A machine vision LED support defect detection process

Abstract

The application discloses a kind of LED support defect detection processes of machine vision, including the following steps: by driving wheel, LED support strip detection row is transported to the first position in detection cavity, reciprocating motor drives angle control component, so that camera is respectively at first, second position to detection row is photographed, while angle control component linkage distance control component pushes illumination component to follow camera movement, and transmission is carried out to the shooting result to computer module, after computer module analysis, drive rejection mechanism respectively to waste and blemished product are rejected, and after rejection waste and blemished product are classified and recycled, finally, the LED support of defect detection is transported to next process link.The whole process does not need manual intervention, can classify and reject and collect defective product, while automatically taking detection row into double-position shooting and cooperating with corresponding illumination structure, improve the accuracy of machine vision detection defect.

Description

Technical Field

[0001] This invention relates to the field of LED bracket inspection technology, specifically to a machine vision-based LED bracket defect detection process. Background Technology

[0002] With declining manufacturing costs and breakthroughs in technologies such as luminous efficiency and light decay, my country's LED lighting industry has entered a phase of accelerated development, with a rapidly growing application market, making my country the world's largest producer of LED packaging. However, the inconsistent quality of LED packaging products within the industry has become a significant obstacle to the industry's growth. If the scrap / defect rate of LED packaging is 0.1%, then out of every trillion LED packaging products produced nationwide, hundreds of millions of scrap / defective products could be generated, resulting in a direct economic loss of nearly 100 million yuan.

[0003] As the base for LED packaging, defects in the LED bracket directly impact the quality of LED packaged products. Due to the huge demand for LED packaged products and the small and delicate nature of LED brackets, conventional manual inspection is inefficient and prone to missed or false detections, which is detrimental to LED bracket manufacturing. Furthermore, defects in LED brackets are categorized into usable defective products after processing and scrap products that must be discarded, based on their size and location. Existing machine vision inspection uniformly rejects defective products, causing difficulties in the subsequent recycling of defective products and resulting in significant material losses. Summary of the Invention

[0004] The purpose of this invention is to provide a machine vision-based LED bracket defect detection process to solve the problems mentioned in the background art.

[0005] To achieve the above objectives, the present invention provides a machine vision-based process for detecting defects in LED brackets, comprising the following steps:

[0006] I. Equipment Preparation Stage:

[0007] S1. Adjust the distance between the two sets of drive wheels according to the width of the LED bracket strip to be tested, so that the distance between the two sets of drive wheels is the same as the distance between the two sides of the LED bracket strip.

[0008] S2. Based on the spacing between two adjacent rows of LED brackets along the conveying direction, set the rotation angle and rotation period of the angle adjustment component;

[0009] II. LED bracket loading stage:

[0010] S3. First, place the outer end of the LED bracket on the upper surface of the roller at the entrance of the cabinet, and simultaneously pass the drive teeth on the outer sides of the two sets of drive wheels through both sides. The second motor works to drive the LED bracket through the detection cavity of the cabinet, and install the protruding outer ends on both sides of the drive teeth on both sides of the drive wheel at the exit.

[0011] S4. Then, adjust the height of the clamping mechanism according to the thickness of the LED bracket strip so that the lower end face of the clamping mechanism contacts the upper end face of the LED bracket strip. With the help of the two sets of drive wheels at the inlet and outlet, the LED bracket strip moves smoothly from the inlet to the outlet of the cabinet.

[0012] The support rod has an angled downward along the horizontal direction. When the LED bracket strip passes the support rod, it is straightened by gravity, which prevents the LED bracket strip from bending and shifting during the transportation process.

[0013] III. LED bracket with visual inspection stage:

[0014] S5. When the LED bracket with detection strip is conveyed to the first position, the reciprocating motor drives the angle adjustment component to move the swing arm to the second position. At the same time, the gear meshing and gear rotation cause the connecting rod to push the crossbar, causing the lighting tube to move in the direction of the swing arm rotation. The connecting rod takes the first picture of the detection strip. Then, the LED bracket is conveyed to the second position by the conveying component, the swing arm returns to the first position, and at the same time, the gear meshing and gear rotation reverses. The connecting rod pulls the crossbar, causing the lighting tube to move back to its original position. The connecting rod takes the second picture of the detection strip. Then, this operation is repeated to take two pictures of each of the rear LED brackets, and the picture data is transmitted to the calculation module.

[0015] S6. Subsequently, the calculation module compares and analyzes the two sets of photographic data based on the original collected data. The comparison results are as follows: a. qualified product, b. defective product, c. scrap product;

[0016] The machine vision component is installed on the upper end of the cabinet near the entrance. The machine vision component includes a mounting frame and an angle adjustment component. A reciprocating motor is installed on the outer wall of the mounting frame. The reciprocating motor drives the angle adjustment component to rotate at a set angle, so that the angle adjustment component periodically changes the first and second camera positions and takes two pictures of each row of LED brackets. The angle adjustment component is driven by a distance adjustment component, and the distance adjustment component is driven by a lighting component. The lighting component includes a crossbar and two sets of connecting plates. Lighting tubes are fixedly connected to the upper and lower ends of adjacent sides of the connecting plates. The tops of the two sets of connecting plates are fixedly connected by the crossbar.

