Magnetic ring coil quality detection system and method based on visual detection

Abstract

The application provides a magnetic ring coil quality detection system and method based on visual detection. The system comprises a magnetic ring coil conveying belt, a mechanical hand arranged close to the magnetic ring coil conveying belt, a front view detection area and a side view detection area arranged along a conveying path of the magnetic ring coil conveying belt, a front view detection camera arranged opposite to the front view detection area, a side view detection camera arranged opposite to the side view detection area, the front view detection camera and the side view detection camera connected to a detection host, and the mechanical hand used for converting a magnetic ring coil to be detected into a side standing state in the side view detection area. The detection host realizes defective product screening according to a front view image and a side view image. The effect is that the magnetic ring coil quality detection can be realized continuously and quickly without wiring test, and the detection efficiency is improved. The safety hidden danger caused by power-on test and the detection error caused by unstable wiring are avoided. The automatic screening of defective products can be realized.

Description

A Vision-Based System and Method for Detecting the Quality of Magnetic Ring Coils Technical Field

[0001] This invention relates to the field of image detection technology, and in particular to a magnetic ring coil quality detection system and method based on visual detection. Background Technology

[0002] Magnetic ring coils are typically made by winding enameled wire around a toroidal magnetic core, as shown in Figure 1. They are mainly used as filtering or energy conversion components in electronic devices. Due to their simple structure, some manufacturers often use manual winding during production, which makes quality control difficult and affects product quality.

[0003] Most existing coil quality testing methods use power-on testing, such as the magnetic ring coil micro-current detector disclosed in Chinese Patent 202122695383.7. Although micro-current detection can reduce test energy consumption, it requires connecting the magnetic ring coil to the sampling circuit during testing, which increases the workload during testing. Moreover, the stability of the circuit connection also affects the test results, making it difficult to meet the needs of rapid testing. Summary of the Invention

[0004] In view of this, the present invention first provides a magnetic ring coil quality inspection system based on visual inspection, which uses image detection methods to directly determine the production quality through the coil structural characteristics.

[0005] To achieve the above objectives, the specific technical solution adopted by the present invention is as follows:

[0006] A magnetic ring coil quality inspection system based on visual inspection is characterized by comprising a magnetic ring coil conveyor belt (1), a robotic arm (2) positioned near the magnetic ring coil conveyor belt (1), a frontal inspection area (3) and a side inspection area (4) positioned along the conveyor path of the magnetic ring coil conveyor belt (1), a frontal inspection camera (5) positioned opposite the frontal inspection area (3), and a side inspection camera (6) positioned opposite the side inspection area (4). The frontal inspection camera (5) and the side inspection camera (6) are connected to an inspection host (7). The robotic arm (2) is used to convert the magnetic ring coil to be inspected into a side-standing state in the side inspection area (4). The inspection host (7) performs defective product screening based on the frontal image obtained by the frontal inspection camera (5) and the side image obtained by the side inspection camera (6).

[0007] Optionally, a defective product storage area (8) and a good product storage area (9) are also provided near the magnetic ring coil transmission belt (1). When the detection host (7) detects a defective product, the robotic arm (2) is also used to screen the defective product.

[0008] Optionally, the robotic arm (2) clamps the magnetic ring coil that has been detected in the front-view detection area (3) and rotates it 90 degrees to obtain the magnetic ring coil in the side-view detection area (4) in a side-standing state.

[0009] Optionally, the detection host (7) performs visual inspection by acquiring the front view image to identify the number of coil turns and the turn spacing. The detection host (7) also performs visual inspection by acquiring the side view image to identify the coil tightness, and performs defective product screening based on the number of coil turns, the turn spacing and the coil tightness.

[0010] Based on the above system, this invention also proposes a visual inspection-based magnetic ring coil quality inspection method, which uses the visual inspection-based magnetic ring coil quality inspection system described above and includes the following steps:

[0011] S1: Obtain a frontal view image through a frontal view detection camera to identify the number of coil turns and the turn spacing;

[0012] S2: Obtain a side view image through a side-view detection camera to identify the tightness of the coil;

[0013] S3: Defective products are screened based on the number of coil turns, the spacing between turns, and the coil tightness.

[0014] Optionally, a defective product storage area (8) and a good product storage area (9) are provided near the magnetic ring coil transmission belt (1). When the detection host (7) detects a defective product, the defective product is sent into the defective product storage area (8) by the robot arm (2).

[0015] Optionally, step S1 specifically includes:

[0016] S11: Obtain the front view image and perform image enhancement and binarization processing;

[0017] S12: Determine the number of copper wire region blocks in the coil using the binarized image. If the number of copper wire region blocks is not equal to the preset number of coil turns, it is considered a defective product; if the number of copper wire region blocks is equal to the preset number of coil turns, proceed to step S13.

[0018] S13: Calculate the area of ​​the magnetic core region between two adjacent copper wire regions of the coil, and denot it as S1 to S2. n The number of magnetic core regions with n intervals is calculated, and their mean square error is determined. If the calculated mean square error exceeds a preset threshold, the coil turn spacing is unqualified and is identified as a defective product.

