A product detection system and method

Abstract

An embodiment of the present invention discloses a product detection system and method. It includes a controller and a detection station. The detection station includes a first conveyor belt, a first servo motor for driving the first conveyor belt, an inlet sensor, an outlet sensor, and a plurality of first intermediate sensors at a plurality of detection stations disposed between the inlet sensor and the outlet sensor; The controller is configured to, when the product is conveyed from the loading station to the inlet of the detection station by the first conveyor belt, generate a product number and record the current servo position as the first servo position in response to the inlet sensor sensing the product; It is further configured to, when the product is conveyed to the detection station by the first conveyor belt, determine a first difference between the current servo position and a first distance in response to the first intermediate sensor sensing the product, the first distance being the distance between the first intermediate sensor and the inlet sensor, determine the first servo position that matches the first difference, and then determine the product number to trigger the detection station to perform detection and store the detection result according to the product number.

Description

Technical Field

[0001] The present invention relates to the technical field of electrical automation control. More specifically, it relates to a product detection system and method. Background Art

[0002] With the rapid development of the photovoltaic industry, the requirements for the production speed of solar cells have also been greatly improved. The raw material of the cell is silicon. First, the silicon rod needs to be cut into silicon wafers, then cleaned. After cleaning, multiple detections need to be carried out on the silicon wafers, such as chipping, size, crack, thickness, and surface contamination, etc. Then, according to different detection results, they are sorted and classified. During the detection process, in order to prevent affecting the detection results, the silicon wafers cannot be engraved with QR codes or barcodes.

[0003] Currently, in the existing detection technologies, there are mainly the following several ways for silicon wafer detection and sorting:

[0004] The first way is the production method using a DD motor turntable. The turntable rotates 360° in one week, corresponding to 2 - 10 detection stations. When each silicon wafer runs to a detection station, it first stops, then triggers the camera to take pictures. After obtaining the feedback result, it rotates and moves to the next detection station for detection. The problems and disadvantages of this technology mainly include: during detection, the silicon wafer needs to wait until there is a detection result before running to the next detection station, resulting in low production efficiency; using the production method of a large turntable with a DD motor, the use cost is high, the equipment volume is large, and it is not convenient to handle; it is not easy to add new detection stations, and the number of sorting levels of the product is limited, and the expansion is not flexible.

[0005] The second way is the production method using a belt line for transmission. The equipment is divided into a loading station, a detection station, and a discharging and sorting station. After the product comes out of the loading station, every time it runs to a detection item, the product needs to stop and wait for the detection result, and then move the silicon wafer to the next detection item for detection. At the same time, the subsequent silicon wafers move to this detection item for detection. The problems and disadvantages of this technology mainly include: during the detection process, the product needs to be stationary and wait for the detection result before running to the next station, resulting in low production efficiency; if one product is removed midway or a new product is added, the entire product sequence will be disrupted, and the corresponding detection results will also be incorrect, with poor compatibility and lack of flexibility.

[0006] Therefore, there is an urgent need to propose a product detection system that can automatically match product numbers, automatically obtain detection results, automatically transmit detection results, and automatically sort. Summary of the Invention

[0007] The purpose of the present invention is to provide a product detection system and method to solve at least one of the problems existing in the prior art.

[0008] To achieve the above object, the present invention adopts the following technical solutions:

[0009] In the first aspect of the present invention, a product detection system is provided, which includes a controller and a detection station. The detection station includes a first conveyor belt, a first servo motor for driving the first conveyor belt, an inlet sensor, an outlet sensor, and a plurality of first intermediate sensors disposed at a plurality of detection stations between the inlet sensor and the outlet sensor;

[0010] The controller is configured to generate a number for the product and record the current motor servo position as the first servo position when the product is conveyed by the first conveyor belt driven by the first servo motor from the loading station to the inlet position of the detection station in response to the inlet sensor sensing the product;

[0011] The controller is further configured to determine a first difference between the current motor servo position and a first distance when the product is conveyed to the detection station by the first conveyor belt driven by the first servo motor. The first distance is the distance between the first intermediate sensor and the inlet sensor, and determine the first servo position corresponding to the first difference, thereby determining the number of the product, so as to trigger the detection station to perform detection and store the detection result according to the number of the product.

[0012] Optionally, the detection stations include a left and right side breakage detection station, a 3D + resistivity detection station, a front and back edge breakage detection station, a dimension detection station, an upper contamination detection station, a lower contamination detection station, and a hidden crack detection station.

[0013] Optionally, the first servo motor operates in a speed control mode.

