A detection method, detection system and detection device for a carrier tape processing die

Abstract

The present invention discloses a detection method, a detection system and a detection device for a carrier tape processing mold, including: the controller receives set image parameters and data parameters, takes pictures and detects the carrier tape processing mold through an image sensor, obtains the image information of the carrier tape processing mold, and sends it to the controller for image processing. Each hole on the carrier tape processing mold is segmented to generate a number of image data as a first data set and a number of size data as a second data set, and they are respectively compared with the image parameters and the data parameters to detect whether the holes are qualified; this device can detect the depth of the holes on the carrier tape processing mold, perform secondary detection according to the detected image information and size data, with higher detection accuracy, can detect before the carrier tape is produced, timely prevent problems occurring in the carrier tape processing process, and reduce processing costs.

Description

Technical Field

[0001] The present invention relates to the technical field of electronic component detection, and particularly to a detection method, a detection system and a detection device for a carrier tape processing mold. Background Art

[0002] A carrier tape is a strip-shaped product used for packaging electronic components. Electronic components are placed through holes formed by processing. The carrier tape is divided into two categories: plastic carrier tape and paper carrier tape. Among them, the plastic carrier tape is suitable for packaging all types of electronic components and is the most widely used.

[0003] The forming of the carrier tape needs to be formed and cured through a carrier tape processing mold. The extruder heats and extrudes plastic particles and transports them to the mold. By using the principle of vacuum thermoforming, the sheet is processed into the corresponding shape and size of the mold. Since there are many holes in the carrier tape, during the detection, generally sampling inspection or intercepting a section of the formed carrier tape is used for detection to ensure the processing accuracy of each hole. This process is very cumbersome and there are often omissions and errors, resulting in the scrapping of the carrier tape.

[0004] The patent with the publication number of CN103581613A provides a multi-CCD image detection system for carrier tape forming, which can detect multiple carrier tapes simultaneously, improving the detection efficiency. However, the formed carrier tapes are transported in parallel, and it is difficult to detect the depth of the holes in the carrier tape or the depth error is large by CCD detection. Moreover, after the carrier tape has problems, it cannot be used continuously, still causing waste of processing costs. Summary of the Invention

[0005] The purpose of the present invention is to solve the disadvantages existing in the prior art, and to propose a detection method, a detection system and a detection device for a carrier tape processing mold.

[0006] To achieve the above purpose, the present invention adopts the following technical solution: A detection method for a carrier tape processing mold, including:

[0007] S1: The controller receives the set image parameters and data parameters, stores them, adjusts and assembles the carrier tape processing mold, and then controls the carrier tape processing mold to continuously rotate. The carrier tape processing mold is photographed and detected by an image sensor to obtain the image information of the carrier tape processing mold, and the image information is sent to the controller;

[0008] S2: The controller performs image processing according to the image information, divides each hole on the carrier tape processing mold, generates a number of image data as the first data set, and generates a number of size data as the second data set;

[0009] S3: Compare the first data set with the image parameters. Compare each piece of image data to determine if it conforms to the image parameters. If not, mark the image data and give an alarm, then return to step S1 to adjust the carrier tape processing die. If it conforms, proceed to the next step;

[0010] S4: Compare the second data set with the data parameters to determine if the dimension data conforms to the data parameters. If not, mark the dimension data and give an alarm, then return to step S1 for adjustment. If it conforms, continue with the detection;

[0011] S5: After the carrier tape processing die rotates one full circle, output the detection result based on the first data set and the second data set, and save it in the controller.

[0012] As a further description of the above technical solution: In step S1, it further includes:

[0013] S11: Set the detection criteria in the controller, set the standard image parameters and data parameters and store them in the controller. Assemble the carrier tape processing die and install it on the control cabinet to control the rotation of the carrier tape processing die.

[0014] S12: Set the image sensor above the carrier tape processing die, continuously take pictures of the rotating carrier tape processing die to obtain the image information of the carrier tape processing die, and send it to the controller in real time.

[0015] As a further description of the above technical solution: In step S2, it further includes:

[0016] S21: The controller receives the image information, divides the holes on the carrier tape processing die according to the image information to generate image data, and captures the length, width, and depth of the holes to generate dimension data.

