belts, wrinkles, uneven coating, bubbles, etc. This technology is mainly applied in the transportation of continuous belt materials. In theory, if the material defects can be judged by industrial vision, weight change, and surface density change, this technology is applicable to all materials. Next, this technology is explained using continuous belt materials as an example.

[0024] In order to clearly illustrate the various components of the continuous material detection system of the present invention, as well as their positional relationships and linkage relationships, the material conveying direction of the material conveying system 30 is defined as the front-to-back direction, the direction perpendicular to the front-to-back direction along the material plane is defined as the left-right direction, the direction along the material conveying direction is defined as the reference direction, the material surface A is located above the material plane, and the material surface B is located below the material plane.

[0025] See also Figure 1 , is a structural block diagram of a continuous material detection system in one embodiment of the present invention.

[0026] The continuous material detection system 100 includes at least one material defect detection system 10, an MES system 20 in communication with the material defect detection system 10, and a material conveying system 30. The MES system (Manufacturing Execution System) 20, i.e., the manufacturing enterprise production process execution system, is a production information management system for the workshop execution layer of the manufacturing enterprise.

[0027] The material conveying system 30 (eg, a coating machine) is used to convey continuous materials and includes a plurality of rollers (not shown) arranged at a certain conveying interval. The material conveying section of the material conveying system 30 includes a conventional material conveying section and a material detection section for entering and exiting the material defect detection system 10 .

[0028] The material defect detection system 10 is used to detect materials with a certain detection interval and collect material data. The value of the detection interval depends on material characteristics, coating parameters, and the frequency of production failures.

[0029] For example, if material A has a lower value, the coating process is continuous, and the frequency of production failures is low, the detection interval is set to a larger value, such as 900mm, and the maximum conveying speed of the electrode is 140m / min; correspondingly, if material B (such as battery electrode) has a high value, the coating process is discontinuous, the production failures are diverse and the frequency of production failures is high, the detection interval is set to a smaller value, such as 150mm, and the maximum conveying speed of the electrode is 20m / min, so as to quickly discover material defects, take timely countermeasures, and reduce losses.

[0030] Specifically, the material defect detection system 10 includes a processing unit 11, a translation mechanism 12, an inkjet printer 13, an input unit 14, a storage unit 15, a display unit 16, an alarm device 18, a physical data collector 171, a first encoder 172, a line sensor or a corresponding optical fiber 173, a color sensor 174 and a second encoder 175, which are respectively connected to the processing unit 11.

[0031] The storage unit 15 is used to store programs executed by the processing unit 11 and data processed and received.

[0032] The processing unit 11 is used to control the display unit 16 to display a material detection control interface.

[0033] The input unit 14 is used to input control instructions or inkjet parameters in the material detection control interface. Specifically, the input unit 14 is at least one of a touch screen, a keyboard, a mouse, or a control button. The inkjet parameters include material ID, NG identification code corresponding to NG type, edge inner deviation distance, front and rear spraying starting point, spraying width, character content of NG identification code, character direction, character length, and character resolution. Among them, each NG identification code corresponds to an NG type; the NG types include broken belt, wrinkles, uneven coating, bubbles, over-coating, and missing coating; the NG information includes NG type and NG position information.

[0034] Optionally, the processing unit 11 may be deployed as a PLC or an industrial computer.

[0035] Please also see Figure 2 , is a schematic structural diagram of a material defect detection system 10 in one embodiment of the present invention.

[0036] The processing unit 11 (not shown), the input unit 14 (not shown), the storage unit 15 (not shown), and the display unit 16 (not shown) are all arranged in the electrical box 101, and are used to perform the functions as described above and detect material defects in the material defect detection system 10.

[0037] Furthermore, the material defect detection system 10 includes a processing table 1 and a detection table 2; in this embodiment, the processing table 2 is horizontally arranged, and the detection table 2 is vertically arranged and arranged on a side of the processing table 2 away from the material inlet 102. A material discharge roller 104 is placed on the processing table 1 near the material inlet 102, and a plurality of rollers for guiding the movement of the material are arranged on both the processing table 1 and the detection table 2 (described in detail below).

[0038] The translation mechanism 12 is disposed on one side of the detection platform 2; in this embodiment, the translation mechanism 12 can be a screw slide.