[0014] Optionally, the controller is further configured to determine a second difference between the current motor servo position and a second distance when the product is conveyed by the first conveyor belt driven by the first servo motor from the loading station to the outlet position of the detection station. The second distance is the distance between the outlet sensor and the inlet sensor, determine the first servo position corresponding to the second difference, thereby determining the number of the product, and summarize the detection results matching the current number of the product according to the number of the product, and control the first servo motor to drive the first conveyor belt to send the product to the unloading and sorting station.

[0015] Optionally, the first conveyor belt extends to the unloading and sorting station, and the unloading and sorting station includes a sorting mechanism. The controller is further configured to control the sorting mechanism to place the product into a bin corresponding to the product grade according to the detection result of the product.

[0016] Optionally, the blanking and sorting station further includes a plurality of second intermediate sensors disposed at a plurality of sorting stations, the sorting stations including the sorting mechanism and the material box, and the controller is further configured to, when the product is conveyed by the first conveyor belt driven by the first servo motor to the sorting station, in response to the second intermediate sensor sensing the product, determine a third difference between the current motor servo position and a third distance, the third distance being the distance between the second intermediate sensor and the inlet sensor, determine a first servo position corresponding to the third difference, and then determine the number of the product, so as to obtain the detection result of the product and determine whether to control the sorting mechanism of the sorting station to place the product into the material box of the sorting station.

[0017] Optionally, the blanking and sorting station includes a second conveyor belt, a second servo motor for driving the second conveyor belt, and a plurality of third intermediate sensors arranged along a first direction on the second conveyor belt, the first direction being the moving direction of the product driven by the second conveyor belt, wherein, one third intermediate sensor is arranged at each sorting station;

[0018] The controller is configured to, during the process of the product being driven by the second conveyor belt driven by the second servo motor to move, continuously record the number of the product determined by the outlet position of the detection station in response to each of the third intermediate sensors arranged along the first direction sensing the product, and when the product is conveyed by the second conveyor belt driven by the second servo motor to the sorting station, in response to the third intermediate sensor arranged at the sorting station sensing the product, obtain the detection result of the product according to the number of the product, and then determine whether to control the sorting mechanism of the sorting station to place the product into the material box of the sorting station.

[0019] Optionally, the distance between adjacent third intermediate sensors is less than the length of the product in the first direction.

[0020] Optionally, the sorting mechanism of the blanking and sorting station includes a lifting module or a manipulator.

[0021] A second aspect of the present invention provides a product detection method, the method including:

[0022] Determine the distances from the outlet sensor and each of the intermediate sensors in a detection station including an inlet sensor, an outlet sensor, and a plurality of first intermediate sensors located between the inlet sensor and the outlet sensor to the inlet sensor;

[0023] When the product is conveyed by the first conveyor belt driven by the first servo motor from the feeding station to the inlet position of the detection station, in response to the inlet sensor sensing the product, generate the number of the product and record the current motor servo position as the first servo position;

[0024] When the product is conveyed to the detection station by the first conveyor belt driven by the first servo motor, in response to the first intermediate sensor sensing the product, determine the first difference between the current servo position of the motor and the first distance, where the first distance is the distance between the first intermediate sensor and the inlet sensor, determine the first servo position corresponding to the first difference, and then determine the product number to trigger the detection station to perform detection and store the detection results according to the product number.

[0025] The beneficial effects of the present invention are as follows:

[0026] A product detection system disclosed by the present invention, by adopting the method of automatically generating product numbers and automatic matching, the detection and sorting of the remaining products are not affected when the product breaks or the number of products is manually increased or decreased during the production process, thereby improving the stability of the equipment and reducing the equipment downtime rate. Brief Description of the Drawings

[0027] The following further details the specific embodiments of the present invention in conjunction with the drawings.

[0028] Figure 1 Shows a schematic diagram of the distribution of each detection station in the product detection system provided by the embodiment of the present invention.

[0029] Figure 2 Shows a schematic diagram of the distribution of each sensor in the detection station of the product detection system provided by the embodiment of the present invention.

[0030] Figure 3 Shows a schematic diagram of the distribution of each sensor and the material box in the blanking and sorting station of the product detection system provided by the embodiment of the present invention.

[0031] Figure 4 Shows a schematic diagram of the structure of the detection and sorting system with the sorting mechanism being the lifting module provided by the embodiment of the present invention. Detailed Description of the Invention

[0032] To more clearly illustrate the present invention, the following further describes the present invention in conjunction with embodiments and drawings. Similar components in the drawings are denoted by the same reference numerals. Those skilled in the art should understand that the content specifically described below is illustrative rather than restrictive, and should not be used to limit the protection scope of the present invention.

