Pallet leg positioning visual inspection system and inspection method

Abstract

The present invention discloses a visual inspection system and method for pallet leg positioning. The inspection system includes an acquisition module, a communication module, a processing module, a display module, and an expansion module. The processing module is electrically connected to the acquisition module and the display module, respectively, and the communication module is electrically connected to the processing module, the display module, and the expansion module. The acquisition module includes an RFID recognition system, several industrial cameras, and LED lighting. The communication module is composed of several industrial Ethernet switches and their communication media. The processing module includes a visual industrial computer, a visual data analysis and processing software system, and a PLC system. The industrial cameras, the visual industrial computer, and the visual data analysis and processing software system constitute the visual system. The display module is composed of a visual display and an HMI display screen. The expansion module is composed of a cloud-based remote and central control display client. The present invention can realize the identification and detection of pallet legs and reduce implementation costs.

Description

Technical Field

[0001] The present invention relates to the field of automobile technology, and in particular to a visual detection system and method for positioning pallet legs. Background Art

[0002] On automotive production lines, it's common to produce multiple models with different outriggers on the same pallet or skid. This wide variety of models makes installation errors easy for employees. Misplaced outriggers can damage the skid-changing station and automated robotic equipment, leading to significant downtime and production losses. To effectively address this issue, a function is needed at the front end of the skid-changing station to automatically identify outrigger installation information.

[0003] Currently, in robot-assisted vision systems, characteristic holes of car bodies or workpieces are mainly identified through 2D photography and 3D laser scanning, compared with system template photos, and the position offset of the car body or workpiece is calculated by software to guide the adjustment of the robot's motion trajectory. However, due to the characteristics of existing visual recognition technology, the plane offset and three-dimensional offset of the car body are identified through 2D photography and 3D laser scanning respectively, and its recognition range is limited. It is only suitable for the identification of larger car bodies or workpieces. It is not applicable to the identification of small workpieces or tooling (such as pallet legs) because the differentiation is too small. In addition, the recognition accuracy requirements of existing technical solutions are relatively high, resulting in high costs. Summary of the Invention

[0004] The purpose of the present invention is to provide a pallet leg positioning visual detection system and detection method to achieve identification and detection of pallet legs and reduce implementation costs.

[0005] A pallet leg positioning visual detection system includes an acquisition module, a communication module, a processing module, a display module and an expansion module;

[0006] The processing module is electrically connected to the acquisition module and the display module respectively, and the communication module is electrically connected to the processing module, the display module and the expansion module respectively;

[0007] The acquisition module includes an RFID identification system, several industrial cameras and LED lighting; the communication module is composed of several industrial Ethernet switches and their communication media; the processing module includes a visual industrial computer, a visual data analysis and processing software system, and a PLC system; and the industrial cameras, visual industrial computer, and visual data analysis and processing software system constitute a visual system, the display module is composed of a visual display and an HMI display screen; the expansion module is composed of a cloud remote and central control display client.

[0008] The above-mentioned pallet leg positioning visual inspection system, wherein the number of industrial cameras is 5, of which 1 is a top camera, 2 are left cameras, and 2 are right cameras. The top camera is used to take photos of the plane layout of the 4 supports of the pallet legs, the left camera is used to take side photos of the two front and rear legs on the left side, and the right camera is used to take side photos of the two front and rear legs on the right side. There are 10 LED lights for fill lighting for the industrial cameras.

[0009] The above-mentioned pallet leg positioning visual inspection system, wherein the visual industrial computer is used to analyze, compare and identify the data collected by the industrial camera through software, and then display the information on the display while interacting with the PLC system information in real time. The PLC system is used to switch the working mode of the visual industrial computer, and also controls the corresponding actions of the equipment and displays the corresponding information on the HIM screen. The RFID identification system is used to provide vehicle model comparison information for visual identification.