[0017] As a further description of the above technical solution: In step S3, it further includes:

[0018] S31: Compare the first data set with the image parameters. Set the resolution size of the defect judged as the first threshold. Identify each piece of image data. If the resolution size of the defect in the image data exceeds the first threshold, then judge that the hole is unqualified. The controller marks the image data and gives an alarm through the buzzer.

[0019] As a further description of the above technical solution: In step S4, it further includes:

[0020] S41: Compare the second data set with the data parameters. The range of the data parameters is the second threshold. Compare the size data of each cavity with the second threshold. The size data that exceeds the range of the second threshold is judged as unqualified. The controller marks this size data and alarms through a buzzer.

[0021] As a further description of the above technical solution: The image processing includes image positioning, grayscale conversion, edge detection, and image enhancement to make the outer contour of the cavity prominent, obtain the image data, then traverse the image information to obtain pixel values, and perform grasping based on the outer contour of the cavity and the pixel values to obtain the size data.

[0022] It also includes a detection system for a carrier tape processing mold. The detection system is applicable to the detection method described in any one of the above technical solutions and includes:

[0023] An acquisition module that performs image acquisition on the carrier tape processing mold, generates image information, and transmits it.

[0024] A control module that controls the rotation of the carrier tape processing mold, and at the same time receives the image information sent by the acquisition module, the image parameters and data parameters set externally, and marks the detection results.

[0025] An image processing module that receives the image information and image parameters sent by the control module, processes the image information to obtain image data and size data, compares the image data with the image parameters for detection, and feeds back the detection results to the control module.

[0026] A judgment module that receives the size parameters sent by the control module and the size data sent by the image processing module, compares them, and feeds back the detection results to the control module.

[0027] An output display module that receives the detection results sent by the control module and performs output display.

[0028] As a further description of the above technical solution: The control module judges whether to stop rotating the carrier tape processing mold or send the size data to the judgment module according to the detection results fed back by the image processing module.

[0029] It also includes a detection device for a carrier tape processing mold. The detection device is applicable to the detection method and the detection system described in any one of the above technical solutions and includes:

[0030] A control cabinet;

[0031] A printer, a display screen, and a controller are provided on the top of the control cabinet;

[0032] A touch screen and control buttons are provided on one side of the control cabinet;

[0033] One side of the control cabinet is provided with an output end extending outwards, and a carrier tape processing die is installed.

[0034] An image sensor is arranged above the carrier tape processing die and is electrically connected to the controller.

[0035] An extrusion die head is arranged on one side of the carrier tape processing die.

[0036] As a further description of the above technical solution: Set the set image parameters and data parameters to the controller through the touch screen. The controller controls the image sensor to take pictures to collect image information and receive and judge it, and directly outputs and displays the detection result through the display screen, or prints and outputs the detection result through the printer.

[0037] The above technical solution has the following advantages or beneficial effects:

[0038] 1. Different from the existing direct detection of the carrier tape finished product, the present invention conducts a comprehensive detection on the carrier tape processing die. By identifying the holes inside the die, it can be detected before the carrier tape is produced, avoiding the problem of production waste caused by the defective carrier tape directly resulting from the die defect.

[0039] 2. Further, the carrier tape die is usually one-to-many, such as a 1-out-6 specification. This makes multiple partitions and forming pieces arranged at intervals on the carrier tape die. Taking 1-out-6 as an example, there are 7 partitions and 6 forming pieces. There are approximately 100 holes on a single forming piece. As long as any one of the holes on each forming piece has a defect, it will result in an unqualified carrier tape finished product. When unqualified products appear, it is basically impossible to locate the defective holes by the naked eye from 600 holes. Even if it can be operated, the efficiency and accuracy are extremely low because not only are the number of holes large but they are also arranged at different angles. The present invention can not only detect the defective holes but also locate the positions of the defective holes, so that the problem points can be quickly located for replacement, and the overall recognition efficiency and accuracy are greatly improved. Description of the Drawings

[0040] Figure 1 is the flow of the detection method proposed by the present invention Figure One ;

[0041] Figure 2 is the flow of the detection method proposed by the present invention Figure Two ;

[0042] Figure 3 is the flow of the detection method proposed by the present invention Figure Three ;

[0043] Figure 4 The flow of the detection method proposed by the present invention Figure Four ;

[0044] Figure 5 The flow of the detection method proposed by the present invention Figure Five ;

[0045] Figure 6 Schematic diagram of the structure of the detection system proposed by the present invention;

[0046] Figure 7 Schematic diagram of the structure of the detection device proposed by the present invention;

[0047] Figure 8 Schematic diagram of the detection result of the image data in the present invention;

[0048] Figure 9 Schematic diagram of the detection result of the dimension data in the present invention.