[0033] Due to the large volume of the existing detection equipment, it is inconvenient to increase the detection items and detection levels. Affected by the rotation angle, the quantity increase is limited; because the product has no code, the corresponding product information cannot be recorded. Each time when obtaining product information and performing detection, the product needs to wait statically for the detection result and then run, resulting in low production efficiency; taking silicon wafers or solar cells as an example of the product, if one product is removed midway or a new product is added, the entire product sequence will be disrupted, and the corresponding detection results will also be incorrect, with poor compatibility and lack of flexibility.

[0034] In view of this, an embodiment of the present invention provides a product detection system, including a controller and a detection station. The detection station includes a first conveyor belt, a first servo motor for driving the first conveyor belt, an inlet sensor, an outlet sensor, and a plurality of first intermediate sensors disposed at a plurality of detection stations between the inlet sensor and the outlet sensor; the controller is configured to generate a product number and record the current motor servo position as the first servo position in response to the inlet sensor sensing the product when the product is conveyed from the loading station to the inlet position of the detection station by the first conveyor belt driven by the first servo motor; the controller is further configured to determine a first difference between the current motor servo position and a first distance when the product is conveyed to the detection station by the first conveyor belt driven by the first servo motor, where the first distance is the distance between the first intermediate sensor and the inlet sensor, determine the first servo position corresponding to the first difference, and then determine the product number, so as to trigger the detection station to perform detection and store the detection result according to the product number.

[0035] Exemplarily, the processing flow of the controller for the relevant data of the above detection station is as follows:

[0036] Obtain the number N of sensors in the detection station, and establish an array of sensor IO address numbers, denoted as SensorIO[1..N]. The sensors in the detection station include an inlet sensor, an outlet sensor, and a plurality of first intermediate sensors disposed at a plurality of detection stations between the inlet sensor and the outlet sensor.

[0037] Establish a UINT-type array for storing the product ID number, which is used to record the product ID number when the product matches at each sensor position, denoted as ID[1..N], and the maximum value of the ID number is IDMax. The product ID number is generated by the controller in response to the inlet sensor sensing the product when the product is conveyed from the loading station to the inlet position of the detection station by the conveyor belt driven by the servo motor.

[0038] Establish a UINT-type array for storing the product detection result, denoted as Result[1..IDMax]. The product detection result includes triggering the detection station to perform detection and storing the detection result according to the product number.

[0039] Establish a two-dimensional LREAL-type array for recording the servo current position when each product reaches the sensor. The first dimension represents the sensor number in the detection station, and the second dimension represents the product ID number, denoted as Pos[1..N,1..IDMax].

[0040] Create an LREAL array to set the actual distances from each sensor in the inspection station to the inlet sensor, denoted as sPos[1..N]. The inlet sensor is the first sensor. For example, the set address of the actual distance value between the second sensor and the first sensor is sPos[2]; the set address of the actual distance value between the third sensor and the first sensor is sPos[3], and so on. The actual distances from each sensor in the inspection station to the inlet sensor are the distances between multiple first intermediate sensors and the inlet sensor at multiple inspection stations.

[0041] Create an LREAL type variable for the tolerance set value, denoted as Offset. The tolerance set value is used to accommodate errors and improve the stability of the equipment.

[0042] When different products reach the inlet sensor of the inspection station, assign different ID numbers to the products, and at the same time record the current servo position in Pos[1,1..IDMax]. Taking silicon wafers or solar cells as an example of the product, when the first product enters the inlet sensor of the inspection station, assign the product ID as 1, and at the same time store the current servo position in the array Pos[1,1]; for the second product entering, assign the product ID as 2, and at the same time store the current servo position in the array Pos[1,2]; for the third product entering, assign the product ID as 3, and at the same time store the current servo position in the array Pos[1,3]; and so on. The product X is stored in the address Pos[1,X].

[0043] When the second sensor in the inspection station detects a product, store the current servo position in the array Pos[2,X], and use the exhaustive algorithm to calculate the absolute value. Calculate the value of X according to the equation |Pos[2,X] - sPos[2] - Pos[1,X]| <= Offset. X is the ID number of the product, send the ID number of the product to the upper computer, and at the same time trigger the inspection station for inspection. The rest of the inspection stations are the same by analogy. If the value of X cannot be calculated and there is no match, the inspection is not triggered, the product does not obtain the inspection result, and it directly goes to the tail DC cassette.

[0044] After all inspection stations have completed the inspection, put the result of the product with the ID number X into Result[X].

[0045] In a possible implementation, the inspection stations include left and right side breakage inspection stations, 3D + resistivity inspection stations, front and back edge breakage inspection stations, size inspection stations, upper contamination inspection stations, lower contamination inspection stations, and hidden crack inspection stations.