[0010] A detection method for a pallet leg positioning visual detection system includes the following steps:

[0011] S1: After the vehicle arrives at the workstation, the RFID identification system reads the vehicle information to be replaced with the skid. The PLC system sends relevant interactive information to the vision system. At the same time, after the pallet with the legs installed is in the visual inspection position, the vision system starts taking pictures.

[0012] S2: The visual system identifies the characteristic information of the outriggers based on the photos taken by the on-site camera. After accurate comparison and analysis with the photos of the standard vehicle model template read by the PLC system, it determines whether the vehicle model corresponding to the current pallet outriggers is correct.

[0013] S3: If the visual system identifies the vehicle type corresponding to the current pallet legs as correct, it sends a recognition success signal to the PLC system, and the PLC system controls the equipment to operate normally; if the visual system identifies the vehicle type corresponding to the current pallet legs as incorrect, it sends specific information about the recognition error to the PLC system, and the PLC system controls the equipment to stop the line;

[0014] S4, the results of the visual system detection are displayed on the on-site display software screen.

[0015] In the above detection method, in step S2, the characteristic information of the legs includes position, direction and height.

[0016] In the above detection method, in step S4, the content displayed on the on-site display software screen includes: photos of the industrial camera, recognition results, detection state switching results and function menus; the content displayed on the HMI screen during the process includes information from the visual system to the PLC system, information from the PLC system to the visual system, and the operating mode and alarm information of the PLC system.

[0017] According to the visual inspection system and method for positioning of pallet legs provided by the present invention, the vehicle type of the legs is identified at the work station of the empty pallet with the legs installed at the front end of the vehicle skid-changing station. At the same time, the vehicle information is identified by using RFID equipment at the work station of the vehicle to be skid-changed. Then the visual system and the PLC system interact to compare whether the leg and vehicle information are consistent. If they are consistent, the vehicle skid-changing work is automatically performed; if they are inconsistent, the equipment alarm stops the line and notifies the personnel to quickly handle it. It can accurately identify the installation position, direction and height of small tooling such as the legs, and does not require the use of 3D laser scanning, so the cost is low.

[0018] Additional aspects and advantages of the present invention will be set forth in part in the description which follows and, in part, will be obvious from the description which follows, or may be learned by practice of the present invention. BRIEF DESCRIPTION OF THE DRAWINGS

[0019] The above and / or additional aspects and advantages of the present invention will become apparent and readily understood from the description of the embodiments with reference to the following drawings, in which:

[0020] Figure 1 2 is a schematic structural diagram of a pallet leg positioning visual inspection system according to an embodiment of the present invention;

[0021] Figure 2 is a connection diagram of a pallet leg positioning visual detection system according to an embodiment of the present invention;

[0022] Figure 3 This is a layout diagram of a visual inspection system for positioning pallet legs according to an embodiment of the present invention;

[0023] Figure 4 The present invention is a flowchart of a detection method of a pallet leg positioning visual detection system according to an embodiment of the present invention. DETAILED DESCRIPTION

[0024] To make the objects, features, and advantages of the present invention more readily apparent, the following detailed description of specific embodiments of the present invention is provided in conjunction with the accompanying drawings. The accompanying drawings illustrate several embodiments of the present invention. However, the present invention may be implemented in many different forms and is not limited to the embodiments described herein. Rather, these embodiments are provided to provide a more thorough and comprehensive understanding of the present invention.

[0025] It should be noted that when an element is referred to as being "fixed to" another element, it may be directly on the other element or there may also be an element centered thereon. When an element is considered to be "connected to" another element, it may be directly connected to the other element or there may also be an element centered thereon. The terms "vertical", "horizontal", "left", "right", "up", "down" and similar expressions used herein are for illustrative purposes only and do not indicate or imply that the device or element referred to must have a specific orientation, be constructed and operate in a specific orientation, and therefore should not be understood as limiting the present invention.

