A detection device applied to the measurement of a buoy inflator

Abstract

The application discloses a kind of detection equipment applied to buoy inflator device measurement, including box, detection area is opened in the side of box, the detection area is equipped with feeding and discharging platform, the bottom of the feeding and discharging platform is fixedly connected with box by rotating mechanism, the feeding and discharging platform is equipped with the fixture for fixing the buoy inflator device of measured object, the left and right sides of the detection area are equipped with image acquisition mechanism and lever jacking mechanism respectively, the top of the detection area is equipped with resistance test probe assembly in cooperation with the resistance test point of the buoy inflator device, the rear of the detection area is equipped with ranging device in cooperation with the buoy inflator device, the rotating mechanism, image acquisition mechanism, lever jacking mechanism, resistance test probe assembly are all through a controller and PC end host computer cooperation.

Description

Technical Field

[0001] This invention belongs to the field of quality inspection technology for inflation devices, and in particular relates to an inspection device for measuring buoy inflation devices. Background Technology

[0002] In the production and assembly process of buoy inflation devices, quality inspection of the inflation device is a necessary step. Existing inspection methods require manual inspection by specialized personnel, which includes three inspection items: ① The gap at the front opening of the inflation device should be between 2.1mm and 2.7mm, determined by specialized personnel using a plug gauge. ② The gap at the rear lever of the inflation device should be between 0.1mm and 2mm, determined by specialized personnel manually pressing the lever to create deformation and then visually observing whether deformation occurs, is excessive, or fails to deform. ③ The resistance value of the circuit board at the top of the inflation device should be between 3.5Ω and 4.5Ω, determined by specialized personnel using a low-resistance tester to test the probes at the test point and observing the instrument's display value.

[0003] Since each buoy requires an inflation device, the demand for these devices is substantial, based on buoy production estimates. In actual production, assembly personnel often produce over a hundred inflation devices before notifying the quality department for inspection. Subsequently, the quality department assigns dedicated inspectors to check each device individually. This process can lead to time conflicts as inspectors need to check other workpieces, causing production to stall. The notification, planning, arrangement, inspection, and recording processes often negatively impact production efficiency. Furthermore, since the inspection process relies on human judgment of product quality, it inevitably introduces errors, leading to rework in subsequent work and inconsistent product quality. Summary of the Invention

[0004] In order to improve the quality consistency of the inflation device in buoys and avoid production slowdowns, this invention provides an automated device for quality inspection of the inflation device in buoys, replacing manual inspection by specialized personnel.

[0005] To achieve the above objectives, the present invention adopts the following technical solution: a testing device for measuring a buoy inflation device, comprising a housing, a testing area on one side of the housing, a loading / unloading platform in the testing area, the bottom of the loading / unloading platform being fixedly connected to the housing via a rotating mechanism, a fixture for fixing the buoy inflation device to be tested on the loading / unloading platform, an image acquisition mechanism and a lever lifting mechanism respectively provided on the left and right sides of the testing area in conjunction with the sides of the buoy inflation device, a resistance test probe assembly provided on the top of the testing area in conjunction with the resistance test point of the buoy inflation device, and a distance measuring device provided at the rear of the testing area in conjunction with the buoy inflation device, wherein the rotating mechanism, the image acquisition mechanism, the lever lifting mechanism, and the resistance test probe assembly are all connected to a PC-based host computer via a controller.

[0006] Furthermore, the rotating mechanism is a 57 stepper motor.

[0007] Furthermore, the image acquisition mechanism includes an industrial camera, a light source controller, a ring light source, and a PoE power supply module. The ring light source is mounted on the industrial camera. The industrial camera acquires images of the gap at the end of the inflation device and transmits the image data to a PC for machine vision processing via a gigabit network cable through the PoE power supply module. The light source controller and the PC are connected via an RS232 serial port and can control the illumination of the ring light source via downlink commands.

[0008] Furthermore, the lever lifting mechanism consists of a first electric cylinder and a lifting block.

[0009] Furthermore, the resistance test probe assembly includes a second electric cylinder, a low resistance tester, and a spring probe. The second electric cylinder is fixed to the wall of the housing, the low resistance tester is fixed inside the housing, and the spring probe is fixed to the probe mounting plate of the resistance tester.

[0010] Furthermore, the housing is also equipped with a motor drive board, which outputs two sets of high and low level signals to the motor drive board through the controller, thereby controlling the extension and retraction of the first and second electric cylinders.

[0011] Furthermore, the ranging device is a laser ranging sensor. The laser ranging sensor obtains an analog output that changes linearly with distance, and converts the analog output into a digital signal transmitted according to a protocol format through an analog-to-digital converter. The laser ranging sensor and the PC host computer are connected through the PC host computer via an RS485 bus, so that the PC host computer receives the digital signal and parses the actual measured distance according to the protocol.