[0046] As Figure 1The figure shows a schematic diagram of the distribution of each detection station in the product detection system provided by an embodiment of the present invention. The number of sensors in the detection station of the product detection system is 2 more than the number of detection stations, which are an inlet sensor and an outlet sensor respectively.

[0047] In a possible implementation manner, the first servo motor operates in a speed control mode.

[0048] In a possible implementation manner, it is also used to, when the product is conveyed from the loading station to the outlet position of the detection station by the first conveyor belt driven by the first servo motor, in response to the outlet sensor sensing the product, determine a second difference between the current motor servo position and a second distance, where the second distance is the distance between the outlet sensor and the inlet sensor, determine a first servo position that matches the second difference to further determine the product number, and summarize the detection results that match the current product number according to the product number, and control the first servo motor to drive the first conveyor belt to send the product to the unloading and sorting station.

[0049] When the product reaches the outlet sensor of the detection station, according to the calculated value of X in |Pos[N,X] - sPos[N] - Pos[N,X]| <= Offset, obtain the test result of Result[X] given by the host computer.

[0050] For the unloading and sorting station, this embodiment provides two alternative sorting schemes.

[0051] Scheme 1

[0052] The first conveyor belt extends to the unloading and sorting station, and the unloading and sorting station includes a sorting mechanism. The controller is further used to control the sorting mechanism to place the product into the corresponding product grade bin according to the detection result of the product.

[0053] In a possible implementation manner, the unloading and sorting station further includes a plurality of second intermediate sensors arranged at a plurality of sorting stations. The sorting stations include the sorting mechanism and the bin. The controller is further used to, when the product is conveyed to the sorting station by the first conveyor belt driven by the first servo motor, in response to the second intermediate sensor sensing the product, determine a third difference between the current motor servo position and a third distance, where the third distance is the distance between the second intermediate sensor and the inlet sensor, determine a first servo position that matches the third difference to further determine the product number, so as to obtain the detection result of the product and determine whether to control the sorting mechanism of the sorting station to place the product into the bin of the sorting station.

[0054] The determination of the first servo position corresponding to the third difference and then the determination of the product number include: when different products reach the sorting station of the blanking sorting station, record the current motor servo position, determine the third difference between the current motor servo position and the third distance, that is, the third difference is |the current motor servo position - the third distance|, where the third distance is the distance between the second intermediate sensor and the inlet sensor. The first servo position corresponding to the third difference can be determined by the formula |the current motor servo position - the third distance - the first servo position| <= tolerance value, and the product ID number is determined based on the first servo position corresponding to the third difference.

[0055] The obtaining of the detection result of the product to determine whether to control the sorting mechanism of the sorting station to place the product into the bin of the sorting station includes: when the product detection result and the product ID number are transmitted to the multiple second intermediate sensors at the multiple sorting stations of the blanking sorting station, determine whether the product detection result is equal to the set grade of the bin at that place. When the product detection result is equal to the set grade of the bin at that place, the sorting mechanism operates to sort the product into the bin; when the product detection result is not equal to the set grade of the bin at that place, the sorting mechanism does not operate, and the product continues to be transmitted downward. If the product does not match all bins, it directly flows to the tail bin.

[0056] Solution 2

[0057] The blanking sorting station includes a second conveyor belt, a second servo motor for driving the second conveyor belt, and a plurality of third intermediate sensors arranged along the first direction on the second conveyor belt. The first direction is the movement direction of the product driven by the second conveyor belt. Among them, one third intermediate sensor is arranged at each sorting station; the controller is used to continuously record the number of the product determined by the outlet position of the detection station in response to each third intermediate sensor arranged along the first direction sensing the product during the movement of the product driven by the second servo motor on the second conveyor belt, and when the product is conveyed to the sorting station by the second conveyor belt driven by the second servo motor, in response to the third intermediate sensor arranged at the sorting station sensing the product, obtain the detection result of the product according to the number of the product to determine whether to control the sorting mechanism of the sorting station to place the product into the bin of the sorting station. Specifically, when the product moves to the first third intermediate sensor, in response to the feedback of the sensor, the controller grabs the product ID number and the detection result sensed by the outlet sensor of the detection station from the system. When the product continues to move to the second third intermediate sensor, in response to the feedback of the sensor, the controller grabs the product ID number and the detection result sensed by the previous sensor of this sensor from the system, and continuously records the numbers of the products discharged from the outlet of the detection station in this way.

[0058] In a possible implementation, the distance between adjacent third intermediate sensors is less than the length of the product in the first direction. With this setting, when the latter third intermediate sensor senses the product, the product has not left the previous third intermediate sensor, ensuring continuous transmission of product information.

[0059] In a possible implementation, the sorting mechanism of the blanking and sorting station includes a lifting module or a manipulator.

