Material saving device and method based on visual detection

Abstract

The application discloses a kind of based on visual inspection's material-saving device and method, it is related to visual inspection technical field, this based on visual inspection's material-saving device includes controller, transmission mechanism and detection mechanism, the controller is electrically connected transmission mechanism and detection mechanism respectively, the transmission mechanism is used to transmit material belt, the material belt includes sequentially connected material section, and all material sections sequentially pass through detection area in transmission process;The detection mechanism is used to carry out defect detection to the material section passing through the detection area, and sends flaw information to the controller;The controller generates control signal according to the flaw information, and the control signal is fed back to back-end device;The back-end device selectively processes the material belt according to the control signal;The present application can immediately order back-end device to stop processing current material section when detecting that current material section appears flaw, effectively avoid raw material waste, greatly reduce production cost.

Description

Technical Field

[0001] This invention relates to the field of visual inspection technology, and more particularly to a material-saving device and method based on visual inspection. Background Technology

[0002] In the production of long, continuous, double-sided strip materials, problems such as breakage, incomplete coating, scratches, and dimensional abnormalities may occur due to material manufacturing processes or product quality issues, affecting product quality and creating potential quality risks. Therefore, before processing the materials, it is necessary to inspect the surface for defects and remove defective materials to ensure reliable product quality.

[0003] In current technology, the rejection of defective materials is generally carried out after the material segment is generated, based on the defect detection results of the vision system. Specifically, if there are defects in the material segment, the entire material segment is rejected.

[0004] Although the above method can remove waste materials, it removes the entire section of material with defects, and cannot immediately stop the production of that section of material when defects occur, resulting in waste of raw materials and greatly increasing production costs. Summary of the Invention

[0005] The purpose of this invention is to provide a material-saving device and method based on visual inspection, which can immediately command the back-end equipment to stop processing the current material segment when a defect is detected, effectively avoiding waste of raw materials and greatly reducing production costs.

[0006] To achieve the above objectives, the present invention discloses a material-saving device based on visual inspection, which includes a controller, a transmission mechanism and a detection mechanism. The controller is electrically connected to the transmission mechanism and the detection mechanism respectively. The transmission mechanism is used to transmit a material strip, which includes material segments connected in sequence, and all material segments pass through the detection area in sequence during the transmission process.

[0007] The detection mechanism is used to detect defects in the material segments passing through the detection area and send the defect information to the controller;

[0008] The controller generates a control signal based on the defect information and feeds the control signal back to the backend device;

[0009] The back-end equipment selectively processes the material strip according to the control signal.

[0010] Preferably, the detection mechanism includes a first detection unit, which is used to detect at least one type of material strip defect on the upper surface of the material segment passing through the detection area.

[0011] Preferably, the first detection unit includes a plurality of first cameras, which are spaced apart above the material strip. Each first camera is communicatively connected to the controller. Each first camera is used to detect a specific type of material strip defect and send first defect information to the controller.

[0012] Preferably, the controller includes a first processing unit, which is communicatively connected to the backend device and each of the first cameras, and the first processing unit processes and summarizes the first defect information of all the first cameras in parallel in a multi-threaded manner.

[0013] Preferably, the detection mechanism includes a second detection unit for detecting at least one type of material strip defect on the lower surface of the material segment passing through the detection area.

[0014] Preferably, the second detection unit includes a plurality of second cameras, which are spaced apart below the material strip. Each of the second cameras is communicatively connected to the controller. Each second camera is used to detect a specific type of material strip defect and send the second defect information to the controller.

[0015] Preferably, the controller includes a second processing unit, which is communicatively connected to the backend device and each of the second cameras, and the second processing unit processes and summarizes the second defect information of all the second cameras in parallel in a multi-threaded manner.

[0016] Preferably, the first processing unit or the second processing unit merges the first defect information and the second defect information to generate the control signal, and feeds the control signal back to the back-end device.

[0017] Preferably, if the upper or lower surface of the current material segment passing through the detection area has defects, the back-end equipment stops processing the current material segment and processes a new material segment.

[0018] Preferably, the conveying mechanism includes multiple rollers, and the material belt passes through all the rollers in sequence and is conveyed in a specified direction under the rolling of all the rollers.

[0019] Correspondingly, the present invention also discloses a material-saving method based on visual detection, applied to the material-saving device based on visual detection as described above. The material-saving method based on visual detection includes the following steps:

[0020] S1. Perform multi-threaded defect detection on the material segments that have passed through the detection area;

[0021] S2. If a defect exists in a segment of the material strip located within the detection area, then the defect is determined to be located at a position on the material strip.