[0019] Optionally, step S2 specifically includes:

[0020] S21: Acquire the side view image and perform image enhancement and binarization processing;

[0021] S22: Extract the position of the magnetic core edge contour and the position of the coil edge contour;

[0022] S23: Calculate the maximum horizontal distance dmax between the core edge profile position and the coil edge profile position;

[0023] S24: If the maximum horizontal spacing dmax exceeds the preset threshold, the loose coil winding is considered a defective product.

[0024] The significant effects of this invention are:

[0025] (1) This invention uses visual inspection, which eliminates the need for wiring testing and enables continuous and rapid quality inspection of magnetic ring coils, thereby improving inspection efficiency.

[0026] (2) Because non-powered measurement is used, the safety hazards caused by power-on testing and the detection errors caused by unstable wiring are avoided.

[0027] (3) Based on automated transmission and sorting devices, it is possible to automatically screen defective products, making control more convenient. Attached Figure Description

[0028] Figure 1 is a schematic diagram of a conventional magnetic ring coil structure;

[0029] Figure 2 is an architecture diagram of a magnetic ring coil quality detection system based on visual inspection provided in an embodiment of the present invention;

[0030] Figure 3 is a flowchart of the magnetic ring coil quality detection method based on visual inspection provided in an embodiment of the present invention;

[0031] Figure 4 is a schematic diagram of the distribution of detection parameters in a front view of an embodiment of the present invention;

[0032] Figure 5 is a schematic diagram of the distribution of detection parameters in a side view of an embodiment of the present invention. Detailed Implementation

[0033] The embodiments of the present invention are described in detail below with reference to the accompanying drawings. The embodiments are given for illustrative purposes only and should not be construed as limiting the present invention. The accompanying drawings are for reference and illustration only and do not constitute a limitation on the scope of patent protection of the present invention, because many changes can be made to the present invention without departing from the spirit and scope of the present invention.

[0034] This embodiment provides a visual inspection-based magnetic ring coil quality inspection system, as shown in Figure 2. It includes a magnetic ring coil transport belt 1, a robotic arm 2 positioned near the transport belt 1, a frontal inspection area 3 and a side-view inspection area 4 along the transport path of the transport belt 1, a frontal inspection camera 5 positioned opposite the frontal inspection area 3, and a side-view inspection camera 6 positioned opposite the side-view inspection area 4. The frontal and side-view inspection cameras 5 and 6 are connected to an inspection host 7. The robotic arm 2 is used to convert the magnetic ring coil to be inspected into a side-standing state in the side-view inspection area 4. The inspection host 7 performs defective product screening based on the frontal image acquired by the frontal inspection camera 5 and the side-view image acquired by the side-view inspection camera 6. A defective product storage area 8 and a good product storage area 9 are also provided near the magnetic ring coil transport belt 1. When the inspection host 7 detects a defective product, the robotic arm 2 is also used to perform defective product screening.

[0035] As shown in Figure 1, in specific implementation, the robotic arm 2 can clamp the magnetic ring coil that has been inspected in the frontal inspection area 3 and rotate it 90 degrees to obtain the magnetic ring coil in the side-view inspection area 4 in a side-standing state, thereby facilitating the acquisition of the side view image. During the control process, the inspection host 7 can perform visual inspection through the acquired front view image to identify the number of coil turns and the turn spacing. The inspection host 7 also performs visual inspection through the acquired side view image to identify the coil tightness, and performs defective product screening based on the number of coil turns, the turn spacing, and the coil tightness.

[0036] As shown in Figure 3, this embodiment also proposes a visual inspection-based magnetic ring coil quality inspection method, which uses the visual inspection-based magnetic ring coil quality inspection system described above, and includes the following steps:

[0037] S1: Obtain a frontal view image through a frontal view detection camera to identify the number of coil turns and the turn spacing;

[0038] S2: Obtain a side view image through a side-view detection camera to identify the tightness of the coil;

[0039] S3: Defective products are screened based on the number of coil turns, the spacing between turns, and the coil tightness.

[0040] As can be seen from Figure 4, in specific implementation, step S1 includes:

[0041] S11: Obtain the front view image and perform image enhancement and binarization processing;

[0042] S12: Determine the number of copper wire region blocks in the coil using the binarized image. If the number of copper wire region blocks is not equal to the preset number of coil turns, it is considered a defective product; if the number of copper wire region blocks is equal to the preset number of coil turns, proceed to step S13.

[0043] S13: Calculate the area of ​​the magnetic core region between two adjacent copper wire regions of the coil, and denot it as S1 to S2. n The number of magnetic core regions with n intervals is calculated, and their mean square error is determined. If the calculated mean square error exceeds a preset threshold, the coil turn spacing is unqualified and is identified as a defective product.

