Calibration device and calibration method

Abstract

The application provides a kind of calibration device and calibration method, wherein calibration device includes calibration tool, different specifications of calibration component and inductive chip, AOI detection unit and PLC control unit are arranged on the calibration tool, wherein the calibration tool is used to assemble the calibration component, and the calibration component is transferred to the process where the AOI detection unit is located;The inductive chip is used to identify whether the calibration tool is transferred to the process where the AOI detection unit is located;The AOI detection unit is used to detect the calibration component;The PLC control unit is used to control the AOI detection unit to detect the calibration component.Using the application, the problems of inaccurate detection caused by loose detection equipment, different test methods and low efficiency of manual inspection in the existing AOI detection process can be solved.

Description

Technical Field

[0001] This invention relates to the field of AOI (Automated Inspection and Calibration) technology, and more specifically, to an automatic calibration device and calibration method. Background Technology

[0002] AOI (Automated Optical Inspection) plays a vital role in industrial production due to advancements in automation. However, AOI calibration remains a significant challenge, currently presenting the following issues:

[0003] 1) Equipment issues: During AOI inspection, the brightness of the light source often decreases, making it impossible to identify defective products; in addition, loose or deviated mechanical positions of the inspection equipment can lead to inaccurate measurement data, causing good products to be judged as defective products and resulting in product scrapping.

[0004] 2) Inconsistent measurement height: The measurement depth of AOI inspection is generally around 5mm, but due to different product inspection positions, the inspection requirements are different, resulting in a height difference of about 15mm-25mm between product measurements.

[0005] 3) Different measurement methods: Different measurement items use different lighting methods. Some require upper lighting, some require lower lighting, and some require both upper and lower lighting, which makes the measurement very inconvenient.

[0006] 4) Inspection method: Currently, manual onboarding inspection and recording is used, which is very inefficient.

[0007] Based on the above problems, the present invention urgently needs to provide an automatic calibration device and calibration method. Summary of the Invention

[0008] In view of the above problems, the purpose of this invention is to provide a calibration device and calibration method to solve the problems of inaccurate detection caused by loose detection equipment, different testing methods, and low efficiency of manual inspection in the existing AOI detection process.

[0009] This invention provides a calibration device, comprising a calibration fixture, calibration components and sensing chips of different specifications disposed on the calibration fixture, an AOI detection unit, and a PLC control unit, wherein...

[0010] The calibration fixture is used to assemble the calibration component and transfer the calibration component to the process where the AOI detection unit is located;

[0011] The sensing chip is used to identify whether the calibration fixture has been transferred to the process where the AOI detection unit is located;

[0012] The AOI detection unit is used to detect the calibration component;

[0013] The PLC control unit is used to control the AOI detection unit to detect the calibration component.

[0014] Furthermore, in a preferred embodiment, the calibration fixture includes a fixture body and a contour groove disposed on the fixture body, wherein,

[0015] The number of contour slots is at least two, and the contour slots are used to accommodate the calibration components, with each contour slot corresponding to one calibration component.

[0016] In addition, a preferred embodiment is to provide a magnet at the bottom of the calibration component, and the calibration component is assembled and fixed in the contour groove by means of the magnet.

[0017] Furthermore, a preferred embodiment is to provide a through hole at the center of the contour groove, corresponding to the through hole of the calibration component.

[0018] In addition, a preferred embodiment is that a receiving groove is provided on the side of the tooling body, and the sensing chip is fixed in the receiving groove.

[0019] Furthermore, in a preferred embodiment, the calibration assembly includes a support block and a POM block, wherein,

[0020] The support block is provided with a groove for accommodating the POM block, and an opening is provided at the center of the groove;

[0021] The POM block is an annular cylinder with a hollow circular hole in the middle. The hollow circular hole corresponds to the opening and together form the through hole.

[0022] In addition, a preferred embodiment is that the support block is provided with an adhesive storage hole for storing UV adhesive.

[0023] Furthermore, a preferred embodiment is that the support block is made of metal, and the POM block is made of plastic or metal.

[0024] The present invention also provides a calibration method, which uses the above-mentioned calibration device for detection and calibration, specifically including: transferring the calibration component to the process where the AOI detection unit is located through calibration fixture;

[0025] The AOI detection unit is controlled by a PLC control unit to detect the calibration components; wherein...