[0022] S3. If the defect is located at the head of the material strip, then stop the processing of the current material strip by the back-end equipment and stop the production process of the current material strip by the front-end equipment.

[0023] S4. Remake a new strip and repeat steps S1 to S3.

[0024] Compared with the prior art, the detection mechanism of the present invention is used to detect defects in material segments passing through the detection area and send the defect information to the controller. The controller generates a control signal based on the defect information and feeds the control signal back to the back-end equipment. The back-end equipment selectively processes the material strip according to the control signal. Specifically, if the upper or lower surface of the current material segment passing through the detection area has defects, the back-end equipment stops processing the current material segment and processes a new material segment. This invention enables the back-end equipment to immediately stop processing the current material segment when a defect is detected, effectively avoiding waste of raw materials and greatly reducing production costs. Attached Figure Description

[0025] Figure 1 This is a schematic diagram of the material-saving device based on vision detection of the present invention;

[0026] Figure 2 This is a schematic diagram of the circuit structure of the material-saving device based on vision detection of the present invention;

[0027] Figure 3 This is a schematic diagram of the material strip structure of the present invention;

[0028] Figure 4 This is a schematic diagram of the material strip structure when the material-saving device based on vision detection of the present invention is applied to the production of lithium battery electrode sheets.

[0029] Figure 5 This is a flowchart of the application of the material-saving device based on vision detection of the present invention in the production of lithium battery electrode sheets.

[0030] Figure 6 This is a process flow diagram of the material-saving method based on visual inspection of the present invention. Detailed Implementation

[0031] To illustrate the technical content, structural features, objectives, and effects of the present invention in detail, the following description is provided in conjunction with the embodiments and accompanying drawings.

[0032] Please see Figures 1-3As shown, the material-saving device based on vision inspection in this embodiment includes a controller 10, a transmission mechanism 20, and a detection mechanism. The controller 10 is electrically connected to the transmission mechanism 20 and the detection mechanism. The transmission mechanism 20 is used to transmit the material strip 1, which includes material segments 101 connected in sequence. During the transmission process, all material segments 101 pass through the detection area in sequence. The detection mechanism is used to perform defect detection on the material segments 101 that have passed through the detection area and send the defect information 102 to the controller 10. The controller 10 generates a control signal based on the defect information 102 and feeds the control signal back to the back-end equipment (not shown in the figure). The back-end equipment selectively processes the material strip 1 according to the control signal. Generally, the host computer of the back-end equipment controls the process according to the control signal.

[0033] Understandably, the material is continuously transported in a specific direction under the action of the conveying mechanism 20. Each material segment 101 connected in sequence will pass through the detection area in sequence. The material segment 101 located at the first segment of the material can be regarded as the head of the material belt 1. When there is no defect 102 at the head of the material belt 1, the back-end equipment starts to process the material belt 1 from the head of the material belt 1. When a defect 102 appears in the first segment or any material segment 101 of the material belt 1, the back-end equipment stops processing the material segment 101 and reprocesses the next material segment 101. At this time, the next material segment 101 to be reprocessed is the new head of the material belt 1.

[0034] Preferably, the inspection mechanism includes a first inspection unit 31, which is used to inspect at least one type of material strip 1 defect on the upper surface of the material segment 101 passing through the inspection area. The material strip 1 defect here includes, but is not limited to, breakage, bad spots, edge burrs, etc.

[0035] Preferably, the first detection unit 31 includes a plurality of first cameras 311, which are spaced apart above the strip 1. Each first camera 311 is communicatively connected to the controller 10. Each first camera 311 is used to detect a specific type of defect in the strip 1 and sends the first defect information to the controller 10. For example, the first detection unit 31 includes three first cameras 311, which are respectively a die-cutting camera, a front AT11 camera, and a back AT11 camera. Each camera detects different types of defects 102 in the strip 1 through its camera structure, placement position, and lighting method.

[0036] Preferably, the controller 10 includes a first processing unit, which is communicatively connected to the backend device and each first camera 311. The first processing unit processes and summarizes the first defect information of all the first cameras 311 in parallel using multiple threads. It is understood that by using multi-threaded parallel processing, data processing efficiency is improved, thereby effectively improving detection efficiency.

[0037] Preferably, the inspection mechanism includes a second inspection unit 32, which is used to inspect at least one type of defect in the strip 1 on the lower surface of the strip 101 passing through the inspection area. The defects in the strip 1 include, but are not limited to, breaks, bad spots, and edge burrs.