[0044] As can be seen from Figure 5, in specific implementation, step S2 includes:

[0045] S21: Acquire the side view image and perform image enhancement and binarization processing;

[0046] S22: Extract the position of the magnetic core edge contour and the position of the coil edge contour;

[0047] S23: Calculate the maximum horizontal distance dmax between the core edge profile position and the coil edge profile position;

[0048] S24: If the maximum horizontal spacing dmax exceeds the preset threshold, the loose coil winding is considered a defective product.

[0049] Using the visual inspection-based magnetic ring coil quality inspection system and method provided by this invention, quality inspectors can pre-determine the standard number of coil turns and the turn spacing according to the model of the magnetic ring coil produced, and determine the preset threshold of the horizontal distance between the magnetic core edge contour position and the coil edge contour position based on the size of the winding used. According to the system and method given in the above embodiments, the magnetic ring coil to be inspected can be continuously transported through the magnetic ring coil transmission belt 1. The winding condition of the magnetic ring coil can be basically determined by the front view image and the side view image. Generally, as long as the number of coil turns is consistent, the turn spacing is uniformly distributed, and the winding is tight, the performance of the coil can be basically maintained stably, thereby ensuring the quality of the coil.

[0050] The above embodiments are preferred embodiments of the present invention, but the embodiments of the present invention are not limited to the above embodiments. Any changes, modifications, substitutions, combinations, or simplifications made without departing from the spirit and principle of the present invention shall be considered equivalent substitutions and shall be included within the protection scope of the present invention.

Claims

1. A magnetic ring coil quality inspection system based on vision inspection, characterized in that, The system includes a magnetic ring coil transmission belt (1), a robotic arm (2) is provided near the magnetic ring coil transmission belt (1), a frontal inspection area (3) and a side inspection area (4) are provided along the transmission path of the magnetic ring coil transmission belt (1), a frontal inspection camera (5) is provided facing the frontal inspection area (3), and a side inspection camera (6) is provided facing the side inspection area (4). The frontal inspection camera (5) and the side inspection camera (6) are connected to the inspection host (7). The robotic arm (2) is used to convert the magnetic ring coil to be inspected into a side-standing state in the side inspection area (4). The inspection host (7) performs visual inspection based on the frontal image obtained by the frontal inspection camera (5) to identify the number of coil turns and the turn spacing. The inspection host (7) also performs visual inspection based on the obtained side image to identify the coil tightness, and performs defective product screening based on the number of coil turns, the turn spacing and the coil tightness.

2. The magnetic ring coil quality inspection system based on vision inspection according to claim 1, characterized in that, Near the magnetic ring coil conveyor belt (1), there is also a defective product storage area (8) and a good product storage area (9). When the detection host (7) detects a defective product, the robotic arm (2) is also used to screen the defective product.

3. The vision-based magnetic ring coil quality inspection system according to claim 1 or 2, characterized in that, The robotic arm (2) clamps the magnetic ring coil that has been detected in the frontal detection area (3) and rotates it 90 degrees to obtain the magnetic ring coil in the side-view detection area (4) in a side-standing state.

4. A method for quality inspection of magnetic ring coils based on vision detection, employing the magnetic ring coil quality inspection system based on vision detection as described in any one of claims 1-3, characterized in that, Includes the following steps: S1: Obtain a frontal view image through a frontal view detection camera to identify the number of coil turns and the turn spacing; S2: Obtain a side view image through a side-view detection camera to identify the tightness of the coil; S3: Defective products are screened based on the number of coil turns, the spacing between turns, and the coil tightness.

5. The method for quality detection of magnetic ring coils based on visual inspection according to claim 4, characterized in that, A defective product storage area (8) and a good product storage area (9) are provided near the magnetic ring coil transmission belt (1). When the detection host (7) detects a defective product, the defective product is sent into the defective product storage area (8) by the robot arm (2).

6. The method for quality detection of magnetic ring coils based on visual inspection according to claim 4 or 5, characterized in that, Step S1 specifically includes: S11: Acquire a front view image and perform image enhancement and binarization processing; S12: Determine the number of coil copper wire region patches through the binarized image. If the number of coil copper wire region patches is not equal to the preset number of coil turns, it is considered a defective product; if the number of coil copper wire region patches is equal to the preset number of coil turns, proceed to step S13: S13: Calculate the area of ​​the magnetic core region between two adjacent coil copper wire regions in sequence, denoted as S1~S n n is the number of spaced magnetic core regions, and its mean square error is calculated. If the calculated mean square error exceeds the preset threshold, the coil turn spacing is unqualified and is identified as a defective product.

7. The method for quality detection of magnetic ring coils based on visual inspection according to claim 6, characterized in that, Step S2 specifically includes: S21: acquiring a side view image and performing image enhancement and binarization processing; S22: extracting the core edge contour position and the coil edge contour position; S23: calculating the maximum horizontal distance dmax between the core edge contour position and the coil edge contour position; S24: if the maximum horizontal distance dmax exceeds a preset threshold, the loose coil winding is identified as a defective product.

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