[0017] IV. LED bracket defective product rejection stage:

[0018] S7. The LED support belt, after the data is recorded, continues to be conveyed forward until the detection row is directly below the rejection mechanism. The second motor stops working, the LED support belt stops, and the position of the defective product in the detection row is determined according to the analysis results of S. The rejection component at the corresponding position is controlled to work. The first electric push rod drives the cutter head to move downward to cut off the defective product around its perimeter. Then the second electric push rod works to push the pressure block down to push the defective product into the feeding port. At the same time, the drive component drives the receiving plate to move below the feeding port. The defective product enters the defective product collection area along the upper surface of the receiving plate.

[0019] S8. Based on the analysis results of S, determine the location of the waste product and control the corresponding rejection component to work. The second electric push rod pushes the pressure block down to directly move the waste product downward and push it into the feeding port. At the same time, the drive component drives the receiving plate away from the feeding port, and the waste product falls directly from the feeding port into the waste collection area.

[0020] S9. After rejection, the second motor moves the lower LED bracket to directly below the rejection mechanism to reject the defective product, and then transports the defective LED bracket to the next process step.

[0021] As a further improvement to this technical solution, a rejection mechanism is installed on one end of the upper surface of the cabinet near the exit. The rejection mechanism includes a mounting box and several sets of rejection components. Each rejection component includes an outer protective shell. A first electric push rod is installed on the top of the inner cavity of the outer protective shell. A connecting sleeve is fixedly connected to the output end of the first electric push rod. A square sliding sleeve is fixedly connected to the end of the connecting sleeve opposite to the first electric push rod. A cutter head is installed on the lower end face of the square sliding sleeve. The cutter head is slidably connected to the outer protective shell. A second electric push rod is installed on the top of the inner cavity of the connecting sleeve. A pressure block is fixedly connected to the output end of the second electric push rod. The pressure block is slidably connected to the inner wall of the square sliding sleeve.

[0022] As a further improvement to this technical solution, the bottom of the cabinet detection cavity is provided with several sets of unloading components. The unloading components are located directly below the rejection components, and the unloading components include a buffer groove and an unloading port. The buffer groove and the unloading port are concentrically arranged. The unloading port is connected to the storage area, and a buffer component is installed in the buffer groove.

[0023] As a further improvement to this technical solution, the conveying assembly includes a second motor and two sets of support rods. The two sets of support rods are arranged in parallel and several sets of crossbars are spaced apart at adjacent positions. The second motor drives one set of crossbars to rotate, and two sets of drive wheels are fixedly connected to the outer wall of the crossbar at intervals. Several sets of drive teeth are fixedly connected to the outer wall of the drive wheels at intervals.

[0024] As a further improvement to this technical solution, the material distribution control component includes a receiving plate and a partition. The partition is fixedly connected to the inner cavity of the cabinet. The receiving plate is disposed on the upper surface of the partition. A driving component is installed on the top of the partition. A toothed groove is formed on the lower surface of the receiving plate. The upper end of the driving component is located on the inner wall of the toothed groove and drives the receiving plate to reciprocate along the toothed groove.

[0025] As a further improvement to this technical solution, the drive assembly includes a dual-head drive motor, and each of the output ends of the dual-head drive motor is fixedly connected to a drive gear, which meshes with the tooth groove.

[0026] As a further improvement to this technical solution, the angle adjustment component includes a gear and a mounting shaft. The mounting shaft is fixedly connected to the inner wall of the mounting frame, and a gear and two sets of drive rings are rotatably connected to the outer wall of the mounting shaft. The gear is positioned adjacent to the two sets of drive rings, and the two sets of drive rings are fixedly connected by the gear. The inner wall of the gear meshes with the outer wall of the gear. The reciprocating motor drives the drive rings to rotate. A swing arm is fixedly connected to the lower end face of the gear, and a camera is mounted on the lower end face of the swing arm.

[0027] As a further improvement to this technical solution, the distance control component includes a mating gear, which is installed on the inner wall of the mounting frame and meshes with the gear. An eccentric shaft is rotatably connected to the front end face of the mating gear, and a connecting rod is fixedly connected to the outer wall of the eccentric shaft. The end of the connecting rod opposite to the eccentric shaft is rotatably connected to the outer wall of the crossbar.

[0028] As a further improvement to this technical solution, the buffer assembly includes a buffer plate, which is slidably connected in the buffer groove, and a number of elastic components are fixedly connected to the lower end face of the buffer plate, with the end of the elastic component opposite to the buffer plate fixedly connected to the bottom of the buffer groove.

[0029] As a further improvement to this technical solution, a cutting groove is provided on the upper surface of the buffer plate, the cutting groove being located directly below the cutting head and adapted to the cutting head.