[0039] The first encoder 172 is installed on the first roller 1720 closest to the unloading roller 104, and the first roller 1720 is arranged behind the unloading roller 104. The first encoder 172 is used to obtain the material conveying speed v of the data collection surface. 1 Specifically, the encoder resolution is the count per rotation. For example, an encoder with a resolution of 2000 means that the encoder counts 2000 per rotation. The length of material conveyed per encoder rotation is a fixed value. The processing unit 11 calculates the encoder count per unit time to obtain the material conveying speed v of the data acquisition surface. 1 .

[0040] The material data collector 171 (not shown) is used to collect material data information. The material data information includes surface density information, weight information, surface information, material image and image acquisition time. Specifically, the material data collector 171 includes:

[0041] The A-side CCD camera 1710 is arranged on the second roller 1714; wherein the second roller 1714 is closest to the first roller 1720 on which the first encoder 172 is installed, and is located behind the first roller 1720; in this embodiment, one end of the cantilever 1715 is fixedly installed on the second roller 1714, and the A-side CCD camera 1710 is installed on the other end, so that the A-side CCD camera 1710 forms a predetermined distance with the processing table 1;

[0042] The B-side CCD camera 1711 is installed between the unwinding roller 104 and the first roller 1720 and is arranged below the processing table 1, that is, located on the B-side.

[0043] In this embodiment, in a direction extending horizontally from one side of the processing table 2 where the material inlet 102 is provided to the other side, a material discharge roller 104, a first roller 1720, and a second roller 1714 are sequentially provided on the processing table 2.

[0044] Furthermore, the image acquisition range facing the A-side CCD camera 1710 is defined as data acquisition surface A, and the image acquisition range facing the B-side CCD camera 1711 is defined as data acquisition surface B; the A-side CCD camera 1710 and the B-side CCD camera 1711 are respectively used to acquire material images on the corresponding data acquisition surfaces A / B during image acquisition time.

[0045] In other embodiments, the material data collector 171 may further include an A / B surface density meter or a weight meter 1716. The weight meter is used to test the weight information of the material, and the A / B surface density meter is used to collect the surface density information of the material on the corresponding data collection surface.

[0046] The A-side CCD camera 1710 and the B-side CCD camera 1711 are used to collect images of the material, the surface density meter is used to collect the surface density information of the material, and the weight meter is used to test the weight information of the material. Specifically, wrinkles, bubbles, missing coating, obvious uneven coating and over-coating can be identified through images, and subtle uneven coating, over-coating and under-coating with a small difference from the standard can be identified through surface density information and weight information.

[0047] The material data collector 171 is further used to send online or offline information to the processing unit 11, and the processing unit 11 is used to control the alarm device 18 to alarm when receiving offline information.

[0048] The inkjet printer 13 is fixed on the translation mechanism 12 and is used to spray the NG identification code in response to the control of the processing unit 11; wherein the inkjet printer 13's inkjet working surface is arranged corresponding to the inkjet working surface roller 130, and the inkjet working surface roller 130 is arranged on the detection table 2.

[0049] The line sensor or the optical fiber 173 is installed on the left and right sides of the inkjet printer 13 to obtain the edge coordinates of the two sides of the material.

[0050] The color sensor 174 includes:

[0051] The first color sensor 1741 is arranged on the detection 2 and is located on the other side opposite to the translation mechanism 12, and is used to identify the starting position of the splicing of the broken material. Since a new roll of material is spliced ​​with the last material of the previous roll before the guided transmission of the material can be achieved through the roller, the first color sensor 1741 distinguishes whether the transmission of a roll of material is completed and the newly spliced ​​material by the different colors of the splicing of the broken tape at the splicing of the two rolls of material and the new material.

[0052] The second color sensor 1742 is installed on the translation mechanism 12 at a position corresponding to the position of the inkjet printer 13, and is used to identify the color information of the NG identification code; the processing unit 11 is used to determine whether the color information is different from the color of the material, and to determine whether the color information is received multiple times within a preset standard time. When it is determined that there is no difference between the color information and the color of the material, it is determined that there is a missed print; when it is determined that the color information is received multiple times within the preset standard time, it is determined that there is an overprint; and when it is determined that there is a missed print or an overprint, the alarm device 18 is controlled to alarm.

[0053] The second encoder 175 is installed on the inkjet printer working surface roller 130 and is used to obtain the material conveying speed of the inkjet printer working surface.

[0054] Furthermore, a UV lamp 120 is installed on the translation mechanism 12 to assist the curing of the sprayed ink by irradiating with special light.

[0055] The material defect detection system 10 also includes an A-side light source 1712 and a B-side light source 1713 for illuminating a data collection surface; wherein the A data collection surface and the B data collection surface are separated by a preset collection interval to avoid mutual influence between the light sources.