[0038] Preferably, the second detection unit 32 includes a plurality of second cameras 321, which are spaced apart below the strip 1. Each second camera 321 is communicatively connected to the controller 10. Each second camera 321 is used to detect a specific type of defect in the strip 1 and sends the second defect information to the controller 10. For example, the second detection unit 32 includes three second cameras 321, which are a backlight camera, an inner slitting camera, and an outer slitting camera, respectively. Each camera detects different types of defects 102 in the strip 1 through its camera structure, placement position, and lighting method.

[0039] Preferably, the cover controller 10 includes a second processing unit, which is communicatively connected to the backend device and each second camera 321. The second processing unit processes and summarizes the second defect information of all second cameras 321 in parallel using multiple threads. It is understood that by using multi-threaded parallel processing, data processing efficiency is improved, thereby effectively improving detection efficiency.

[0040] Preferably, the first processing unit or the second processing unit merges the first defect information and the second defect information to generate a control signal, and then feeds the control signal back to the back-end device. It is understood that one of the first processing unit or the second processing unit acts as the main processor for final data aggregation processing. Of course, the controller 10 may also include a main processing unit, with the first and second processing units electrically connected to this main processing unit. The main processing unit merges the first defect information and the second defect information to generate a control signal, and then feeds the control signal back to the back-end device.

[0041] Preferably, if a defect 102 is found on the upper or lower surface of the current material segment 101 passing through the detection area, the back-end equipment stops processing the current material segment 101 and processes the new material segment 101. It is understood that the control signals for determining whether the back-end equipment needs to stop processing the current material segment 101 include a stop processing signal for the current material segment 101 and a continue processing signal for the current material segment 101. The processing unit responsible for summarizing these signals can use an OR logic approach, generating a stop processing signal for the current material segment 101 when any camera detects a defect 102.

[0042] Preferably, the conveying mechanism 20 includes a plurality of rollers 21, through which the material belt 1 passes in sequence and is conveyed in a specified direction under the rolling of all rollers 21.

[0043] The following explanation uses the production of lithium battery electrodes as an example:

[0044] Please see Figures 1-5 In the production process of lithium battery electrodes, a lithium battery is composed of several EAs (Electrical Assemblages), each EA being equivalent to a segment 101 in strip 1, meaning a lithium battery consists of multiple continuous segments 101. Each EA is a unit. When a defect 102 exists in an EA, it will be removed in the subsequent process to ensure battery quality. During production, if a defect 102 is detected in the current EA, the relevant information of the defect 102 (EA number, defect type, coordinates, etc.) and a signal will be sent to the previous station to stop producing that EA. After receiving the signal from the vision inspection system, the previous station will end the production of that EA and start producing a new EA, thus saving materials.

[0045] Figure 5 The flowchart of the material-saving device based on vision detection in this embodiment is shown. In the lithium battery electrode detection process: taking the cathode as an example, the first detection unit 31 and the second detection unit 32 are equipped with different cameras and perform defect 102 detection in different threads.

[0046] When one or more cameras on the first detection unit 31—the die-cutting camera, the front AT11 camera, and the back AT11 camera—detect defect 102, they integrate the defect 102 information and transmit it to the first processing unit via TCP communication (defect 102 is divided into inner and outer sides). Similarly, the backlight camera, the inner slitting camera, and the outer slitting camera on the second detection unit 32 detect defect 102 and integrate the defect 102 information. The processor determines the position of defect 102 in the current EA and whether production of that section of material needs to be stopped. If so, it transmits the corresponding signal to the host computer to perform the appropriate action.

[0047] After repeated verification, upon detecting a defect at the head of material strip 1, a corresponding control signal is sent to the back-end equipment, causing it to stop and skip the production of that section, thus avoiding the complete discarding of material strip 1 due to a defect at the head. This method significantly reduces material waste and effectively lowers costs. Furthermore, this invention utilizes multi-threading technology multiple times, resulting in a faster detection response time; its processing speed is eight times that of traditional defect detection techniques. Moreover, this invention combines multiple detection methods in an interactive manner to meet the demands of highly variable industrial products, achieving an accuracy rate of up to 99.8%.