[0030] Compared with the prior art, the beneficial effects of the present invention are as follows:

[0031] In this machine vision-based LED bracket defect detection process, a machine vision component and an illumination component are set. A corresponding rotation angle is set based on the spacing between adjacent groups of LED brackets. A reciprocating motor drives a drive ring to rotate a gear at this set angle. The gear meshes with a gear, causing the gear to rotate by the corresponding angle. A swing arm moves the camera from a first position to a second position. Simultaneously, the gear rotates, engaging a cooperating gear. The eccentric shaft at the front of the cooperating gear pushes a connecting rod, causing the lower end of the connecting rod to push a crossbar towards the second position. The reciprocating motor rotates in the opposite direction, returning the camera from the second position to the first position. At the same time, the connecting rod pulls the crossbar towards the first position. By controlling the rotation angle and cycle of the reciprocating motor, the camera can sequentially take dual-position photos of each row of LED brackets while the illumination component moves synchronously with the photo-taking positions. Four sets of illumination tubes are arranged in parallel and positioned at the four corners of the detection cavity. The illumination component moves with the camera positions, ensuring that the LED bracket detection is always located at the center of the overlapping illumination area of ​​the four sets of illumination tubes. This improves the resolution and accuracy of the machine vision for LED bracket defects.

[0032] In this machine vision-based LED bracket defect detection process, a rejection mechanism is set up. This mechanism includes multiple rejection components, which can simultaneously reject multiple defects in each row of LED brackets. Based on the analysis results of the calculation module, a corresponding processing mode is set. For qualified products, the rejection components do not work. For defective products, the rejection components at the relative position work. The first electric push rod drives the cutter head to cut off the defective product around its perimeter, and then the second electric push rod drives the pressure block to push the defective product into the feeding port. At the same time, the drive component drives the receiving plate to move to the bottom of the feeding port. The defective product slides down the upper surface of the receiving plate through the feeding port to the defective product collection area, and the cutter head and pressure block reset. For scrap products, after the defective products are rejected, the second electric push rod drives the pressure block to push the scrap product downward through the feeding port. At this time, the drive component drives the receiving plate away from the lower end of the feeding port, and the scrap product falls directly into the scrap collection area. This separates and collects scrap and defective products, while avoiding damage to defective products caused by violent rejection and falling, which would affect secondary recycling. Attached Figure Description

[0033] Figure 1 This is a schematic diagram of the overall assembly structure of Example 1;

[0034] Figure 2 This is a schematic diagram of the overall assembly half-section structure of Example 1;

[0035] Figure 3 As in Example 1 Figure 2 Enlarged structural diagram at point A;

[0036] Figure 4 As in Example 1 Figure 2 Enlarged structural diagram at point B;

[0037] Figure 5 This is a schematic diagram of the machine vision component structure in Example 1;

[0038] Figure 6 This is a schematic diagram of the lighting component structure in Example 1;

[0039] Figure 7 This is a schematic diagram of the rejection mechanism structure in Example 1;

[0040] Figure 8 This is a schematic diagram of the rejection component structure in Example 1;

[0041] Figure 9 This is a schematic diagram of the feeding assembly structure in Example 1;

[0042] Figure 10 This is a schematic diagram of the LED bracket structure in Example 1.

[0043] The meanings of the labels in the diagram are as follows:

[0044] 1. Cabinet; 2. Rejection Mechanism; 21. Mounting Box; 22. Rejection Component; 221. First Electric Push Rod; 222. Connecting Sleeve; 223. Square Sliding Sleeve; 224. Cutter Head; 225. External Protective Shell; 226. Pressure Block; 227. Second Electric Push Rod; 3. Machine Vision Component; 31. Mounting Frame; 32. Angle Adjustment Component; 321. Gear; 322. Gear; 323. Drive Ring; 324. Mounting Shaft; 325. Swing Arm; 326. Camera; 33. Reciprocating Motor; 34. Distance Adjustment Component; 341. Eccentric Rotary Shaft. 342 Gear assembly, 343 Linkage rod, 4 Lighting assembly, 41 Lighting tube, 42 Connecting plate, 43 Crossbar, 44 Slider, 5 Conveying assembly, 51 Support rod, 52 Crossbar, 53 Roller, 54 Slide groove, 55 Drive wheel, 56 Second motor, 6 Unloading assembly, 61 Buffer groove, 62 Unloading port, 63 Buffer plate, 64 Knife groove, 65 Elastic assembly, 7 Material distribution and control assembly, 71 Receiving plate, 72 Partition plate, 73 Drive assembly, 74 Gear groove, 8 Calculation module, 9 Pressing mechanism. Detailed Implementation

[0045] The technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.

[0046] In the description of this invention, it should be understood that the terms "central axis", "longitudinal", "lateral", "length", "width", "thickness", "upper", "lower", "front", "rear", "left", "right", "vertical", "horizontal", "top", "bottom", "inner", "outer", etc., indicating the orientation or positional relationship are based on the orientation or positional relationship shown in the accompanying drawings, and are only for the convenience of describing this invention and simplifying the description, and are not intended to indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation, and therefore should not be construed as a limitation of this invention.

[0047] Furthermore, in the description of this invention, "a number" means two or more, unless otherwise explicitly specified. Example 1

[0048] This invention provides a machine vision-based process for detecting defects in LED brackets, comprising the following steps:

[0049] I. Equipment Preparation Stage:

[0050] S1. Adjust the distance between the two sets of drive wheels 55 according to the width of the LED bracket strip to be tested, so that the distance between the two sets of drive wheels 55 is the same as the distance between the two sides of the LED bracket strip 100.