[0012] Furthermore, the controller is a Siemens S7-200 PLC.

[0013] Furthermore, the motor drive board is an L298N motor drive board.

[0014] In summary, by rationally utilizing PLC, stepper motor, laser rangefinder, analog-to-digital converter, low-resistance tester, U-slot photoelectric switch, industrial camera, light source controller, and light source, and using a LabVIEW-based host computer as the human-machine interaction and control center, an automated device is formed. This invention can be used to detect the gap at the front end of the inflation device, the gap at the rear end of the lever opening, and the resistance value at the top, generating a test report. This equipment can optimize the quality consistency of the inflation device in the buoy and replace manual inspection by specialized personnel, thereby avoiding production stoppages in the workshop. Attached Figure Description

[0015] Figure 1 This is a flowchart of the existing testing method.

[0016] Figure 2 This is a flowchart of the testing method of the present invention.

[0017] Figure 3 This is a task framework diagram for the host computer software.

[0018] Figure 4 This is a schematic diagram of the detection device of the present invention.

[0019] Figure 5 This is a schematic diagram of the internal structure of the detection device of the present invention.

[0020] In the diagram: 1. Box body, 2. Loading and unloading platform, 4. Stepper motor 57, 3. Test object fixture, 5. Industrial camera, 50. Ring light source, 6. First electric cylinder, 60. Lifting block, 7. Second electric cylinder, 70. Spring probe, 8. Laser rangefinder sensor. Detailed Implementation

[0021] like Figure 1-5As shown, a testing device for measuring a buoy inflation device is disclosed. The buoy inflation device is used to inflate buoys. The testing device includes a housing 1, with a testing area on one side. The testing area has a loading / unloading platform 2, the bottom of which is fixedly connected to the housing 1 via a 57 stepper motor 4. A U-shaped photoelectric switch is provided on the loading / unloading platform 2 for positioning the platform at its initial position. A fixture 3 for fixing the buoy inflation device is also provided on the loading / unloading platform 2. Image acquisition mechanisms and lever lifting mechanisms are respectively provided on the left and right sides of the testing area to cooperate with the sides of the buoy inflation device. A resistance test probe assembly is provided on the top of the testing area to cooperate with the resistance test point of the buoy inflation device. A distance measuring device is provided at the rear of the testing area to cooperate with the buoy inflation device. The rotation mechanism, image acquisition mechanism, lever lifting mechanism, and resistance test probe assembly are all connected to a PC-based host computer via a Siemens S7-200 PLC. The PLC can output high pulse and level signals to the driver of the 57 stepper motor. By controlling the 57 stepper motor through the Siemens S7-200 PLC, the loading and unloading platform 2 can achieve smooth forward and reverse rotation, and the motor rotation speed and rotation position can be controlled.

[0022] Specifically, the image acquisition mechanism includes an industrial camera 5, a light source controller, a ring light source 50, and a POE power supply module. The ring light source 50 is mounted on the industrial camera 5. The industrial camera 5 acquires images of the gap at the end of the inflation device and transmits the image data to a PC for machine vision processing via a gigabit network cable through the POE power supply module. The light source controller and the PC are connected via an RS232 serial port and can control the illumination of the ring light source 50 through downlink commands.

[0023] Specifically, the lever lifting mechanism consists of a first electric cylinder 6 and a lifting block 60, which is used to generate pressure on the lever in the inflation device to form a gap. Finally, the deformation is measured by a distance measuring device to measure the lever opening gap.

[0024] Specifically, the resistance test probe assembly includes a second electric cylinder 7, a low resistance tester, and a spring probe 70. The second electric cylinder 7 is fixed to the wall of the housing 1, the low resistance tester is fixed inside the housing 1, and the spring probe 70 is fixed to the probe mounting plate of the resistance tester. The low resistance tester is connected to the PC host computer via an RS232 serial cable. When the second electric cylinder 7 drives the spring probe 70 to move and make it contact the resistance test point of the inflation device, the resistance value can be measured by the low resistance tester. Then, the test data is uploaded to the PC host computer for judgment via the RS232 serial cable. The inflation device includes a gas cylinder, a bottle-piercing component, and a spring. The bottle-piercing component is used to puncture the gas cylinder. The end of the bottle-piercing component away from the bottle-piercing component is connected to one end of the spring. The spring is fitted with a nylon rope, which is used to compress the spring and cause it to deform. A nickel-chromium alloy wire is spirally wound on the nylon rope. The resistance value of the alloy wire is measured by using a resistance test probe. Based on the measured resistance value, and combined with the principle of resistance heating, the alloy wire is energized to generate heat and burn off the nylon rope, releasing the spring force, thereby causing the bottle-piercing component to puncture the gas cylinder and achieve the inflation effect.