[0056] Due to the high-speed conveying of materials, different degrees of jitter may occur in the non-roller contact area, which will affect the quality of the execution of actions by devices such as CCD cameras and inkjet printers. Therefore, the devices that execute actions are set in the wrapping section between the material and the roller.

[0057] The processing unit 11 is used to identify the NG type and NG position information of the material defect according to the material data information and the material transmission speed of the data collection surface, and is also used to determine the corresponding inkjet parameters, spraying area, spraying speed according to the NG type, NG position information, the edge coordinates on both sides, the inkjet code and the material transportation speed of the working surface, and control the servo or stepper motor of the translation mechanism to drive the translation mechanism and the inkjet printer to spray the NG identification code according to the inkjet parameters and the spraying speed.

[0058] Each NG type corresponds to an NG status information, and the NG status information includes normal production and production-affecting information. The processing unit is also used to control the alarm device 18 to alarm when the NG status information of the NG type is production-affecting information. Specifically, when the NG type is belt breakage, the corresponding NG status information is production-affecting information.

[0059] Wherein, the NG identification code is a graphic, a barcode or a QR code.

[0060] Through the technical solution of the material defect detection system mentioned above, it is possible to collect material data of continuous materials transported by the material conveying system, and identify whether the collected data contains material defects, thereby realizing real-time detection of material defects.

[0061] The following is a detailed description of the implementation scheme of material defect identification using an embodiment. This embodiment is only an application scheme of the material defect detection system of the present invention. Figure 3 , which is a schematic diagram of CCD camera capturing images of continuous materials.

[0062] The material conveying direction of the material conveying system 30 is defined as the front-to-back direction, and the direction perpendicular to the front-to-back direction along the material plane is defined as the left-to-right direction. The length of the data acquisition surface in the front-to-back direction is set as m, and the length in the left-to-right direction is set as s. A coordinate system is established with the geometric center O of the data acquisition surface as the origin of the data acquisition surface, with the front-to-back direction as the y-axis of the coordinate system, and the left-to-right direction as the x-axis of the coordinate system, wherein the positive direction of the y-axis is consistent with the conveying direction.

[0063] Assume that the side where the material first enters the data collection surface is the material detection starting side L. When the material detection starting side L reaches the material output side of the data collection surface, the image at this time is the starting detection image P 0 , the image acquisition time at this time is the starting detection time T 0 .

[0064] The material data collector 171 starts detecting at the time T 0 For the initial detection image P 0 And its corresponding materials to collect material data, and then according to the data collection surface material conveying speed v 1 , at the start detection time T 0After that, when the material is transported for the nth time with a length of m, the detection image P n and its corresponding materials to collect material data; wherein, the detection image P n The detection time T n =n×m / v 1 , n≥1 and n∈N, the material data includes a starting detection image or a detection image, surface density information, weight information, and surface information.

[0065] The processing unit 11 identifies the defect G according to the initial detection image or the detection image, the surface density information, the weight information, and the surface information. k NG type and NG position information (a k , b k +n×m), the NG information including NG type, NG surface and NG position information is associated with the material ID to form a material defect list and uploaded to the MES system 20, where (a k , b k ) is defect G k The position coordinates on the data collection surface, b k +n×m is defect G k The distance from the starting edge L of the material detection, k>0 and k∈N.

[0066] See also Figure 4 , is the kth defect G k Corresponding NG identification code NG k Schematic diagram of the spraying area.

[0067] The processing unit 11 is used to determine the corresponding spraying parameters according to the NG information, wherein the spraying parameters include material ID, NG identification code corresponding to the NG type, edge inner deviation distance, forward and backward spraying starting point, spraying width, character content of NG identification code, character direction, character length, and character resolution.

[0068] The line sensor or the reflected optical fiber 173 obtains the edge coordinates on both sides of the material, and the processing unit 11 determines the spraying area according to the edge coordinates of the selected side, the spraying width, the character length and the edge inner deviation distance. Assume that the spraying width is r, the character length is u, the edge inner deviation distance is h, the left edge is x=A, and the right edge is x=B. If the right edge is selected, the left and right directions of the spraying area are (B+hr / 2, B+h+r / 2). If the left edge is selected, the left and right directions of the spraying area are (A-h+r / 2, Ahr / 2). In this embodiment, the front-to-back direction range of the spraying area is (a k -u / 2,a k +u / 2), that is, the horizontal coordinate of the center of the spraying area is the defect G k The horizontal coordinate a kIn other embodiments, any other suitable coordinates may be set as the center of the spraying area.