[0051] S2. Based on the spacing between two adjacent rows of LED brackets along the conveying direction, set the rotation angle and rotation period of the angle adjustment component 32.

[0052] II. LED bracket loading stage:

[0053] S3. First, place the outer end of the LED bracket on the upper surface of the roller 53 at the entrance of the cabinet 1, and simultaneously pass the drive teeth on the outer sides of the two sets of drive wheels 55 through the two sides 100. The second motor 56 works to drive the LED bracket to pass through the detection cavity of the cabinet 1, and install the 100 on both sides of the extended outer end on the drive teeth on both sides of the drive wheel 55 at the exit.

[0054] S4. Then, according to the thickness of the LED bracket strip, adjust the height of the pressing mechanism 9 so that the lower end face of the pressing mechanism 9 contacts the upper end face of the LED bracket strip. With the help of the two sets of drive wheels 55 at the inlet and outlet, the LED bracket strip moves smoothly from the inlet to the outlet of the cabinet 1.

[0055] The support rod 51 has an angled downward in the horizontal direction. When the LED bracket strip passes through the support rod 51, it is straightened by gravity to avoid bending and deviation of the LED bracket strip during the transportation process.

[0056] III. LED bracket with visual inspection stage:

[0057] S5. When the LED bracket belt is conveyed to the first position, the reciprocating motor 33 drives the angle adjustment component 32, causing the swing arm 325 to move to the second position. At the same time, the gear 322 meshes with the gear 342 to rotate, causing the connecting rod 343 to push the crossbar 43, causing the lighting tube 41 to move in the direction of rotation of the swing arm 325. The connecting rod 343 takes the first picture of the detection row. Then, the LED bracket belt is conveyed to the second position by the conveying component 5. The swing arm 325 returns to the first position. At the same time, the gear 322 meshes with the gear 342 to rotate in the opposite direction. The connecting rod 343 pulls the crossbar 43, causing the lighting tube 41 to move back to its original position. The connecting rod 343 takes the second picture of the detection row. Then, this operation is repeated to take two pictures of each of the rear LED brackets, and the picture data is transmitted to the calculation module 8.

[0058] S6. Subsequently, the calculation module 8 compares and analyzes the two sets of photographic data based on the original collected data. The comparison results are as follows: a. qualified product, b. defective product, c. scrap product;

[0059] The machine vision component 3 is installed on the upper end of the cabinet 1 near the entrance. The machine vision component 3 includes a mounting frame 31 and an angle adjustment component 32. A reciprocating motor 33 is installed on the outer wall of the mounting frame 31. The reciprocating motor 33 drives the angle adjustment component 32 to rotate at a set angle, so that the angle adjustment component 32 periodically changes the first and second positions and takes two pictures of each row of LED brackets. The angle adjustment component 32 is connected to a distance adjustment component 34. The distance adjustment component 34 is connected to a lighting component 4. The lighting component 4 includes a crossbar 43 and two sets of connecting plates 42. The upper and lower ends of the adjacent side of the connecting plates 42 are fixedly connected to lighting tubes 41. The tops of the two sets of connecting plates 42 are fixedly connected by the crossbar 43.

[0060] IV. LED bracket defective product rejection stage:

[0061] S7. The LED support belt, after the data is recorded, continues to be conveyed forward until the detection row is directly below the rejection mechanism 2. The second motor 56 stops working, and the LED support belt stops. Based on the analysis results of S6, the position of the defective product in the detection row is determined, and the rejection component 22 at the corresponding position is controlled to work. The first electric push rod 221 drives the cutter head 224 to move downward to cut off the defective product around its perimeter. Then, the second electric push rod 227 works to push the pressure block 226 downward to push the defective product into the feeding port 62. At the same time, the drive component 73 drives the receiving plate 71 to move below the feeding port 62, and the defective product enters the defective product collection area along the upper surface of the receiving plate 71.

[0062] S8. Based on the analysis results of S6, determine the location of the detected waste and control the corresponding rejection component 22 to work. The second electric push rod 227 pushes the pressure block 226 down to directly move the waste down and push it into the discharge port 62. At the same time, the drive component 73 drives the receiving plate 71 away from the discharge port 62, and the waste falls directly from the discharge port 62 into the waste collection area.

[0063] S9. After rejection, the second motor 56 moves the lower station LED bracket to directly below the rejection mechanism 2 to reject the defective product, and then transports the defective LED bracket to the next process step.