[0049] Legend:

[0050] 1. Control cabinet; 2. Printer; 3. Display screen; 4. Controller; 5. Touch screen; 6. Control button; 7. Carrier tape processing die; 8. Image sensor; 9. Extrusion die head; 10. Acquisition module; 11. Control module; 12. Image processing module; 13. Judgment module; 14. Output display module. Specific embodiments

[0051] Next, the technical solutions in the embodiments of the present invention will be clearly and completely described in conjunction with the accompanying drawings in the embodiments of the present invention. Obviously, the described embodiments are only a part of the embodiments of the present invention, rather than all the embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those of ordinary skill in the art without creative efforts shall fall within the protection scope of the present invention.

[0052] Referring to Figure 1 , an embodiment provided by the present invention: A detection method for a carrier tape processing die, comprising:

[0053] S1: The controller receives the set image parameters and data parameters, stores them, adjusts and assembles the carrier tape processing die, then controls the carrier tape processing die to continuously rotate, takes a photo of the carrier tape processing die through the image sensor, obtains the image information of the carrier tape processing die, and sends it to the controller;

[0054] S2: The controller performs image processing according to the image information, divides each hole on the carrier tape processing die, generates a number of image data as the first data set, and generates a number of dimension data as the second data set;

[0055] S3: Compare the first data set with the image parameters. Compare each image data to determine whether it meets the image parameters. If not, mark and give an early warning to the image data, return to step S1, and adjust the carrier tape processing die. If it meets the requirements, proceed to the next step;

[0056] S4: Compare the second data set with the data parameters. Determine whether the dimension data meets the data parameters. If not, mark and give an early warning to the dimension data, return to step S1 for adjustment. If it meets the requirements, continue the detection;

[0057] S5: After the carrier tape processing die rotates one circle, output the detection result according to the first data set and the second data set, and save it in the controller.

[0058] The inventor found in the research that during the carrier tape processing, the forming process is a key link, which determines the dimensional accuracy, shape accuracy, surface quality, etc. of the carrier tape holes. If it can be ensured that the die is qualified for detection before being put into use from the source, the effectiveness of proofing can be greatly improved, creating favorable conditions for subsequent production and avoiding the production of defective products.

[0059] After a new carrier tape die is made, it is necessary to conduct trial molding, proofing, and detection to confirm the quality of the die and determine whether it can be put into production. During production, before each die change for production, it is also necessary to conduct detection and confirmation of the first-piece die to ensure that the wear of the die is within the normal range and it can continue to be used for normal production. Since there are many forming holes on the entire set of dies, for example, a forming die with one cavity producing six (i.e., producing 6 carrier tapes at a time) has 6 * 96 = 576 holes distributed on it, and at least key dimensions such as A0, B0, and K0 (length, width, depth) need to be detected for each hole, and the number of detections is huge. However, through the design scheme of the present invention, only one image sensor is set to realize the identification and detection of the holes of the carrier tape processing die, which not only makes the overall device more concise but also makes the detection accuracy higher.

[0060] In this embodiment, the operator installs the carrier tape processing mold to be detected on the control cabinet, sets the image parameters and data parameters for carrier tape processing according to production requirements, stores them in the controller, controls the rotation of the carrier tape processing model, so that the holes on the surface rotate accordingly, and moves under the image sensor for identification. The image sensor is preferably a CCD image sensor, which detects the carrier tape processing mold below and sends the detected image information to the controller for judgment. The controller processes the image information, compares the image information with the set image parameters, and detects whether there are defects such as burrs, pits, and protrusions on the outer shape and inner side of the holes, which affect the formation of the carrier tape. After confirming that the hole shape is qualified, the size of the hole is captured, and the corresponding size data is compared with the data parameters to detect whether the size of the hole is qualified. Through secondary detection, the hole accuracy on the carrier tape processing mold is higher. When detecting unqualified holes, since the holes are arranged in a circumferential array on the carrier tape processing mold, in the captured image information, the holes are arranged in an array, and the unqualified holes are directly marked in the image information and a warning is given. After the detection is completed, the detection result can be directly output, and the staff can directly find the holes at the corresponding positions according to the detection result for adjustment.

