Visual intelligent system for detecting welding quality of automobile fuel tank

Abstract

The invention relates to the technical field of inspection and detection, and particularly provides a visual intelligent system for detecting the welding quality of an automobile fuel tank. The system includes an input device; a detection device; the output device comprises a transfer jacking mechanism, a transfer conveying belt, a limiting grating, an alarm, a qualified product temporary storage area and an unqualified product temporary storage area; the structure supporting device comprises a structure frame, a supporting platform at the bottom of the frame and locking moving ground feet; the pneumatic loop comprises a pneumatic valve set, a first pneumatic sliding rail set and a second pneumatic sliding rail set, the system solves the problems that detection and collection positions cannot be freely selected and automatic continuous detection cannot be achieved, the accuracy and expansibility of detection are improved, the difficulty that reasons of the problems of the detected oil tank cannot be traced is overcome, and the detection efficiency is improved. The number of field personnel can be reduced, and the intrinsic safety level of production links is improved.

Description

Technical Field

[0001] The invention relates to the field of inspection and detection technology, and in particular to a visual intelligent system for detecting the welding quality of automobile fuel tanks. Background Art

[0002] At present, the welding of oil tanks is mainly inspected manually, which requires the operator to manually drag the welded oil tanks from the welding line and conduct manual visual inspection. It only realizes the shooting and sampling of the main directions above and around the oil tanks, but does not cover the collection direction below the oil tanks. It cannot detect specific positions of the oil tanks. Manual inspection cannot obtain the position and size of the welding. In addition, since the oil tanks are produced continuously, manual inspection is prone to fatigue and safety accidents. From on-site manual inspection to the production inspection results in the MES system, it is impossible to trace the cause of the problem of the inspected oil tank. Summary of the invention

[0003] In view of this, the present invention provides a visual intelligent system for detecting the welding quality of automobile fuel tanks, which is used to solve the problems of not being able to freely select the detection and collection position and not being able to achieve automatic continuous detection, improve the accuracy and scalability of detection, and overcome the difficulty of not being able to trace the causes of problems in the detection of fuel tanks. It can reduce the number of on-site personnel and improve the inherent safety level of the production process.

[0004] In a first aspect, the present invention provides a visual intelligent system for detecting the welding quality of an automobile fuel tank, wherein the system is supported by a structural frame and comprises: An input device, the input device includes a plurality of photoelectric switches, an input roller, a fuel tank mold and a mold lifting mechanism; a detection device, the detection device includes a collaborative robot, a first acquisition camera to a fourth acquisition camera, an illumination light source, a camera structure, an industrial computer, a PLC, a wireless network bridge, a first display and a second display; an output device, the output device includes a transfer and lifting mechanism, a transfer conveyor belt, an entry limiting grating, an alarm, a qualified product temporary storage area and a unqualified product temporary storage area; the two temporary storage areas are located on both sides of the input direction, and the output direction is perpendicular to the input direction; the fuel tank mold and the transfer and lifting mechanism are powered by a pneumatic circuit and controlled by a PLC; a structural support device, the structural support device includes a structural frame, a support platform at the bottom of the frame and a lockable movable foot; a pneumatic circuit, the pneumatic circuit includes a pneumatic valve group, a first pneumatic slide rail group, and a second pneumatic slide rail group.