[0064] Please see Figures 1 to 9As shown, this invention provides a cabinet 1 for detecting defects in LED brackets. The cabinet 1 is divided into an upper detection chamber and a lower cabinet body. The cabinet body contains an inner cavity and a mounting cavity. A feeding assembly 6 is located on the upper surface of the inner cavity, connecting the inner cavity and the detection chamber. A material distribution control assembly 7 is installed inside the inner cavity. A calculation module 8 is installed in the mounting cavity. The calculation module 8 is connected to the rejection mechanism 2, the machine vision assembly 3, the conveying assembly 5, and the material distribution control assembly 7 via signal transmission. Conveying assemblies 5 are installed at both ends of the detection chamber of the cabinet 1 to transport LED bracket strips into the detection chamber for detection and to transport the detected LED bracket strips to the next process. When a group of LED brackets is transported to the next process... In the first position, the reciprocating motor 33 drives the drive ring 323 to rotate the gear 321, placing the camera 326 in the second position. Simultaneously, gear 322 meshes with gear 342, causing the connecting rod 343 to push the lighting assembly 4 towards the first position, taking the first picture of the LED bracket. When the LED bracket moves to the second position, the reciprocating motor 33 drives the drive ring 323 to reset, placing the swing arm 325 in the first position. Simultaneously, gear 322 meshes with gear 342 in the opposite direction, causing the connecting rod 343 to pull the lighting assembly 4 towards the second position, taking the second picture of the LED bracket. The data from both pictures is transmitted to the computing module 8. In the comparative analysis, the reciprocating motor 33 periodically drives the angle adjustment component 32 to work, so that the camera 326 collects data twice for each group of LED brackets. The LED brackets whose data are collected are transmitted row by row to the area directly below the rejection mechanism 2. The position of the rejection component 22 corresponds to each LED bracket in the detection row. The calculation module 8 compares and analyzes the two sets of collected data with the original reference data. First, the defective products are rejected. The rejection component 22 at the position corresponding to the defective product works. At this time, the first electric push rod 221 pushes the connecting sleeve 222 so that the cutter head 224 extends out of the lower end of the outer protective shell 225 and cuts off the defective product around the corresponding position. Then the second electric push rod 227 works and pushes the pressure block 226 to extend. The cutting head 224 pushes the defective product into the feeding port 62. At the same time, the drive component 73 controls the receiving plate 71 to move to the lower end of the feeding port 62. The defective product falls along the upper surface of the receiving plate 71 to the defective product collection area, and then the waste product is removed. The corresponding removal component 22 of the waste product works. At this time, the second electric push rod 227 pushes the pressure block 226 to extend out of the lower end of the outer protective shell 225 and pushes the corresponding waste product downward into the feeding port 62. At the same time, the drive component 73 controls the receiving plate 71 to move away from the lower end of the feeding port 62. The waste product passes through the feeding port 62 and falls directly into the waste collection area. The LED bracket with the defective product removed is transported to the inner cavity outlet of the cabinet 1 and enters the next process stage.

[0065] Specifically, the inner cavity of the cabinet 1 is located directly below the rejection mechanism 2, and a storage area is provided inside the inner cavity. This storage area is connected to the detection cavity of the cabinet 1 through the unloading component 6. Two sets of outlet ends are provided on the lower side wall of the storage area, and these outlet ends are connected to the outside of the cabinet 1.

[0066] It should be added that the detection chamber sidewall of cabinet 1 is symmetrically provided with two sets of control slides. The clamping mechanism 9 includes a mounting shaft and a roller. Both ends of the mounting shaft are slidably connected in the control slide. The roller is rotatably connected to the outer wall of the mounting shaft. The outer wall of the roller is provided with elastic sleeves at intervals to avoid damage to the LED bracket when it comes into contact with the LED bracket.

[0067] Furthermore, a rejection mechanism 2 is installed on the upper end of the cabinet 1 near the exit. The rejection mechanism 2 includes a mounting box 21 and several rejection components 22. The rejection components 22 include an outer protective shell 225. A first electric push rod 221 is installed on the top of the inner cavity of the outer protective shell 225. A connecting sleeve 222 is fixedly connected to the output end of the first electric push rod 221. A square sliding sleeve 223 is fixedly connected to the end of the connecting sleeve 222 away from the first electric push rod 221. A blade 224 is installed on the lower end of the square sliding sleeve 223. The blade 224 is slidably connected to the outer protective shell 225. A second electric push rod 227 is installed on the top of the inner cavity of the connecting sleeve 222. A pressure block 226 is fixedly connected to the output end of the second electric push rod 227. The pressure block 226 is slidably connected to the inner wall of the square sliding sleeve 223.

[0068] Specifically, the number and spacing of the rejection components 22 correspond to the position of the LED brackets in the detection row. The first electric push rod 221 works to push the connecting sleeve 222. The connecting sleeve 222 drives the square sliding sleeve 223 and the cutter head 224 at its lower end to move, which can cut the LED brackets around the bottom. Then, the second electric push rod 227 pushes the pressure block 226 down to push the cut LED brackets out of the bracket belt, thus completing the rejection of defective products. Alternatively, the second electric push rod 227 can work alone to drive the pressure block 226 through the lower end face of the outer protective shell 225, pushing the LED brackets downward out of the bracket belt, thus completing the rejection of waste products.

[0069] Furthermore, the bottom of the detection chamber of the cabinet 1 is provided with several sets of unloading components 6. The unloading components 6 are located directly below the rejection components 22. The unloading components 6 include a buffer groove 61 and an unloading port 62. The buffer groove 61 and the unloading port 62 are concentrically arranged. The unloading port 62 is connected to the storage area. A buffer component is installed in the buffer groove 61.

[0070] Specifically, the first electric push rod 221 pushes the cutter head 224 into the buffer groove 61 to cut the LED bracket around its perimeter. The buffer assembly reduces damage to the cutter head 224 and prevents excessive impact from the cutter head 224, which could deform the LED bracket. The rejected defective products are pushed into the discharge port 62 by the pressure block 226 for storage.