[0061] The detection device is installed on the current production line. The forming mold is detected before production. After passing the inspection, production can be carried out without removing the forming mold, which belongs to on-line detection and further reduces the time required for detection and disassembly.

[0062] Refer to Figure 2 , in step S1, it further includes:

[0063] S11: Set the detection standard in the controller, set the standard image parameters and data parameters and store them in the controller, assemble the carrier tape processing mold, install it on the control cabinet and control the rotation of the carrier tape processing mold;

[0064] S12: Set an image sensor above the carrier tape processing mold, continuously take pictures of the rotating carrier tape processing mold, obtain the image information of the carrier tape processing mold, and send it to the controller in real time.

[0065] In this embodiment, the structure of the carrier tape processing mold is a splicing type. The holes are formed by alternately arranging the forming pieces and the partitions. After being clamped and positioned by the fixing plates on both sides, they are fixed by bolts. When assembling or repairing the carrier tape processing mold, the inner forming pieces can be disassembled and replaced, and carrier tapes of different models can be produced. The carrier tape processing mold is connected to the motor output end on the control cabinet to control the rotation direction and rotation speed of the carrier tape processing mold. At the same time, it is identified by the CCD image sensor above, and the holes on the curved surface of the carrier tape processing mold are identified, and the generated image information is sent to the controller.

[0066] Refer toFigure 3 , in step S2, it further includes:

[0067] S21: The controller receives the image information, segments the holes on the carrier tape processing die according to the image information to generate image data, and grabs the length, width, and depth of the holes to generate dimension data.

[0068] In this embodiment, the controller receives the image information, performs image processing. After identifying the contour information of the carrier tape processing module, only the image information of the carrier tape processing die is retained, and the rest is deleted. It is segmented according to the stored image data (the shape of the holes) to generate the image data of each hole as the first data set. According to the transmission order of the image information, the first data set is arranged to facilitate the subsequent output of the detection results in the form of an array. The first data set is compared with the image data, and the dimension data of the length, width, and depth of the holes are identified and grabbed according to each image data as the second data set. Among them, each type of dimension data can be output as a detection result.

[0069] The image processing includes image positioning, grayscale conversion, edge detection, and image enhancement to make the outer contour of the holes prominent to obtain image data, then traverse the image information to obtain pixel values, and grab according to the outer contour of the holes and the pixel values to obtain dimension data.

[0070] The carrier tape processing die and the holes are positioned and identified through image positioning to facilitate segmentation. The shape of the holes in the image information is processed through grayscale conversion and edge detection. The outer contour of the holes is made more obvious through image enhancement to obtain the image data of the holes. Then, by traversing the outer contour of the holes, the corresponding pixel values are obtained. By setting the ratio of the outer contour to the pixel values obtained by traversing, the dimension data of the holes are obtained.

[0071] Refer to Figure 4 , in step S3, it further includes:

[0072] S31: Compare the first data set with the image parameters, set the resolution size of the defect judged as the first threshold, identify each image data. If the resolution size of the defect in the image data exceeds the first threshold, it is judged that the hole is unqualified. The controller marks the image data and alarms through a buzzer.

[0073] In this embodiment, by setting the defect size for comparison, assuming that the resolution size of the defect is 0 - 3 as the first threshold. When there are defect spots such as depressions and protrusions in the detected image data, according to the contour of the holes after image processing, it is judged whether the resolution of the defect exceeds the set first threshold. If it exceeds, it is judged that the hole is unqualified. The controller marks the image data (refer to Figure 8) Inside the controller, a buzzer is provided to give an audible alarm to alert the operator.