[0026] During the testing process, if any test result of the calibration component exceeds the set threshold, the PLC control unit will issue an alarm and stop the machine for troubleshooting. After troubleshooting and repair, the testing task will be re-executed.

[0027] If the calibration component passes the test, the calibration worker loads the calibration component and transfers it to the next process.

[0028] Furthermore, in a preferred embodiment, the AOI detection unit is controlled by a PLC control unit to detect the calibration component, which includes a support block and a POM block. The specific detection steps are as follows:

[0029] First, the average grayscale of the reflection on the metal surface of the support block is detected to obtain the grayscale value of the metal surface.

[0030] By comparing the grayscale value of the metal surface with the upper illumination threshold, it is determined whether the brightness of the upper illumination white light source meets the detection requirements;

[0031] Secondly, the average grayscale of the UV adhesive in the adhesive storage hole is detected to obtain the grayscale value of the UV adhesive.

[0032] The brightness of the UV light source is determined to meet the detection requirements by comparing the grayscale value and UV light threshold of the UV adhesive.

[0033] Next, average grayscale detection is performed on the bottom light source through the hollow circular hole of the POM block to obtain the grayscale value of the bottom light source.

[0034] The brightness of the bottom light source is determined to meet the detection requirements by comparing the grayscale value and the bottom light threshold.

[0035] Finally, the measured annular diameter of the POM block is fitted to obtain the fitted annular ring;

[0036] By comparing the preset circular threshold with the fitted circular ring, it is determined whether the size of the POM block meets the detection requirements.

[0037] As can be seen from the above technical solutions, the calibration device and calibration method provided by the present invention can achieve the following beneficial effects compared with the prior art:

[0038] 1) An automatic calibration method is adopted. The calibration fixture is identified by the sensor chip, and the matching AOI detection unit is automatically called to perform size measurement and light source brightness measurement. When the detected size and light source brightness exceed the threshold, an alarm is triggered and the machine is stopped, thereby avoiding safety hazards for operators.

[0039] 2) Different specifications (different heights and dimensions) of calibration components are used to meet the detection requirements of different AOI detection fields of view; the calibration components of different specifications (different heights) can be replaced by the magnet at the bottom, thereby realizing the calibration of detection data on the detection surface at different heights;

[0040] 3) Simultaneous detection of top and bottom lighting can be achieved by setting the POM block.

[0041] To achieve the foregoing and related objectives, one or more aspects of the invention include the features that will be described in detail below. The following description and accompanying drawings illustrate certain exemplary aspects of the invention. However, these aspects indicate only a few of the various ways in which the principles of the invention can be used. Furthermore, the invention is intended to encompass all such aspects and their equivalents. Attached Figure Description

[0042] Other objects and results of the invention will become more apparent and readily understood with reference to the following description taken in conjunction with the accompanying drawings. In the drawings:

[0043] Figure 1 This is a schematic diagram of the logic structure of a calibration device according to an embodiment of the present invention;

[0044] Figure 2 This is a three-dimensional structural diagram of the calibration device according to an embodiment of the present invention;

[0045] Figure 3 This is a schematic diagram of the calibration component structure according to an embodiment of the present invention;

[0046] Figure 4 This is a schematic diagram of the calibration method according to an embodiment of the present invention.

[0047] The reference numerals in the figures include: 1, calibration fixture; 2, calibration component; 3, sensing chip; 4, PLC control unit; 5, AOI detection unit; 11, contour groove; 12, through hole; 13, receiving groove; 21, support block; 211, groove; 212, opening; 213, glue storage hole; 22, POM block; 221, hollow round hole.

[0048] In all the accompanying drawings, the same reference numerals indicate similar or corresponding features or functions. Detailed Implementation

[0049] In the following description, numerous specific details are set forth for illustrative purposes and to provide a thorough understanding of one or more embodiments. However, it will be apparent that these embodiments may also be implemented without these specific details. In other instances, well-known structures and devices are shown in block diagram form for ease of description of one or more embodiments.