[0071] Furthermore, the conveying component 5 includes a second motor 56 and two sets of support rods 51. The two sets of support rods 51 are arranged in parallel and several sets of crossbars 52 are spaced apart at adjacent positions. The second motor 56 drives one set of crossbars 52 to rotate, and two sets of drive wheels 55 are fixedly connected to the outer wall of the crossbar 52 at intervals. Several sets of drive teeth are fixedly connected to the outer wall of the drive wheels 55 at intervals.

[0072] Specifically, the outer wall of the crossbar 52 is provided with a groove 54, and the inner wall of the drive wheel 55 is provided with a positioning slider, which is slidably connected to the groove 54.

[0073] In other embodiments, the crossbar 52 is divided into a drive roller and a driven roller. The two ends of the driven roller are fixedly connected to the outer wall of the support rod 51. The roller 53 is rotatably connected to the crossbar 52. The two ends of the drive roller are rotatably connected to the support rod 51, and one end is driven to rotate by the second motor 56.

[0074] Furthermore, the material distribution control component 7 includes a receiving plate 71 and a partition plate 72. The partition plate 72 is fixedly connected to the inner cavity of the cabinet 1. The receiving plate 71 is disposed on the upper end face of the partition plate 72. A drive component 73 is installed on the top of the partition plate 72. A toothed groove 74 is opened on the lower end face of the receiving plate 71. The upper end of the drive component 73 is located on the inner wall of the toothed groove 74 and drives the receiving plate 71 to reciprocate along the toothed groove 74.

[0075] Specifically, the partition 72 divides the bottom of the storage area into two parts. The receiving plate 71 is set at an angle to the horizontal. When the receiving plate 71 moves to the bottom of the discharge port 62, the LED support passing through the discharge port 62 falls onto the upper surface of the receiving plate 71 and slides down the receiving plate 71 to the right storage area. When the receiving plate 71 moves away from the bottom of the discharge port 62, the LED support passing through the discharge port 62 falls directly into the left storage area.

[0076] It should also be noted that the receiving plate 71 is slidably connected to the side wall of the storage area on both sides, and the receiving plate 71 is fixedly connected to the limit sliders on both sides. The corresponding position of the side wall of the storage area is provided with a dovetail groove, and the limit slider is slidably connected in the dovetail groove.

[0077] Furthermore, the drive assembly 73 includes a dual-head drive motor, and each of the output ends of the dual-head drive motor is fixedly connected to a drive gear, which meshes with the tooth groove 74.

[0078] Specifically, the dual-head motors cause two sets of drive gears to rotate coaxially, in the same direction, and at the same speed. The drive gears mesh with the tooth groove 74, pushing the receiving plate 71 to move in the inclined direction, thereby controlling the relative position of the receiving plate 71 and the discharge port 62, and realizing the separation of defective products and waste products.

[0079] Furthermore, the angle adjustment component 32 includes a gear 321 and a mounting shaft 324. The mounting shaft 324 is fixedly connected to the inner wall of the mounting frame 31, and a gear 322 and two sets of drive rings 323 are rotatably connected to the outer wall of the mounting shaft 324. The gear 322 is positioned adjacent to the two sets of drive rings 323, and the two sets of drive rings 323 are fixedly connected by the gear 321. The inner wall of the gear 321 meshes with the outer wall of the gear 322. The reciprocating motor 33 drives the drive rings 323 to rotate. A swing arm 325 is fixedly connected to the lower end face of the gear 322, and a camera 326 is mounted on the lower end face of the swing arm 325.

[0080] Specifically, the reciprocating motor 33 drives the drive ring 323 to rotate at a set angle. The drive ring 323 engages with the gear 322 through the gear 321, which in turn drives the swing arm 325 to rotate, causing the camera 326 to switch from the first position to the second position. At the same time, the gear 322 engages with the cooperating gear 342, and the rotation of the cooperating gear 342 drives the connecting rod 343 to push the crossbar 43 towards the first position. Then, the reciprocating motor 33 rotates in the opposite direction by the same angle, causing the camera 326 to switch from the second position back to the first position. Simultaneously, the connecting rod 343 pulls the crossbar 43 to move it towards the second position. By setting the rotation angle and period of the reciprocating motor 33, the position of the camera 326 in the second position and the switching time between the two positions are controlled. While the camera 326 switches positions, the crossbar 43 moves accordingly, ensuring that the LED bracket detection row is always in the center of the overlapping area of ​​the four sets of lighting tubes 41.

[0081] It should also be noted that the first position of camera 326 is vertical, at which point camera 326 is perpendicular to the central axis of the detection row. The second position is set according to the spacing between the two adjacent rows of LED brackets, so that the axis of camera 326 in the second position intersects with the central axis of the detection row.

[0082] Furthermore, the distance control component 34 includes a mating gear 342. The mating gear 342 is installed on the inner wall of the mounting frame 31, and the mating gear 342 meshes with the gear 322. The front end face of the mating gear 342 is rotatably connected to an eccentric shaft 341. A connecting rod 343 is fixedly connected to the outer wall of the eccentric shaft 341. The end of the connecting rod 343 opposite to the eccentric shaft 341 is rotatably connected to the outer wall of the crossbar 43.