[0074] Referring to Figure 5 , in step S4, it further includes:

[0075] S41: Compare the second data set with the data parameters. The range of the data parameters is the second threshold. Compare the size data of each cavity with the second threshold. The size data that exceeds the range of the second threshold is judged as unqualified. The controller marks this size data and gives an alarm through the buzzer.

[0076] In this embodiment, the second data set is the size data of the cavity, which is compared with the set data parameters. Assume that among the stored data parameters, the range of the length A0 is 1.64 - 1.68, which is used as the second threshold. The length of each detected cavity is output according to the array position of the image data, and at the same time, it is judged whether it exceeds the second threshold. If it is within the range of the second threshold, it is judged as qualified; if it exceeds the second threshold, the size data is judged as unqualified (referring to Figure 9 ), the controller makes a mark and gives an alarm.

[0077] Referring to Figure 6 , the present invention also provides an embodiment of a detection system for a carrier tape processing die. The detection system is applicable to any of the detection methods in the above technical solutions and includes:

[0078] An acquisition module 10 that acquires an image of the carrier tape processing die, generates image information, and transmits it;

[0079] A control module 11 that controls the rotation of the carrier tape processing die, and at the same time receives the image information sent by the acquisition module 10, the externally set image parameters and data parameters, and marks the detection results;

[0080] An image processing module 12 that receives the image information and image parameters sent by the control module 11, processes the image information to obtain image data and size data, compares the image data with the image parameters for detection, and feeds back the detection results to the control module 11;

[0081] A judgment module 13 that receives the size parameters sent by the control module 11 and the size data sent by the image processing module 12, compares them, and feeds back the detection results to the control module 11;

[0082] An output display module 14 that receives the detection results sent by the control module 11 and outputs and displays them.

[0083] In this embodiment, the acquisition module 10 is located above the carrier tape processing die, takes pictures and identifies, generates corresponding image information, and sends it to the control module 11. The control module 10 receives the image parameters and dimension parameters set by external devices, and the image information sent by the acquisition module 10, and sends them to the image processing module 12 and the judgment module 13 respectively. The first data set is compared with the image parameters, and the second data set is compared with the data parameters to detect the shape and size of the holes, improve the detection accuracy, and feedback the detection result to the control module 11, and output the detection result through the output display module 14.

[0084] The control module 11 determines whether to stop rotating the carrier tape processing die or send the dimension data to the judgment module 13 according to the detection result fed back by the image processing module 12.

[0085] In this embodiment, if the control module 11 receives the detection results fed back by the image processing module 12 and all are qualified, the dimension data is sent to the judgment module 13 for secondary detection. If not qualified, the control module 11 can control the carrier tape processing die to stop rotating, interrupt the detection, and the operator can carry out disassembly and maintenance.

[0086] Refer to Figure 7 , the present invention also provides an embodiment of a carrier tape processing die detection device. The detection device is applicable to any one of the detection methods and detection systems in the above technical solutions, and includes: a control cabinet 1; a printer 2, a display screen 3 and a controller 4 are arranged on the top of the control cabinet 1; a touch screen 5 and control buttons 6 are arranged on one side of the control cabinet 1; an output end extending outward is arranged on one side of the control cabinet 1, and a carrier tape processing die 7 is installed; an image sensor 8 is arranged above the carrier tape processing die 7 and is electrically connected to the controller 4; an extrusion die head 9 is arranged on one side of the carrier tape processing die 7.

[0087] In this embodiment, the carrier tape processing die 7 is installed at the output end of the control cabinet 1, and the rotation and stop of the carrier tape processing die 7 are controlled by the control buttons 6. A printer 2 and a display screen 3 are arranged on the top of the control cabinet 1, and the detection results can be output, and it is convenient for the operator to observe at the same time. A controller 4 is arranged on the top of the control cabinet 1, and a touch screen 5 is arranged on one side of the control buttons 6. The controller 4 is electrically connected to the touch screen 5. The image parameters and data parameters are set through the touch screen and stored in the controller 4. There is an image sensor 8 above the carrier tape processing die 7. The controller 4 controls the image sensor 8 to take pictures, collect image information and make a judgment, takes pictures and identifies the carrier tape processing die 7 through the image sensor 8, and sends the image information to the controller 4, and directly outputs and displays the detection results through the display screen 3, or prints and outputs the detection results through the printer 2. There is a USB socket on the controller 4, and relevant detection and analysis data can be copied out for long-term storage and more detailed off-line comprehensive comparative analysis.