[0050] In the description of this invention, it should be understood that the terms "center," "longitudinal," "lateral," "length," "width," "thickness," "upper," "lower," "front," "rear," "left," "right," "vertical," "horizontal," "top," "bottom," "inner," "outer," "clockwise," "counterclockwise," "axial," "radial," and "circumferential" indicate the orientation or positional relationship based on the orientation or positional relationship shown in the accompanying drawings. They are used 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. Therefore, they should not be construed as limitations on this invention.

[0051] In response to the aforementioned problems in existing AOI inspection processes, such as inaccurate detection due to loose inspection equipment, different testing methods, and low efficiency of manual inspection, this invention proposes a calibration device and calibration method.

[0052] The specific embodiments of the present invention will now be described in detail with reference to the accompanying drawings.

[0053] To illustrate the structure of the calibration device provided by the present invention, Figures 1 to 3 The structure of the calibration device is illustrated by way of example from different perspectives. Specifically, Figure 1 The logical structure of a calibration device according to an embodiment of the present invention is shown; Figure 2 The three-dimensional structure of the calibration device according to an embodiment of the present invention is shown; Figure 3 The structure of a calibration component according to an embodiment of the present invention is shown.

[0054] like Figures 1 to 3 As shown, the calibration device provided by the present invention includes a calibration fixture 1, calibration components 2 of different specifications and a sensing chip 3 disposed on the calibration fixture 1, an AOI detection unit 5, and a PLC control unit 4. The calibration fixture 1 is used to assemble the calibration components 2 and transfer the calibration components 2 to the process (i.e., the AOI detection station) where the AOI detection unit 5 is located. The sensing chip 3 is used to identify whether the calibration fixture 1 has been transferred to the AOI detection station. The AOI detection unit 5 is disposed at the AOI detection station and is used to detect the calibration components 2. The PLC control unit 4 is used to control the AOI detection unit 5 to detect the calibration components 1.

[0055] The calibration fixture 1 includes a fixture body and a contour groove 11 disposed on the fixture body. The number of contour grooves 11 is at least two. The contour grooves 11 are used to accommodate calibration components 1 of different specifications, and each contour groove 11 corresponds to one calibration component 2.

[0056] A through hole 12 is provided at the center of the contour groove 11, corresponding to the through hole of the calibration component 2. A receiving groove 13 is provided on the side of the tooling body, and the sensing chip 3 is fixed in the receiving groove 13. In this embodiment of the invention, the sensing chip 3 is an RFID (Radio Frequency Identification) chip.

[0057] A magnet is provided at the bottom of the calibration component 2, and the calibration component 2 is assembled and fixed in the contour groove 11 by the magnet. In the embodiment of the present invention, the calibration component 2 is a replaceable structure, and can be designed with different sizes (13mm-20mm) and different heights (height difference increases sequentially by 0.2mm), or can be designed with different numbers such as: 1-20.

[0058] The calibration component 2 includes a support block 21 and a POM block 22. The support block 21 has a groove 211 for accommodating the POM block 22, and an opening 212 is provided at the center of the groove 211. The POM block 22 is an annular cylinder with a hollow circular hole 221 in the middle. The hollow circular hole 221 corresponds to the opening 212 and together form the through hole corresponding to the through hole 12 of the contour groove 11.

[0059] The specific structural design of the calibration component 2 described above is to ensure that both upward and downward lighting are simultaneously available during AOI inspection. A hollow circular hole 221 is placed in the center of the POM block 22 to meet the light transmission requirements of downward lighting inspection; the metal light source edges of the black POM block 22 and support block 21 are used as the detection features for upward lighting due to the strong reflectivity of metal and the clear edge features.

[0060] The support block 21 is made of metal, while the POM block 22 is made of either plastic (polyoxymethylene) or metal. For economic reasons, the POM block 22 can be made of plastic; however, in practical applications, the appropriate material should be selected based on the specific circumstances, and the choice is not limited to the aforementioned specific materials.

[0061] In an embodiment of the present invention, an adhesive storage hole 213 is provided on the support block 21 for storing UV adhesive. The UV adhesive on the support block 21 is used to identify the brightness of the UV light source.

[0062] Corresponding to the above-described device, the present invention also provides a calibration method. Figure 4 A calibration method flow according to an embodiment of the present invention is shown.