[0069] The second encoder 175 obtains the material conveying speed v of the inkjet printer working surface 2 The processing unit 11 determines the material transmission speed v of the spraying area and the inkjet printer working surface according to the spraying area and the inkjet printer working surface. 2 The corresponding spraying speed is determined according to the spraying parameters, and the servo or stepper motor used to control the translation mechanism 12 according to the spraying parameters and the spraying speed drives the translation mechanism and the inkjet printer 13 to spray the NG identification code.

[0070] The beneficial effects of the embodiments of the present invention are: The beneficial effects of the embodiments of the present invention are: The technical solution disclosed in the embodiments of the present invention can collect real-time material data of continuous materials in transportation for defect identification, and can spray NG identification codes for marking material defects, thereby realizing real-time detection, marking, and recording of material defect information of material data during the production process.

[0071] It should be noted that the preferred embodiments of the present invention are given in the specification and drawings of the present invention. However, the present invention can be implemented in many different forms and is not limited to the embodiments described in this specification. These embodiments are not intended to be additional limitations on the content of the present invention. The purpose of providing these embodiments is to make the understanding of the disclosure of the present invention more thorough and comprehensive. In addition, the above-mentioned technical features continue to be combined with each other to form various embodiments not listed above, which are all considered to be within the scope of the present invention; further, for ordinary technicians in this field, they can be improved or transformed according to the above description, and all these improvements and transformations should belong to the scope of protection of the claims attached to the present invention.

Claims

1. A material defect detection system, comprising a processing table, a detection table, and a material discharge roller placed on the processing table and close to the material inlet, wherein a plurality of rollers are arranged on the processing table and the detection table to guide the material during movement; characterized in that: The material defect detection system is arranged in the material detection section of the material conveying system, and the material conveying system comprises a plurality of rollers arranged at a certain conveying interval; the material defect detection system comprises: A first encoder is installed on the first roller closest to the unwinding roller and is used to obtain the material conveying speed on the data collection surface; Material data collector, including: A-side CCD camera, mounted on the second roller, for capturing images of materials on the data collection surface facing side A during image collection time; wherein the second roller is closest to the first roller and is arranged behind the first roller; A B-side CCD camera is installed between the unwinding roller and the first roller and is arranged below the processing table, and is used to collect material images on the data collection surface facing the B-side within the image collection time; A cantilever, one end of which is fixedly mounted on the second roller, and the other end of which is mounted with the A-surface CCD camera, so that the A-surface CCD camera forms a predetermined distance with the processing table; A translation mechanism, arranged on one side of the detection platform; A coding machine is fixed on the translation mechanism; wherein the coding working surface of the coding machine is arranged correspondingly to a coding working surface roller, and the coding working surface roller is arranged on the detection table; Line sensors or through-beam optical fibers are installed on the left and right sides of the inkjet printer to obtain the edge coordinates of both sides of the material; A second encoder is installed on the inkjet printer working surface roller and is used to obtain the material conveying speed of the inkjet printer working surface; A color sensor includes a second color sensor installed on the translation mechanism corresponding to the position of the inkjet printer, and is used to identify the color information of the NG identification code.

2. A material defect detection system according to claim 1, characterized in that: The material defect detection system also includes an A-side light source and a B-side light source for illuminating an A-side data collection surface and a B-side data collection surface respectively; wherein the A-side data collection surface and the B-side data collection surface are separated by a preset collection interval.

3. A material defect detection system according to claim 1, characterized in that: It also includes a processing unit, and an input unit, a storage unit and a display unit respectively connected to the processing unit; The processing unit is used to control the display unit to display a material detection control interface, and the input unit is used to input control instructions or coding parameters on the material detection control interface.

4. A material defect detection system according to claim 3, characterized in that: The material defect detection system also includes an alarm device connected to the processing unit.

5. A material defect detection system according to claim 3, characterized in that: The processing unit is connected to the first encoder and the material data collector.

6. A material defect detection system according to claim 4, characterized in that: The processing unit is deployed as a PLC or an industrial computer.

7. A continuous material detection system, characterized in that: It comprises at least one material defect detection system as described in any one of claims 1 to 6, the continuous material detection system also comprises an MES system and a material conveying system which are communicatively connected to the material defect detection system; the material conveying system comprises a plurality of rollers arranged at a certain conveying interval, the material conveying section of the material conveying system comprises a conventional material conveying section and a material detection section entering and exiting the material defect detection system, and the material defect detection system is used to detect and collect material conveying speed and material images on a data collection surface.

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