[0048] Please see Figure 6 As shown, correspondingly, the present invention also discloses a material-saving method based on visual detection, applied to the material-saving device based on visual detection as described above. The material-saving method based on visual detection includes the following steps:

[0049] S1. Perform multi-threaded defect detection on the material segment 101 that has passed through the detection area;

[0050] S2. If a defect 102 exists in a segment 101 of the material strip 1 located within the detection area, then it is determined that the defect 102 is located at a position on the material strip 101.

[0051] S3. If the defect 102 is located at the head of the material strip 1, then stop the processing of the current material strip 1 by the back-end equipment and stop the production process of the current material strip 1 by the front-end equipment.

[0052] S4. Make a new strip 1 and repeat steps S1 to S3.

[0053] Combination Figures 1-6 The detection mechanism of the present invention is used to perform defect detection on the material segment 101 passing through the detection area and send the defect 102 information to the controller 10. The controller 10 generates a control signal based on the defect 102 information and feeds the control signal back to the back-end equipment. The back-end equipment selectively processes the material strip 1 according to the control signal. Specifically, if the upper or lower surface of the current material segment 101 passing through the detection area has a defect 102, the back-end equipment stops processing the current material segment 101 and processes the new material segment 101. This invention can immediately command the back-end equipment to stop processing the current material segment 101 when a defect 102 is detected, effectively avoiding waste of raw materials and greatly reducing production costs.

[0054] The above-disclosed embodiments are merely preferred embodiments of the present invention and should not be construed as limiting the scope of the present invention. Therefore, any equivalent variations made in accordance with the claims of the present invention are still within the scope of the present invention.

Claims

1. A material-saving method based on visual inspection, characterized in that: Includes the following steps: S1. Perform multi-threaded defect detection on the material segments that have passed through the detection area; S2. If there is a defect in the material segment located within the detection area of ​​the material strip, then it is determined that the defect is located in the material strip. S3. If the defect is located at the head of the material strip, then stop the processing of the current material strip by the back-end equipment and stop the production process of the current material strip by the front-end equipment. S4. Remake a new strip and repeat steps S1 to S3; The material-saving method based on vision detection employs the following material-saving device based on vision detection: the material-saving device based on vision detection includes a controller, a transmission mechanism, and a detection mechanism. The controller is electrically connected to the transmission mechanism and the detection mechanism respectively. The transmission mechanism is used to transmit the material strip, which includes material segments connected in sequence, and all material segments pass through the detection area in sequence during the transmission process. The detection mechanism is used to detect defects in the material segments passing through the detection area and send the defect information to the controller; The controller generates a control signal based on the defect information and feeds the control signal back to the backend device; The back-end equipment selectively processes the material strip according to the control signal.

2. The material-saving method based on visual detection as described in claim 1, characterized in that: The detection mechanism includes a first detection unit, which is used to detect at least one type of material strip defect on the upper surface of the material segment passing through the detection area.

3. The material-saving method based on visual detection as described in claim 2, characterized in that: The first detection unit includes a plurality of first cameras, which are spaced apart above the material strip. Each first camera is communicatively connected to the controller. Each first camera is used to detect defects in the material strip and send the defect information to the controller.

4. The material-saving method based on visual detection as described in claim 3, characterized in that: The controller includes a first processing unit, which is communicatively connected to the backend device and each of the first cameras. The first processing unit processes and summarizes the defect information of all the first cameras in parallel using multiple threads.

5. The material-saving method based on visual detection as described in claim 4, characterized in that: The detection mechanism includes a second detection unit, which is used to detect at least one type of material strip defect on the lower surface of the material segment passing through the detection area.

6. The material-saving method based on visual detection as described in claim 5, characterized in that: The second detection unit includes a plurality of second cameras, which are spaced apart below the material strip. Each second camera is communicatively connected to the controller. Each second camera is used to detect defects in the material strip and send the defect information to the controller.

7. The material-saving method based on visual detection as described in claim 6, characterized in that: The controller includes a second processing unit, which is communicatively connected to the backend device and each of the second cameras. The second processing unit processes and summarizes the defect information of all the second cameras in parallel using multiple threads.

8. The material-saving method based on visual detection as described in claim 7, characterized in that: The first processing unit or the second processing unit merges the defect information from the first camera and the defect information from the second camera to generate the control signal, and feeds the control signal back to the back-end device. If the upper or lower surface of the current material segment passing through the detection area has defects, the back-end device stops processing the current material segment and processes the new material segment.

9. The material-saving method based on visual detection as described in claim 1, characterized in that: The conveying mechanism includes multiple rollers, and the material belt passes through all the rollers in sequence and is conveyed in a specified direction under the rolling of all the rollers.

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