[0063] like Figure 4As shown, the calibration method provided by the present invention uses the above-mentioned calibration device for detection and calibration, specifically including:

[0064] S110: The calibration components are transferred to the AOI inspection unit via calibration fixtures;

[0065] S120: The AOI detection unit is controlled by the PLC control unit to detect the calibration component; wherein...

[0066] S130: During the testing process, if any test result of the calibration component exceeds the set threshold, the PLC control unit will issue an alarm and stop the machine for troubleshooting. After troubleshooting and repair, the testing task will be re-executed.

[0067] S140: If the calibration component passes the test, the calibration worker loads the calibration component and transfers it to the next process.

[0068] In step S120, the AOI detection unit, controlled by the PLC control unit, detects the calibration component, which includes a support block and a POM block. The specific detection steps are as follows:

[0069] S121: Perform average grayscale detection on the reflection of the metal surface of the support block to obtain the grayscale value of the metal surface;

[0070] By comparing the grayscale value of the metal surface with the upper illumination threshold, it is determined whether the brightness of the upper illumination white light source meets the detection requirements;

[0071] S122: Perform average grayscale detection on the UV adhesive in the adhesive storage hole to obtain the grayscale value of the UV adhesive;

[0072] The brightness of the UV light source is determined to meet the detection requirements by comparing the grayscale value and UV light threshold of the UV adhesive.

[0073] S123: Perform average grayscale detection on the bottom light source through the hollow circular hole of the POM block to obtain the grayscale value of the bottom light source.

[0074] The brightness of the bottom light source is determined to meet the detection requirements by comparing the grayscale value and the bottom light threshold.

[0075] S124: Fit the measured annular diameter of the POM block to obtain the fitted annular ring;

[0076] By comparing the fitted ring and the ring threshold, it is determined whether the size of the POM block meets the detection requirements.

[0077] In embodiments of the present invention, top and bottom lighting are used for inspection to check whether the product's dimensions and condition meet requirements. Inspection of the UV adhesive is to check whether the bonding between various components using the UV adhesive meets requirements. Inspection of the POM block's ring diameter is to check whether the equipment's mechanical position is loose and to check the accuracy of the equipment's identification.

[0078] In this invention, during calibration, the calibration fixture 1 is assembled with calibration components 2 of the required number of the sub-item and sequentially transferred to the AOI inspection station. The AOI inspection station identifies the calibration fixture 1 by the information stored in the sensing chip 3 assembled in the calibration fixture 1. The PLC control unit 4 controls the AOI inspection unit 5 to jump to the calibration program and perform the measurement of the calibration components 2.

[0079] During the measurement process, the AOI inspection station detects the brightness of the white light source by reflecting light from the metal surface of the support block 21. Specifically, it identifies whether the brightness of the white light source is within the threshold range by using the average gray value of the surface detection area; it identifies whether the brightness of the UV light source is within the threshold range by using the RGB value of the UV glue poured into the glue storage hole 213; and it detects the brightness of the bottom light source by using the average gray value of the hollow circular hole 221 set in the middle of the POM block 22.

[0080] In addition, the machining dimensions of POM block 22 are measured, and the diameter of the fitted circle is used to detect the ring diameter, thus achieving the accuracy of AOI inspection (whether the inspection equipment is malfunctioning). Specifically, when any detected value exceeds the set threshold range, the PLC control unit sends a notification to the AOI inspection equipment to stop and issue an alarm, which then alerts the equipment debugging personnel to troubleshoot the problem. After the problem is fixed, the inspection process is re-executed. If the inspection is successful, the measurement information is recorded and saved to the system server, then transferred to the next inspection station for further inspection. After all inspections are completed and all are successful, the tooling is discharged at the final station.

[0081] As the embodiments of the calibration method provided by the present invention are basically similar to the embodiments of the calibration device, the relevant parts are described in the description of the calibration embodiments, and will not be repeated here.

[0082] In the embodiments of the present invention, automatic inspection is adopted, reducing the time of a single inspection from 200 seconds to 10 seconds, and improving the overall efficiency by 95%; at the same time, it also reduces the risk of equipment failure and improves the reliability of the product.