[0083] Specifically, a support shaft is fixedly connected to the inner wall of the mounting frame 31, and a clearance groove is opened on the lower end face of the mounting frame 31. The gear 342 is rotatably mounted on the outer wall of the support shaft, and the eccentric shaft 341 is rotatably mounted on the eccentric position of the front end face of the gear 342. When the gear 342 rotates, the distance between the connecting rod 343 and the crossbar 43 changes, thereby driving the crossbar 43 to move back and forth.

[0084] It should be noted that the connecting plate 42 is U-shaped, and the lighting tubes 41 are set at both ends of the U-shaped groove. The two sets of connecting plates 42 are symmetrically arranged. The center line of the overlapping area of ​​the four sets of lighting tubes 41 coincides with the axis of symmetry of the two sets of connecting plates 42. The connecting plate 42 is equipped with sliders 44 in both the vertical and horizontal directions. The detection cavity of the cabinet 1 is provided with a limit groove at the corresponding position to ensure that the four sets of lighting tubes 41 always move along the center line of the overlapping area.

[0085] Furthermore, the buffer assembly includes a buffer plate 63, which is slidably connected in the buffer groove 61, and a number of elastic components 65 are fixedly connected to the lower end face of the buffer plate 63. The end of the elastic component 65 facing away from the buffer plate 63 is fixedly connected to the bottom of the buffer groove 61.

[0086] Specifically, when the first electric push rod 221 pushes the cutter head 224 out of the lower end of the outer protective shell 225 and moves to the defective product position, the cutter head 224 continues to move downward, pushing the buffer plate 63 to compress the elastic component 65 downward. After the defective product is cut off around its perimeter, the elastic potential energy of the elastic component 65 is released, pushing the buffer plate 63 to push the cutter head 224 out of the buffer groove 61, thus buffering and protecting the cutter head 224 while facilitating its removal.

[0087] Furthermore, a blade groove 64 is provided on the upper surface of the buffer plate 63. The blade groove 64 is located directly below the blade head 224 and is adapted to the blade head 224.

[0088] Specifically, the downward movement of the blade 224 engages with the blade groove 64, making it easier to cut off the edges of the defective product.

[0089] The foregoing has shown and described the basic principles, main features, and advantages of the present invention. Those skilled in the art should understand that the present invention is not limited to the above embodiments. The embodiments and descriptions in the specification are merely preferred examples and are not intended to limit the invention. Various changes and modifications can be made to the invention without departing from its spirit and scope, and all such changes and modifications fall within the scope of the present invention as claimed. The scope of protection of the present invention is defined by the appended claims and their equivalents.

Claims

1. A machine vision-based defect detection process for LED brackets, characterized in that: Includes the following steps: I. Equipment Preparation Stage: S1. Adjust the distance between the two sets of drive wheels according to the width of the LED bracket strip to be tested, so that the distance between the two sets of drive wheels is the same as the distance between the two sides of the LED bracket strip. S2. Based on the spacing between two adjacent rows of LED brackets along the conveying direction, set the rotation angle and rotation period of the angle adjustment component; II. LED bracket loading stage: S3. First, place the outer end of the LED bracket on the upper surface of the roller at the entrance of the cabinet, and simultaneously pass the drive teeth on the outer sides of the two sets of drive wheels through both sides. The second motor works to drive the LED bracket through the detection cavity of the cabinet, and install the protruding outer ends on both sides of the drive teeth on both sides of the drive wheel at the exit. S4. Then, adjust the height of the clamping mechanism according to the thickness of the LED bracket strip so that the lower end face of the clamping mechanism contacts the upper end face of the LED bracket strip. With the help of the two sets of drive wheels at the inlet and outlet, the LED bracket strip moves smoothly from the inlet to the outlet of the cabinet. The support rod has an angled downward along the horizontal direction. When the LED bracket strip passes the support rod, it is straightened by gravity, which prevents the LED bracket strip from bending and shifting during the transportation process. III. LED bracket with visual inspection stage: S5. When the LED bracket with detection strip is conveyed to the first position, the reciprocating motor drives the angle adjustment component to move the swing arm to the second position. At the same time, the gear meshes and rotates, causing the connecting rod to push the crossbar, moving the lighting tube in the direction of the swing arm rotation. The connecting rod takes the first picture of the detection strip. Then, the LED bracket is conveyed to the second position by the conveying component, the swing arm returns to the first position, and the gear meshes and rotates in the opposite direction. The connecting rod pulls the crossbar, moving the lighting tube back to its original position. The connecting rod takes the second picture of the detection strip. This operation is repeated to take two pictures of each of the rear LED brackets, and the picture data is transmitted to the calculation module. The angle adjustment component includes a toothed gear and a mounting shaft. The mounting shaft is fixedly connected to the inner wall of the mounting frame, and the outer wall of the mounting shaft is rotatably connected to a gear and two sets of drive rings. The gear is set in an adjacent position to the two sets of drive rings. The two sets of drive rings are fixedly connected by the toothed gear. The inner wall of the toothed gear meshes with the outer wall of the gear. The reciprocating motor drives the drive ring to rotate. The lower end face of the gear is fixedly connected to a swing arm, and a camera is mounted on the lower end face of the swing arm. S6. Subsequently, the calculation module compares and analyzes the two sets of photographic data based on the original collected data. The comparison results are as follows: a. qualified product, b. defective product, c. scrap product; The machine vision component is installed on the upper side of the cabinet near the entrance. The machine vision component includes a mounting frame and an angle adjustment component. A reciprocating motor is installed on the outer wall of the mounting frame. The reciprocating motor drives the angle adjustment component to rotate at a set angle, so that the angle adjustment component periodically changes the first and second camera positions and takes two pictures of each row of LED brackets. The angle adjustment component is driven by a distance adjustment component, and the distance adjustment component is driven by a lighting component. The lighting component includes a crossbar and two sets of connecting plates. Lighting tubes are fixedly connected to the upper and lower ends of adjacent sides of the connecting plates. The tops of the two sets of connecting plates are fixedly connected by the crossbar. IV. LED bracket defective product rejection stage: S7. The LED support belt, after the data is recorded, continues to be conveyed forward until the detection row is directly below the rejection mechanism. The second motor stops working, the LED support belt stops, and the position of the defective product in the detection row is determined according to the analysis results of S6. The rejection component at the corresponding position is controlled to work. The first electric push rod drives the cutter head to move downward to cut off the defective product around its perimeter. Then the second electric push rod works to push the pressure block down to push the defective product into the feeding port. At the same time, the drive component drives the receiving plate to move below the feeding port. The defective product enters the defective product collection area along the upper surface of the receiving plate. S8. Based on the analysis results of S7, determine the location of the waste product and control the corresponding rejection component to work. The second electric push rod pushes the pressure block down to directly move the waste product downward and push it into the feeding port. At the same time, the drive component drives the receiving plate away from the feeding port, and the waste product falls directly from the feeding port into the waste collection area. S9. After rejection, the second motor moves the lower LED bracket to directly below the rejection mechanism to reject the defective product, and then transports the defective LED bracket to the next process step.