[0060] Exemplarily, in Solution 2, the processing flow of the controller for the relevant data of the blanking and sorting station is as follows:

[0061] Obtain the number M of sensors on the main line of the blanking and sorting station, and set the sensor spacing to be less than the width of the product in the conveying direction. The sensors on the main line of the blanking and sorting station include a plurality of third intermediate sensors arranged along the first direction on the second conveyor belt.

[0062] Establish a UINT-type array for product ID number transmission in the blanking and sorting station, denoted as SortID[1..M]. The product ID number transmission can be carried out by the controller continuously recording the number of the product determined at the outlet position of the detection station in response to each of the third intermediate sensors arranged along the first direction sensing the product during the movement of the product driven by the second servo motor on the second conveyor belt.

[0063] Establish a UINT-type array for setting the sorting level of the storage bin, denoted as SortLevel[1..number of bins]. The setting of the sorting level of the storage bin is mainly used to obtain the detection result of the product according to the number of the product, so as to judge whether to control the sorting mechanism of this sorting station to place the product into the bin of this sorting station.

[0064] Establish a UINT-type array for detection result transmission in the blanking and sorting station, denoted as SortResult[1..M]. The detection result transmission can be carried out by the controller obtaining the detection result of the product according to the number of the product in response to the third intermediate sensor sensing the product when the product is conveyed to the sorting station by the second conveyor belt driven by the second servo motor.

[0065] When the product reaches the first sensor at the blanking and sorting station, the value of Result[X] of the product with ID number X is assigned to SortResult[1], and at the same time, the value of Result[X] is cleared; the value of the product ID number X is assigned to SortID[1], and at the same time, X is cleared; when it reaches the second sensor at the blanking station, the product result SortResult[1] is assigned to SortResult[2], and SortID[1] is assigned to SortID[2]. After the assignment is completed, the values of SortResult[1] and SortID[1] are cleared, and so on for sequential transfer. When it is transferred to the Mth sensor, the product result is SortResult[M], and the product ID is SortID[M].

[0066] When the product result and ID are transferred to the sensor at the sorting mechanism, it is judged whether the product result SortResult[X] is equal to the set level of the bin at that place. When SortResult[X] is equal to SortLevel[bin number], the sorting mechanism acts and sorts the product into that bin; when SortResult[X] is not equal to SortLevel[bin number], the sorting mechanism does not act, and the product continues to be transferred downward. If the product does not match all bins, it directly flows to the tail bin.

[0067] A product detection system provided by this embodiment, by adopting the method of automatically generating product numbers and automatic matching, the detection and sorting of the remaining products are not affected when the product breaks or the number of products is manually increased or decreased during the production process, thereby improving the stability of the equipment and reducing the equipment downtime rate.

[0068] In a specific example, such as Figure 2 shows the schematic diagram of the distribution of each sensor at the detection station in the product detection system provided by the embodiment of the present invention. Figure 2 Among them, there are a total of 9 trigger sensors at the detection station, which respectively correspond to the inlet sensor 1, the left and right side collapse sensors 2, the 3D + resistivity sensor 3, the front and back edge collapse sensors 4, the dimension sensor 5, the upper dirt sensor 6, the lower dirt sensor 7, the hidden crack sensor 8, and the outlet sensor 9. The sensor selection includes an infrared ranging sensor for detecting when the product reaches the detection station.

[0069] Next, specific numerical examples are given for the data related to the detection station and the blanking and sorting station to illustrate the product detection system provided by this embodiment:

[0070] The length and width of the product are obtained as 182 mm respectively, and the total length of the inspection station and the blanking and sorting station is 5 m. The actual distances from each sensor of the inspection station to the inlet sensor are obtained. The actual distance between inlet sensor 1 and inlet sensor 1 is 0 mm, the actual distance between inlet sensor 1 and the left and right side edge collapse sensors 2 is 120 mm, the actual distance between inlet sensor 1 and the 3D + resistivity sensor 3 is 350 mm, the actual distance between inlet sensor 1 and the front and back edge collapse sensors 4 is 710 mm, the actual distance between inlet sensor 1 and the dimension sensor 5 is 900 mm, the actual distance between inlet sensor 1 and the upper dirt sensor 6 is 1250 mm, the actual distance between inlet sensor 1 and the lower dirt sensor 7 is 1500 mm, the actual distance between inlet sensor 1 and the hidden crack sensor 8 is 1790 mm, and the actual distance between inlet sensor 1 and the outlet sensor 9 is 2550 mm.