[0026] In the present invention, unless otherwise expressly specified or limited, the terms "installed," "connected," "connected," "fixed," and the like should be understood in a broad sense. For example, they may refer to fixed connections, detachable connections, or integral connections; they may refer to mechanical connections or electrical connections; they may refer to direct connections or indirect connections through an intermediate medium; and they may refer to internal communication between two components. Those skilled in the art will understand the specific meanings of the above terms in the present invention based on the specific circumstances. The term "and / or" as used herein includes any and all combinations of one or more of the relevant listed items.

[0027] See also Figures 1 to 3 The pallet leg positioning visual detection system proposed in an embodiment of the present invention includes an acquisition module 10, a communication module 20, a processing module 30, a display module 40 and an expansion module 50.

[0028] The processing module 30 is electrically connected to the acquisition module 10 and the display module 40 respectively, and the communication module 20 is electrically connected to the processing module 30 , the display module 40 and the expansion module 50 respectively.

[0029] The acquisition module 10 includes an RFID identification system, several industrial cameras and LED lighting; the communication module 20 is composed of several industrial Ethernet switches and their communication media; the processing module 30 includes a visual industrial computer, a visual data analysis and processing software system, and a PLC system; and the industrial cameras, visual industrial computer, and visual data analysis and processing software system constitute a visual system, the display module 40 is composed of a visual display and an HMI display screen; the expansion module 50 is composed of cloud remote and central control display clients, providing a foundation for intelligent digital construction.

[0030] In this embodiment, the number of industrial cameras is 5, of which 1 is a top camera, 2 are left cameras, and 2 are right cameras. The top camera is used to take a planar layout photo of the 4 supports of the pallet legs, the left camera is used to take a side photo of the 2 front and rear legs on the left side, and the right camera is used to take a side photo of the 2 front and rear legs on the right side (because each vehicle model on the pallet has 4 supports).

[0031] There are 10 LED lights, which are used to provide supplementary light for the industrial camera to ensure that the quality of the photos taken meets the recognition requirements when the ambient light is insufficient, thereby reducing system errors.

[0032] The visual industrial computer is the core of the system, which is used to analyze, compare and identify the data collected by the industrial camera through software, display the information on the monitor and interact with the PLC system information in real time.

[0033] The switch network system mainly serves as a bridge for information communication among various systems, ensuring timely transmission of information.

[0034] The PLC system is used to switch the working mode of the visual industrial computer, and also controls the corresponding actions of the equipment and displays the corresponding information on the HIM screen, so that on-site employees can obtain accurate information in a timely manner.

[0035] The RFID recognition system is used to provide information for vehicle model comparison for visual recognition. From another perspective, the use of the visual system can also reversely intercept the situation where vehicle model information errors occur.

[0036] See also Figure 4 , based on the above pallet leg positioning visual detection system, a detection method is provided, comprising the following steps:

[0037] S1: After the vehicle arrives at the workstation, the RFID identification system reads the vehicle information of the skid to be replaced, and the PLC system sends relevant interactive information to the visual system. At the same time, after the pallet with the legs installed is in the visual inspection position, the visual system starts taking pictures.

[0038] S2: The visual system identifies the characteristic information of the outriggers based on the photos taken by the on-site camera. After accurate comparison and analysis with the photos of the standard vehicle model template read by the PLC system, it determines whether the vehicle model corresponding to the current pallet outriggers is correct.

[0039] The characteristic information of the legs includes position, direction and height.

[0040] S3: If the visual system identifies the vehicle type corresponding to the current pallet legs correctly, it sends a recognition success signal to the PLC system, and the PLC system controls the equipment to operate normally; if the visual system identifies the vehicle type corresponding to the current pallet legs incorrectly, it sends specific information about the recognition error to the PLC system, and the PLC system controls the equipment to stop the line.

[0041] S4, the results of the visual system detection are displayed on the on-site display software screen.

[0042] Among them, in step S4, the content displayed on the on-site display software screen includes: photos of the industrial camera (specifically 5 photos), recognition results (correct or incorrect), detection state switching results (start detection or stop detection) and function menus; the display content of the HMI screen during the process includes information from the vision system to the PLC system, information from the PLC system to the vision system, the operating mode of the PLC system (online, retry, bypass, manual release, etc.) and alarm information.