2. The LED bracket defect detection process according to claim 1, characterized in that: A rejection mechanism is installed on one end of the upper surface of the cabinet near the exit. The rejection mechanism includes a mounting box and several rejection components. Each rejection component includes an outer protective shell. A first electric push rod is installed on the top of the inner cavity of the outer protective shell. A connecting sleeve is fixedly connected to the output end of the first electric push rod. A square sliding sleeve is fixedly connected to the end of the connecting sleeve opposite to the first electric push rod. A cutter head is installed on the lower end face of the square sliding sleeve. The cutter head is slidably connected to the outer protective shell. A second electric push rod is installed on the top of the inner cavity of the connecting sleeve. A pressure block is fixedly connected to the output end of the second electric push rod. The pressure block is slidably connected to the inner wall of the square sliding sleeve.

3. The LED bracket defect detection process according to claim 1, characterized in that: The bottom of the cabinet detection cavity is provided with several sets of unloading components. The unloading components are located directly below the rejection components. Each unloading component includes a buffer groove and an unloading port. The buffer groove and the unloading port are concentrically arranged. The unloading port is connected to the storage area. A buffer component is installed in the buffer groove.

4. The LED bracket defect detection process according to claim 1, characterized in that: The conveying assembly includes a second motor and two sets of support rods. The two sets of support rods are arranged in parallel and several sets of crossbars are spaced apart at adjacent positions. The second motor drives one set of crossbars to rotate, and two sets of drive wheels are fixedly connected to the outer wall of the crossbar at intervals. Several sets of drive teeth are fixedly connected to the outer wall of the drive wheels at intervals.

5. The LED bracket defect detection process according to claim 1, characterized in that: The material distribution control component includes a receiving plate and a partition. The partition is fixedly connected to the inner cavity of the cabinet. The receiving plate is disposed on the upper surface of the partition. A drive component is installed on the top of the partition. A toothed groove is formed on the lower surface of the receiving plate. The upper end of the drive component is located on the inner wall of the toothed groove and drives the receiving plate to reciprocate along the toothed groove.

6. The LED bracket defect detection process according to claim 5, characterized in that: The drive assembly includes a dual-head drive motor, and each of the output ends of the dual-head drive motor is fixedly connected to a drive gear, which meshes with the tooth groove.

7. The LED bracket defect detection process according to claim 1, characterized in that: The distance adjustment component includes a mating gear, which is installed on the inner wall of the mounting frame and meshes with the gear. An eccentric shaft is rotatably connected to the front end face of the mating gear. A connecting rod is fixedly connected to the outer wall of the eccentric shaft. One end of the connecting rod away from the eccentric shaft is rotatably connected to the outer wall of the crossbar.

8. The LED bracket defect detection process according to claim 3, characterized in that: The buffer assembly includes a buffer plate, which is slidably connected in the buffer groove, and a number of elastic components are fixedly connected to the lower end face of the buffer plate. The end of the elastic component opposite to the buffer plate is fixedly connected to the bottom of the buffer groove.

9. The LED bracket defect detection process according to claim 8, characterized in that: The upper surface of the buffer plate is provided with a cutting groove, which is located directly below the cutting head and is adapted to the cutting head.

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