[0025] Specifically, the housing 1 is also equipped with an L298N motor drive board, which outputs two sets of high and low level signals to the L298N motor drive board through a Siemens S7-200 PLC, and can control the extension and retraction of the first electric cylinder 6 and the second electric cylinder 7.

[0026] Specifically, the ranging device is a laser ranging sensor 8. The laser ranging sensor 8 obtains an analog output that changes linearly with distance, and converts the analog output into a digital signal transmitted according to a protocol format through an analog-to-digital converter. The laser ranging sensor 8 and the PC host computer are connected through the PC host computer via an RS485 bus, so that the PC host computer receives the digital signal and parses the actual measured distance according to the protocol.

[0027] Specifically, a power supply module is also provided in conjunction with the enclosure 1. The power supply module uses a 24V Mean Well switching power supply and a 12V Mean Well switching power supply to power all components, mechanisms and modules inside the enclosure.

[0028] Specifically, the upper front of the housing 1 has a front panel, and the PC-based host computer acts as the "central hub" of the device, playing a role in process control, data processing, and result storage for the entire testing process. This is divided into five tasks: front panel event task, serial port command task, image processing task, result judgment task, and data storage task. After the device is powered on, the PC-based host computer automatically starts and runs its software. The user can touch the "Initial Position" button on the front panel to reset all mechanisms to their initial positions, waiting for the testing to begin. Subsequently, the user places the inflation device on the test fixture 3 and touches the "Start Test" button on the front panel to trigger the entire testing process. The PC-based host computer sends downlink serial port commands to the controller, thereby controlling the rotating platform to rotate 180°, and also sends downlink commands to the light source controller to open the loop. The ring light source 50 illuminates the front end of the inflation device. The industrial camera 5 then transmits the captured image to the PC host computer, which displays the image in real time on the front panel. The PC host computer then initiates an image processing task to measure the opening gap at the front end. Subsequently, the PC host computer sends a downlink serial port command to the controller, thereby controlling the extension of the first electric cylinder 6 and the second electric cylinder 7, achieving contact between the spring probe 70 and the measured point, and causing deformation of the rear lever of the inflation device. The PC host computer then analyzes the resistance value through the uplink serial port data from the low-resistance tester and compares the uplink serial port data from the analog-to-digital converter before and after deformation to determine the deformation amount, which is the opening gap of the rear lever of the inflation device. At this point, all three test indicators have been obtained. The PC host computer then uses corresponding serial port commands to turn off the ring light source 50 and retract the first electric cylinder 6 and the second electric cylinder 7.

[0029] Finally, the three test indicators are displayed on the front panel. After the software makes its own judgment, the user can clearly know whether the quality of the inflatable device being tested meets the standard through the words "PASS" and "NG". If all three indicators are "PASS", the quality of the inflatable device being tested is qualified. The host computer will execute the data storage task and save the test data in the form of an EXCEL file to the specified directory. If "NG" appears, the quality is unqualified, and the host computer on the PC will not execute the data storage task.

[0030] The implementation method is as follows:

[0031] 1) Connect the device to a 220V power supply, start the device, and run the PC-side host computer software.

[0032] 2) Click the "Initial Position" button on the PC host computer. Then, the loading and unloading platform 2 will rotate counterclockwise to the limit position of the U-shaped groove photoelectric switch. At the same time, the first electric cylinder 6 and the second electric cylinder 7 will retract.

[0033] 3) Place the inflation device to be tested on the test fixture 3 of the loading and unloading platform 2. Then, click the "Start Test" button on the PC. When the button is pressed, the loading and unloading platform 2 rotates 180° and places the inflation device to be tested in the test area.

[0034] Subsequently, the equipment will automatically perform the following detection process: The PC-side host computer issues a command to turn on the light source—the ring light source 50 is turned on—the PC-side host computer displays the image captured by the industrial camera 5—the image processing task calculates the front opening gap M—the PC-side host computer requests the current value L1 from the laser sensor 8—the PC-side host computer sends a command to the controller to extend the first electric cylinder 6 and the second electric cylinder 7—the controller controls the first electric cylinder 6 and the second electric cylinder 7 to extend to their positions—the PC-side host computer requests the resistance value—the resistance value R is parsed according to the communication protocol—the PC-side host computer requests the laser sensor's current value L1— The current value L2 of the light sensor 8 is used to calculate the lever gap L = L2 - L1. The PC host computer sends a command to turn off the light source. The ring light source 50 is turned off. The PC host computer sends a command to the controller to retract the first electric cylinder 6 and the second electric cylinder 7. The controller controls the first electric cylinder 6 and the second electric cylinder 7 to retract into place. The PC host computer judges whether the measured M, R, and L are qualified. If M, R, and L are qualified, the PC host computer displays "PASS" after the corresponding test item and automatically saves the test results. If they are not qualified, "NG" is displayed and the test results are not saved.