[0043] In summary, according to the above-mentioned visual inspection system and method for positioning pallet outriggers, the outrigger vehicle model is identified at the station where the empty pallet with the outriggers is installed at the front end of the vehicle skid-changing station. At the same time, the vehicle information is identified using RFID equipment at the station of the vehicle to be skid-changed. Then the visual system and the PLC system interact to compare the outrigger and vehicle information to see if they are consistent. If they are consistent, the vehicle skid-changing work is automatically performed; if they are inconsistent, the equipment alarm stops the line and notifies personnel to quickly handle it. This can accurately identify the installation position, direction and height of small tooling such as outriggers, and does not require the use of 3D laser scanning, thereby achieving low cost.

[0044] Throughout this specification, reference to terms such as "one embodiment," "some embodiments," "examples," "specific examples," or "some examples" means that a specific feature, structure, material, or characteristic described in conjunction with that embodiment or example is included in at least one embodiment or example of the present invention. In this specification, schematic representations of the above terms do not necessarily refer to the same embodiment or example. Furthermore, the specific features, structures, materials, or characteristics described may be combined in any suitable manner in any one or more embodiments or examples.

[0045] The above-described embodiments merely illustrate several implementations of the present invention, and while their descriptions are relatively specific and detailed, they should not be construed as limiting the scope of the present invention. It should be noted that a person skilled in the art would be able to make numerous variations and improvements without departing from the spirit of the present invention, all of which fall within the scope of protection of the present invention. Therefore, the scope of protection of the present invention shall be determined by the appended claims.

Claims

1. A detection method for a pallet leg positioning visual detection system, characterized in that: The pallet leg positioning visual inspection system includes an acquisition module, a communication module, a processing module, a display module and an expansion module; the processing module is electrically connected to the acquisition module and the display module respectively, and the communication module is electrically connected to the processing module, the display module and the expansion module respectively; the acquisition module includes an RFID identification system, several industrial cameras and LED lighting; the communication module is composed of several industrial Ethernet switches and their communication media; the processing module includes a visual industrial computer, a visual data analysis and processing software system, and a PLC system; and the industrial camera, the visual industrial computer, and the visual data analysis and processing software system constitute a visual system, the display module is composed of a visual display and an HMI display screen; the expansion module is composed of a cloud remote and central control display client; The method comprises the following steps: S1: After the vehicle arrives at the workstation, the RFID identification system reads the vehicle information to be replaced with the skid. The PLC system sends relevant interactive information to the vision system. At the same time, after the pallet with the legs installed is in the visual inspection position, the vision system starts taking pictures. S2: The visual system identifies the characteristic information of the outriggers based on the photos taken by the on-site camera. After accurate comparison and analysis with the photos of the standard vehicle model template read by the PLC system, it determines whether the vehicle model corresponding to the current pallet outriggers is correct. S3: If the visual system identifies the vehicle type corresponding to the current pallet legs as correct, it sends a recognition success signal to the PLC system, and the PLC system controls the equipment to operate normally; if the visual system identifies the vehicle type corresponding to the current pallet legs as incorrect, it sends specific information about the recognition error to the PLC system, and the PLC system controls the equipment to stop the line; S4, the results of the visual system detection are displayed on the on-site display software screen.

2. The detection method of the pallet leg positioning visual detection system according to claim 1, characterized in that: In step S2, the characteristic information of the legs includes position, direction and height.

3. The detection method of the pallet leg positioning visual detection system according to claim 1, characterized in that: In step S4, the contents displayed on the on-site display software screen include: photos of the industrial camera, recognition results, detection status switching results and function menus; the contents displayed on the HMI screen during the process include information from the visual system to the PLC system, information from the PLC system to the visual system, the operating mode of the PLC system and alarm information.

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