[0071] It is obtained that when the servo motor rotates 1 circle, the distance that the conveyor belt (belt line) moves is 125 mm; the encoder resolution is 1048576, and the number of pulses required for the motor to rotate 1 circle is set to 1048576; the speed mode is adopted when the servo motor runs. Taking the product as a silicon wafer as an example, the distance between the main belt line sensors at the blanking station is set to be less than the width of a silicon wafer, which is 182 mm, and the moving speed of the product during production at the inspection station and the blanking and sorting station is 1000 mm / s.

[0072] It is set that there cannot be 50 products on the belt line at the same time. The array for storing the product ID numbers is ID[1..50], and the maximum value of the ID number is 50. When the ID number is greater than 50, it is re - assigned to 1 to ensure that the product IDs on the belt line do not repeat. The array for storing the product inspection results is Result[1..50]. The array for setting the sorting grades of the storage bins is SortLevel[1..6]. The two - dimensional array for recording the servo current position when each product reaches the sensor is Pos[1..9,1..50].

[0073] The array of the actual distances from each sensor in the detection station to the inlet sensor is sPos[1..9]. The inlet sensor is the first sensor, sPos[1]=0mm. The set address of the actual distance value between the left and right side collapse sensors and the inlet sensor is sPos[2]=120mm. The set address of the actual distance value between the 3D + resistivity sensor and the inlet sensor is sPos[3]=350mm. The set address of the actual distance value between the front and back edge collapse sensors and the inlet sensor is sPos[4]=710mm. The set address of the actual distance value between the size sensor and the inlet sensor is sPos[5]=900mm. The set address of the actual distance value between the upper dirt sensor and the inlet sensor is sPos[6]=1250mm. The set address of the actual distance value between the lower dirt sensor and the inlet sensor is sPos[7]=1500mm. The set address of the actual distance value between the hidden crack sensor and the inlet sensor is sPos[8]=1790mm. The set address of the actual distance value between the outlet sensor and the inlet sensor is sPos[9]=2550mm. The tolerance set value Offset is 10mm.

[0074] As Figure 3 Shown is a schematic diagram of the distribution of each sensor and the material box in the blanking and sorting station of the product detection system provided by the embodiment of the present invention. The number of sensors M on the main line of the blanking and sorting station is 11. The array used for ID transmission in the blanking and sorting station is SortID[1..11], and the array used for detecting result transmission is SortResult[1..11].

[0075] When the first product reaches the detection station inlet sensor, the product number is assigned ID = 1. At the same time, the value of the servo current position 230mm is recorded in Pos[1,1], that is, Pos[1,1]=230; when the second product reaches the detection station inlet sensor, the product number is assigned ID = 2. At the same time, the value of the servo current position 633mm is recorded in Pos[1,2], that is, Pos[1,2]=633; similarly, for the third product, ID = 3, Pos[1,3]=1035; for the fourth product, ID = 4, Pos[1,4]=1440; for the fifth product, ID = 5, Pos[1,5]=1850; for the sixth product, ID = 6, Pos[1,6]=2245; and so on; when ID is greater than 50, it loops back, that is, ID is reassigned to 1. Since 50 products cannot be detected simultaneously, there will be no products with the same ID in the detection station.

[0076] When the left and right side collapse sensors at the inspection station detect a product, obtain the current position of the servo. For example, if the current position of the servo is equal to 1157 mm, store it in the array Pos[2,X], that is, Pos[2,X]=1157. The actual distance sPos[2] from the left and right side collapse sensors to the inlet sensor is 120 mm. Use the exhaustive algorithm to calculate the absolute value. According to the equation |Pos[2,X] - sPos[2] - Pos[1,X]| <= Offset, calculate the value of X. X is the ID number of the product, that is, 1157 - 120 - Pos[1,X] <= 10, and it can be known that the value of Pos[1,X] should be between 1027 and 1047. From this, it can be seen that X = 3, that is, the product with ID = 3 has reached the left and right side collapse detection item.

[0077] Inform the inspection system of the product information ID = 3, and at the same time trigger the left and right side collapse cameras to take pictures for inspection. If the ID is not matched, the product ID is assigned a value of 0 and there is no inspection result. At each inspection item, inform the inspection system of the product information ID = 3 number and trigger the inspection at the same time. After the inspection system has completed the inspection of all inspection items, store the product inspection result 2 in the product information with ID = 3, that is, Result[3]=2. When the product reaches the outlet sensor and the product ID is matched, for example, if the product information with ID = 3 is matched, obtain the value of Result[3] in the system and start to transfer it to the blanking station, and sequentially obtain the values of the inspection results Result[1..50] of each product.

[0078] When the product leaves the inspection station and reaches the first sensor at the blanking station, assign the value of the inspection result Result[3]=2 of the product with ID number 3 to SortResult[1], and at the same time clear the value of Result[3]; assign the value of the product ID number 3 to SortID[1], and at the same time clear the ID; when it reaches the second sensor at the blanking station, assign the product result SortResult[1] to SortResult[2] and SortID[1] to SortID[2]. After the assignment is completed, clear the values of SortResult[1] and SortID[1].