[0035] Now, the user waits to place the new inflatable device to be tested onto the test fixture 3. When the user clicks the "Start Test" button again, the loading and unloading platform 2 rotates 180° to rotate the previously tested inflatable device to the outside of the equipment. The user can then classify it according to the test results.

[0036] The specific process of image processing on the PC is as follows: the PC performs grayscale processing on the acquired image, template matching, creating a new coordinate system, edge extraction, edge ranging, and conversion to the real coordinate system unit.

Claims

1. A testing device for measuring a buoy inflation device, the device performing the detection of an opening gap at the front end of the inflation device, the detection of a lever opening gap at the rear end of the inflation device, and the measurement of a resistance value at the top, characterized in that: The device includes a housing (1), a detection area is provided on one side of the housing (1), a loading and unloading platform (2) is provided in the detection area, the bottom of the loading and unloading platform (2) is fixedly connected to the housing (1) through a rotating mechanism, a fixture (3) for fixing the buoy inflation device is provided on the loading and unloading platform (2), an image acquisition mechanism and a lever lifting mechanism are provided on the left and right sides of the detection area respectively in conjunction with the sides of the buoy inflation device, a resistance test probe assembly is provided on the top of the detection area in conjunction with the resistance test point of the buoy inflation device, and a distance measuring device is provided at the rear of the detection area in conjunction with the buoy inflation device. The rotating mechanism, the image acquisition mechanism, the lever lifting mechanism and the resistance test probe assembly are all connected to a PC host computer through a controller. The image acquisition mechanism includes an industrial camera (5), a light source controller, a ring light source (50) and a POE power supply module. The lever lifting mechanism consists of a first electric cylinder (6) and a lifting block (60). The resistance test probe assembly includes a second electric cylinder (7), a low resistance tester and a spring probe (70). The ranging device is a laser ranging sensor (8). The device automatically performs the following tests: The PC host computer issues an instruction to turn on the light source, the ring light source (50) is turned on, the PC host computer displays the image captured by the industrial camera (5), the image processing task calculates the front opening gap M, the PC host computer requests the current value L1 of the laser rangefinder (8), the PC host computer issues an instruction to extend the first electric cylinder (6) and the second electric cylinder (7) to the controller, the controller controls the first electric cylinder (6) and the second electric cylinder (7) to extend to their positions, the PC host computer requests the resistance value, the resistance value R is parsed according to the communication protocol, the PC host computer requests the current value L2 of the laser rangefinder (8), the lever gap L = L2 - L1 is calculated, the PC host computer issues an instruction to turn off the light source, the ring light source (50) is turned off, the PC host computer issues an instruction to retract the first electric cylinder (6) and the second electric cylinder (7) to the controller, the controller controls the first electric cylinder (6) and the second electric cylinder (7) to retract to their positions, and it is determined whether the measured M, R, and L are qualified.

2. The detection device for measuring buoy inflation devices according to claim 1, characterized in that: The rotating mechanism is a 57 stepper motor (4).

3. The detection device for measuring buoy inflation devices according to claim 1, characterized in that: The ring light source (50) is mounted on the industrial camera (5). The industrial camera (5) acquires images of the gap at the end of the buoy inflation device and transmits the image data to the PC host computer via a gigabit network cable through the POE power supply module for machine vision processing. The light source controller and the PC host computer are connected via an RS232 serial port and can control the ring light source (50) to turn on and off by sending down commands.

4. The detection device for measuring buoy inflation devices according to claim 1, characterized in that: The second electric cylinder (7) is fixed on the wall of the box (1), the low resistance tester is fixed inside the box (1), the spring probe (70) is fixed on the probe mounting plate of the resistance tester, and the low resistance tester is connected to the PC host computer via an RS232 serial cable.

5. The detection device for measuring buoy inflation devices according to claim 4, characterized in that: The housing (1) is also equipped with a motor drive board. The controller outputs two sets of high and low level signals to the motor drive board, which can control the extension and retraction of the first electric cylinder (6) and the second electric cylinder (7).

6. The detection device for measuring buoy inflation devices according to claim 1, characterized in that: The laser ranging sensor (8) obtains an analog output that changes linearly with distance, and converts the analog output into a digital signal transmitted according to the protocol format through an analog-to-digital converter. The laser ranging sensor (8) and the PC host computer are connected through the PC host computer via an RS485 bus, so that the PC host computer receives the digital signal and parses the actual measured distance through the protocol.

7. The detection device for measuring buoy inflation devices according to claim 1, characterized in that: The controller is a Siemens S7-200 PLC.

8. The detection device for measuring buoy inflation devices according to claim 6, characterized in that: The motor driver board is the L298N motor driver board.

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