[0005] Optionally, the photoelectric switch includes a trigger photoelectric switch, a deceleration photoelectric switch and an in-position photoelectric switch; the trigger photoelectric switch is used to detect whether the oil tank is about to be input into the detection system. After the detection system receives the trigger signal, it starts the input roller, and the input roller accelerates at this time; the deceleration photoelectric switch is used to send a deceleration signal to the detection system when the oil tank is about to be transported to the detection position, so as to decelerate the running speed of the input roller; the detection system obtains the in-position signal sent by the in-position photoelectric switch, and when it is determined that the oil tank is in position, it immediately stops the input roller to make the oil tank stop at the detection position; the trigger photoelectric switch is fixed to the two support rods on one side of the oil tank entry equipment by bolts, and the height is flush with the entry height of the oil tank. It is a reflected photoelectric switch; the deceleration photoelectric switch and the in-position photoelectric switch are reflective photoelectric switches, which are fixed under the input roller by bolts and are arranged in sequence according to the direction of the oil tank entering the detection system. The interval of the cylinder of the input roller; the input roller is installed on the structural frame by bolts, and the height is 1 / 3 from the bottom surface; the oil tank backing mold is used to support the oil tank to ensure that the oil tank is in a fixed state during the inspection process. The supporting structure contour of the oil tank backing mold is designed according to the oil tank contour, and is divided into two parts, front and rear, according to the input direction of the oil tank; similarly, the backing mold lifting mechanism is divided into two parts, front and rear, according to the input direction of the oil tank, and the two oil tank backing molds are respectively fixed on the backing mold lifting mechanism, positioned by pins, and fixed by bolts; the backing mold lifting mechanism is fixed to the first pneumatic slide rail group by bolts and is located below the input roller; the backing mold lifting mechanism is used to lift the backing mold, and the backing mold lifting mechanism lifts the oil tank backing mold so that the oil tank no longer contacts the input roller, and relies on gravity to make the oil tank fall into the backing mold; when the backing mold lifting mechanism falls, the highest point of the oil tank backing mold is lower than the highest point of the input roller to avoid affecting the movement of the oil tank.

[0006] Optionally, the collaborative robot is fixed to the top center of the structural frame by bolts, and the robot controller is placed on the bottom platform of the structural frame; the collaborative robot is installed upside down and is used to operate the collaborative robot to move according to the set movement route and points. After the robot controller receives the movement instruction, the collaborative robot drives the light source and the first acquisition camera to the acquisition position, and when all position detections are completed, the collaborative robot moves to the initial position; the detection position is set according to the structure and size of the oil tank, and the lighting source is used to provide lighting for the acquisition; the first to fourth acquisition cameras are used to realize image acquisition of the target position of the oil tank detection; the second to fourth acquisition cameras fixed at the fixed position of the structural frame and the first acquisition camera fixed to the end of the collaborative robot through the camera structure are all fixed by bolts; the industrial computer is fixed to the support at the bottom of the frame by bolts. The industrial computer receives the image captured by the camera, completes image detection, recognition, and measurement, summarizes the overall quality of the fuel tank, and determines the output direction of the fuel tank; the PLC is fixed to the support platform at the bottom of the frame by bolts, and is located on the opposite side of the fuel tank input position; the wireless bridge includes a transmitting end and a receiving end, the transmitting end is placed on the industrial computer, and has four antennas; the receiving end is fixed to the end of the collaborative robot by bolts, and has two antennas, and the wireless bridge plays the role of wirelessly transmitting the robot camera image to the industrial computer; the first display and the second display are both touch screen displays, the first display is fixed by bolts, and is mounted on the anti-touch net above the PLC installation position near the qualified product temporary storage area, and the second display is fixed by bolts, and is mounted on the anti-touch net above the unqualified product temporary storage area, away from the fuel tank input side.

[0007] Optionally, the transfer conveyor belt and the transfer lifting mechanism are divided into two parts, front and rear, according to the input direction of the oil tank. The transfer conveyor belt is used to output the inspected oil tanks to two types of temporary storage areas, and the transfer and conveying direction is perpendicular to the input roller; the transfer lifting mechanism is connected to the transfer conveyor belt by bolts at the top and the second pneumatic slide rail group at the bottom. The two parts of the transfer lifting mechanism can be simultaneously driven to be lifted up or driven to fall down by the second pneumatic slide rail group, and drive the transfer conveyor belt to move in the vertical direction; the entry limiting grating is installed on the structural frame on one side of the qualified product temporary storage area by bolts, and is a counter-radiation type; the alarm is used to receive system detection The qualified product temporary storage area is a telescopic conveyor roller structure with railings on both sides and the rear end to prevent the oil tank from falling. When the oil tank is to be moved into the qualified product temporary storage area, it will be started together with the transfer conveyor belt, and the length will be adjusted according to the expected temporary storage quantity. Up to 4 mailboxes can be temporarily stored. The qualified product temporary storage area communicates with the system structure frame through cables and draws power. The unqualified product temporary storage area is a bucket-shaped structure fixed to the system structure frame by bolts. There is space for temporary storage of one oil tank. If it has been temporarily stored, subsequent unqualified products will no longer be transferred and will need to be emptied before they can be temporarily stored again.