[0088] Finally, it should be noted that the above are only the preferred embodiments of the present invention and are not intended to limit the present invention. Although the present invention has been described in detail with reference to the foregoing embodiments, those skilled in the art can still modify the technical solutions described in the foregoing embodiments or perform equivalent replacements for some of the technical features. Any modifications, equivalent replacements, improvements, etc. made within the spirit and principle of the present invention shall be included within the protection scope of the present invention.

Claims

1. A method for detecting a carrier processing mold, characterized in that: include: S1: The controller receives the set image parameters and data parameters, stores them, adjusts and assembles the carrier processing mold, controls the carrier processing mold to rotate continuously, takes a photo of the carrier processing mold through an image sensor, obtains image information of the carrier processing mold, and sends it to the controller; S2: the controller performs image processing according to the image information, segments each hole on the carrier processing mold, generates a plurality of image data as a first data set, and generates a plurality of size data as a second data set; S3: Compare the first data set with the image parameters, compare each image data, and determine whether it meets the image parameters. If not, mark the image data and issue an early warning, return to step S1, adjust the carrier processing mold, and if it meets, proceed to the next step; S4: Compare the second data set with the data parameters to determine whether the size data meets the data parameters. If not, mark the size data and issue an early warning, and return to step S1 for adjustment. If yes, continue the test. S5: After the carrier processing mold rotates one circle, the detection result is output according to the first data set and the second data set, and is stored in the controller; In step S2, it also includes: S21: The controller receives the image information, segments the holes on the carrier processing mold according to the image information to generate image data, and captures the length, width and depth of the holes to generate size data.

2. The detection method according to claim 1, characterized in that: In the step S1, it also includes: S11: Set the inspection standard in the controller, set the standard image parameters and data parameters and store them in the controller, assemble the carrier processing mold, install it on the control cabinet to control the carrier processing mold to rotate, S12: the image sensor is arranged above the carrier processing mold to continuously photograph the rotating carrier processing mold to obtain image information of the carrier processing mold and send the image information to the controller in real time.

3. The detection method according to claim 1, characterized in that: In the step S3, it also includes: S31: Compare the first data set with the image parameters, set the resolution size of the defect as a first threshold, identify each image data, and if the resolution size of the defect in the image data exceeds the first threshold, the hole is judged to be unqualified, and the controller marks the image data and alarms through a buzzer.

4. The detection method according to claim 1, characterized in that: In the step S4, it also includes: S41: Compare the second data set with the data parameter, the range of the data parameter is the second threshold, compare the size data of each hole with the second threshold, and judge the size data beyond the range of the second threshold as unqualified. The controller marks the size data and alarms through the buzzer.

5. The detection method according to claim 1, characterized in that: The image processing includes image positioning, graying, edge detection and image enhancement, so as to highlight the outer contour of the hole and obtain the image data, and then traverse the image information to obtain pixel values, and capture according to the hole outer contour and pixel values ​​to obtain the size data.

6. A detection system for a carrier processing mold, characterized in that: The detection system is applicable to the detection method according to any one of claims 1 to 5, comprising: A collection module (10) collects images of the carrier processing mold, generates image information, and transmits it; A control module (11) controls the rotation of the carrier processing mold, receives the image information sent by the acquisition module (10) and externally set image parameters and data parameters, and marks the detection results; An image processing module (12) receives the image information and image parameters sent by the control module (11), processes the image information to obtain image data and size data, compares and detects the image data and the image parameters, and feeds back the detection results to the control module (11); A judgment module (13) receives the size parameter sent by the control module (11) and the size data sent by the image processing module (12), compares them, and feeds back the detection result to the control module (11); An output display module (14) receives the detection result sent by the control module (11) and outputs and displays it.

7. The detection system according to claim 6, characterized in that: The control module (11) determines whether to stop rotating the carrier processing mold or send the size data to the judgment module (13) based on the detection result fed back by the image processing module (12).

Images