[0079] Such as Figure 4The figure shows a schematic diagram of the structure of the detection and sorting system in which the sorting mechanism provided by the embodiment of the present invention is a lifting module. When the product is transferred to the position of the sensor 3 of the unloading station, it is determined whether the set sorting level of the material box 1 and the material box 4 matches the result of the product. When SortResult[3]=SortLevel[1], the lifting module rises, the belt rotates, and the product is transferred to the material box 1; when SortResult[3]=SortLevel[4], the lifting module rises, the belt rotates, and the product is transferred to the material box 4. When SortResult[3]<>SortLevel[1] and SortResult[3]<>SortLevel[4], the lifting module does not act, and the sorting result and ID of the product continue to be transmitted backward. If the product does not match the set level of all the material boxes, the product is sent to the terminal DC material box.

[0080] All products are processed in parallel using multiple processes. The system will automatically ignore detection of products added in the middle, and will automatically delete information of products removed. Ignored products will not trigger detection and will flow to the DC material box at the end.

[0081] It can be seen that, in combination with a product inspection system provided in this embodiment, the inspection station is separated from the material unloading and sorting station, and a certain inspection item or sorting box can be enabled or disabled at will without deliberately changing the program, thereby improving the flexibility and compatibility of the equipment, and there is no need to stop and wait for the results when obtaining product information during the inspection, which greatly improves production efficiency.

[0082] Another embodiment of the present invention provides a product detection method, the method comprising:

[0083] Determine the distance from the outlet sensor and each intermediate sensor to the import sensor in the inspection station including an import sensor, an outlet sensor and multiple first intermediate sensors located at multiple inspection stations between the import sensor and the outlet sensor; when the product is transported from the loading station to the import position of the inspection station by the first conveyor belt driven by the first servo motor, in response to the import sensor sensing the product, generate the product number and record the current motor servo position as the first servo position; when the product is transported to the inspection station by the first conveyor belt driven by the first servo motor, in response to the first intermediate sensor sensing the product, determine the first difference between the current motor servo position and the first distance, the first distance being the distance between the first intermediate sensor and the import sensor, determine the first servo position consistent with the first difference, and then determine the product number, so as to trigger the inspection station to perform inspection and store the inspection result according to the product number.

[0084] A product detection method provided by this embodiment, by adopting the method of automatically generating product numbers and automatic matching, during the production process, even if the product breaks or the number of products is manually increased or decreased, it does not affect the detection and sorting of the remaining products, thereby improving the stability of the equipment and reducing the equipment downtime rate.

[0085] It should be noted that the product detection method provided by this embodiment is similar to the principle and working process of the above product detection system. For the relevant parts, reference can be made to the above description and will not be elaborated here.

[0086] In the description of the present invention, it should be noted that the orientation or positional relationship indicated by terms such as "upper" and "lower" is based on the orientation or positional relationship shown in the drawings. It is only for the convenience of describing the present invention and simplifying the description, rather than indicating or implying that the device or element referred to must have a specific orientation, be constructed and operated in a specific orientation. Therefore, it cannot be understood as a limitation to the present invention. Unless otherwise clearly specified and defined, the terms "installed", "connected", and "connected" should be understood in a broad sense. For example, it can be a fixed connection, a detachable connection, or an integral connection; it can be a mechanical connection or an electrical connection; it can be directly connected or indirectly connected through an intermediate medium, and it can be the communication inside two elements. For those of ordinary skill in the art, the specific meanings of the above terms in the present invention can be understood according to specific situations.

[0087] It also should be noted that in the description of the present invention, relational terms such as first and second are only used to distinguish one entity or operation from another entity or operation, and do not necessarily require or imply any actual relationship or order between these entities or operations. Moreover, the terms "including", "comprising" or any other variant thereof are intended to cover non-exclusive inclusion, so that a process, method, article or device including a series of elements not only includes those elements, but also includes other elements not explicitly listed, or also includes elements inherent to such process, method, article or device. Without further limitation, the element defined by the statement "including one..." does not exclude the existence of additional identical elements in the process, method, article or device including the said element.

[0088] Obviously, the above embodiments of the present invention are only examples for clearly illustrating the present invention, rather than limitations on the implementation manners of the present invention. For those of ordinary skill in the art, other different forms of changes or variations can be made based on the above description. It is impossible to list all the implementation manners here. Any obvious changes or variations derived from the technical solutions of the present invention still fall within the protection scope of the present invention.