[0083] As can be seen from the above embodiments, the calibration device and calibration method provided by the present invention adopt an automatic calibration method. It identifies the calibration fixture through a sensor chip, automatically calls the matching AOI detection unit to perform size measurement and light source brightness measurement, and alarms and stops the machine when the detected size and light source brightness exceed the threshold, thereby avoiding safety hazards for operators. Different specifications (different heights and dimensions) of calibration components are used to correspond to the detection requirements of different AOI detection fields of view. The replacement of calibration components of different specifications (different heights) is achieved through the magnet at the bottom, thereby realizing detection data calibration on detection surfaces at different heights. Simultaneous detection by upper and lower lighting is achieved by setting a POM block.

[0084] The calibration apparatus and calibration method according to the present invention have been described above by way of example with reference to the accompanying drawings. However, those skilled in the art should understand that various modifications can be made to the calibration apparatus and calibration method proposed in the present invention without departing from the scope of the invention. Therefore, the scope of protection of the present invention should be determined by the contents of the appended claims.

Claims

1. A calibration device, characterized in that, include: The calibration fixture includes calibration components and sensing chips of different specifications mounted on it, an AOI detection unit, and a PLC control unit. The calibration fixture is used to assemble the calibration component and transfer the calibration component to the process where the AOI detection unit is located; The sensing chip is used to identify whether the calibration fixture has been transferred to the process where the AOI detection unit is located; The AOI detection unit is used to detect the calibration component; The PLC control unit is used to control the AOI detection unit to detect the calibration component; The calibration assembly includes a support block and a POM block, wherein... The support block is provided with a groove for accommodating the POM block, and an opening is provided at the center of the groove; The POM block is an annular cylinder with a hollow circular hole in the middle. The hollow circular hole corresponds to the opening and together they form a through hole.

2. The calibration device according to claim 1, characterized in that, The calibration fixture includes a fixture body and a contour groove disposed on the fixture body, wherein... The number of contour slots is at least two, and the contour slots are used to accommodate the calibration components, with each contour slot corresponding to one calibration component.

3. The calibration device according to claim 2, characterized in that, A magnet is provided at the bottom of the calibration component, and the calibration component is assembled and fixed in the contour groove by means of the magnet.

4. The calibration device according to claim 2, characterized in that, A through hole is provided at the center of the contour groove, corresponding to the through hole of the calibration component.

5. The calibration device according to claim 4, characterized in that, A receiving groove is provided on the side of the tooling body, and the sensing chip is fixed in the receiving groove.

6. The calibration apparatus according to claim 1, characterized in that, The support block is provided with an adhesive storage hole for storing UV adhesive.

7. The calibration apparatus according to claim 1, characterized in that, The support block is made of metal.

8. A calibration method, characterized in that, The calibration is performed using the calibration apparatus as described in any one of claims 1-7, specifically including: The calibration components are transferred to the AOI inspection unit via calibration fixtures. The AOI detection unit is controlled by a PLC control unit to detect the calibration components; wherein... During the testing process, if any test result of the calibration component exceeds the set threshold, the PLC control unit will issue an alarm and stop the machine for troubleshooting. After troubleshooting and repair, the testing task will be re-executed. If the calibration component passes the test, the calibration worker loads the calibration component and transfers it to the next process.

9. The calibration method according to claim 8, characterized in that, The calibration component, which is controlled by a PLC control unit to perform AOI detection, includes a support block and a POM block. The specific detection steps are as follows: First, the average grayscale of the reflection on the metal surface of the support block is detected to obtain the grayscale value of the metal surface. By comparing the grayscale value of the metal surface with the upper illumination threshold, it is determined whether the brightness of the upper illumination white light source meets the detection requirements; Secondly, the average grayscale of the UV adhesive in the adhesive storage hole is detected to obtain the grayscale value of the UV adhesive. The brightness of the UV light source is determined to meet the detection requirements by comparing the grayscale value and UV light threshold of the UV adhesive. Next, average grayscale detection is performed on the bottom light source through the hollow circular hole of the POM block to obtain the grayscale value of the bottom light source. The brightness of the bottom light source is determined to meet the detection requirements by comparing the grayscale value and the bottom light threshold. Finally, the measured annular diameter of the POM block is fitted to obtain the fitted annular ring; By comparing the preset circular threshold with the fitted circular ring, it is determined whether the size of the POM block meets the detection requirements.

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