Claims

1. A product detection system, characterized in that, it includes a controller and a detection station. The detection station includes a first conveyor belt, a first servo motor for driving the first conveyor belt, an inlet sensor, an outlet sensor, and a plurality of first intermediate sensors at a plurality of detection stations disposed between the inlet sensor and the outlet sensor; The controller is configured to generate a number for the product and record the current motor servo position as the first servo position in response to the inlet sensor sensing the product when the product is conveyed from the loading station to the inlet position of the detection station by the first conveyor belt driven by the first servo motor; The controller is further configured to, when the product is conveyed to the detection station by the first conveyor belt driven by the first servo motor, determine a first difference between the current motor servo position and a first distance in response to the first intermediate sensor sensing the product, where the first distance is the distance between the first intermediate sensor and the inlet sensor, determine the first servo position corresponding to the first difference and then determine the number of the product, so as to trigger the detection station to perform detection and store the detection result according to the number of the product.

2. The product detection system according to claim 1, characterized in that, the detection stations include a left and right side chipping detection station, a 3D + resistivity detection station, a front and back chipping detection station, a dimension detection station, an upper contamination detection station, a lower contamination detection station, and a hidden crack detection station.

3. The product detection system according to claim 1, characterized in that, the first servo motor operates in a speed control mode.

4. The product detection system according to claim 1, characterized in that, the controller is further configured to, when the product is conveyed from the loading station to the outlet position of the detection station by the first conveyor belt driven by the first servo motor, determine a second difference between the current motor servo position and a second distance in response to the outlet sensor sensing the product, where the second distance is the distance between the outlet sensor and the inlet sensor, determine the first servo position corresponding to the second difference and then determine the number of the product, and summarize the detection results matching the current number of the product according to the number of the product, and control the first servo motor to drive the first conveyor belt to send the product to the unloading and sorting station.

5. The product detection system according to claim 4, characterized in that, the first conveyor belt extends to the unloading and sorting station and the unloading and sorting station includes a sorting mechanism. The controller is further configured to control the sorting mechanism to place the product into a corresponding product grade bin according to the detection result of the product.

6. The product detection system according to claim 5, characterized in that, The blanking and sorting station further includes a plurality of second intermediate sensors disposed at a plurality of sorting stations. The sorting stations include the sorting mechanism and the material box. The controller is further configured to, when the product is conveyed to the sorting station by the first conveyor belt driven by the first servo motor, in response to the second intermediate sensor sensing the product, determine a third difference between the current motor servo position and a third distance, where the third distance is the distance between the second intermediate sensor and the inlet sensor, determine a first servo position corresponding to the third difference, and then determine the product number, so as to obtain the detection result of the product and determine whether to control the sorting mechanism of the sorting station to place the product into the material box of the sorting station.

7. The product detection system according to claim 5, wherein, the blanking and sorting station includes a second conveyor belt, a second servo motor for driving the second conveyor belt, and a plurality of third intermediate sensors arranged along a first direction on the second conveyor belt. The first direction is the moving direction of the product driven by the second conveyor belt, and one third intermediate sensor is arranged at each sorting station; the controller is configured to, during the process of the product being driven by the second conveyor belt driven by the second servo motor, continuously record the product number determined by the outlet position of the detection station in response to each of the third intermediate sensors arranged along the first direction successively sensing the product, and when the product is conveyed to the sorting station by the second conveyor belt driven by the second servo motor, in response to the third intermediate sensor arranged at the sorting station sensing the product, obtain the detection result of the product according to the product number, and then determine whether to control the sorting mechanism of the sorting station to place the product into the material box of the sorting station.

8. The product detection system according to claim 7, wherein, the distance between adjacent third intermediate sensors is less than the length of the product in the first direction.

9. The product detection system according to any one of claims 5-8, wherein, the sorting mechanism of the blanking and sorting station includes a lifting module or a manipulator.

10. A product detection method, wherein, the method includes: determining the distances from the outlet sensor and each of the intermediate sensors in a detection station including an inlet sensor, an outlet sensor, and a plurality of first intermediate sensors located between the inlet sensor and the outlet sensor to the inlet sensor; when the product is conveyed from the feeding station to the inlet position of the detection station by the first conveyor belt driven by the first servo motor, in response to the inlet sensor sensing the product, generating the product number and recording the current motor servo position as the first servo position; when the product is conveyed to the detection station by the first conveyor belt driven by the first servo motor, in response to the first intermediate sensor sensing the product, determining a first difference between the current motor servo position and a first distance, where the first distance is the distance between the first intermediate sensor and the inlet sensor, determining a first servo position corresponding to the first difference, and then determining the product number, so as to trigger the detection station to perform detection and store the detection result according to the product number.

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