[0008] Optionally, the structural frame is a rectangular structure. Except for the upper and lower 1 / 3 of the other three sides on the side of the qualified product temporary storage area, they are closed with anti-touch nets. The middle 1 / 3 is left empty and used as the space for entering and exiting the oil tank. There is no anti-touch net on one side of the qualified product temporary storage area, and the entry of personnel is restricted by the input roller; the support platform at the bottom of the frame is used to support industrial computers, robot controllers and PLCs.

[0009] Optionally, the pneumatic valve group is fixed by bolts to the structural frame at about 1 / 3 below the side opposite to the oil tank input position. The first pneumatic slide rail group includes two pneumatic slide rails, denoted as A and B, which are respectively connected to the mold lifting mechanism by bolts, and are fixed to the center of the bottom support platform of the frame by bolts; the second pneumatic slide rail group includes two pneumatic slide rails, denoted as C and D, which are respectively connected to the transfer lifting mechanism by bolts, and are fixed to the center of the bottom support platform of the frame by bolts; the second pneumatic slide rail group is located on the inner side of the first pneumatic slide rail group, and is arranged as ACDB in the order of the oil tank input, and the four pneumatic slide rails are arranged in a straight line.

[0010] Optionally, the PLC is used to control the alarm, transfer conveyor belt, input roller, output roller, gas valve of the oil tank mold, and collaborative robot; the PLC is connected to the collaborative robot through protocol communication, and is connected to the system master control device through TCP communication, so as to read the robot status signal in real time and forward it to the system master control device; the PLC controls the descent of the mold lifting mechanism, the start and stop of the input roller, and the movement of the collaborative robot by receiving data sent by the system master control device; the PLC reads the status of its controlled hardware equipment and the signals triggered by multiple photoelectric switches, and sends them to the system to realize real-time monitoring of the status by the system master control device; the PLC is connected to the production site MES control system through a network cable, and the MES control system receives the read signal sent by the PLC, reads the current oil tank detection result, and completes the upload of the detection result.

[0011] Optionally, the system further comprises: a robot control device and a detection and identification device; The robot control device runs in the robot controller and is used to receive the control signal sent by the PLC and control the movement mode, movement speed and movement route of the collaborative robot; The detection and identification device has an independent operable interface, which includes a collection and detection module and a first communication module; The acquisition and detection module adopts machine vision and deep learning technology, including image noise reduction, image enhancement, gamma correction, image rotation, template matching, strength segmentation, serial communication, and TCP communication functions; the acquisition and detection module receives images from the first acquisition camera to the fourth acquisition camera, and based on the robot position signal obtained by the first communication module, enables corresponding preprocessing algorithms and detection and recognition algorithms for different targets to detect the similarity, size, position, and height of weldments; the detection and recognition device is connected to the second communication module of the system master control device through the first communication module, receives its signal and performs corresponding operations; after the target detection of a single fuel tank is completed, the detection and recognition device automatically summarizes all results, stores them locally, and sends the results to the system master control device.

[0012] Optionally, the system master control device includes a second communication module and a human-computer interaction module; The second communication module realizes communication interconnection with the PLC and the detection and identification device based on TCP, and realizes transparent transmission of TCP results to the PLC; the second communication module sends the position of the collaborative robot to the detection and identification device, triggers the corresponding position detection operation of the detection and identification device, receives the next target position, and forwards it to the PLC; receives the oil tank detection result, enters the result into the database, and then forwards it to the PLC; the second communication module sends the target position signal to the PLC, receives the current position signal of the robot, and forwards it to the first communication module of the detection and identification device; the second communication module sends the control signal of the hardware device and receives the system operation status signal; The human-computer interaction module has a switchable display interface, which includes a signal interface, an operation interface, an alarm interface, a history record interface and a statistical interface; the display interface is used to display all system states, including photoelectric switch signals, transfer and backing position, motor start and stop, robot position, detection status, detection tank model, detection task batch, date, and detection results; the operation interface includes operation buttons, automatic or manual equipment state switching, roller, backing or transfer control cases, communication test cases, and robot reset cases; the alarm interface is used to display the alarm records of the equipment; the history record interface is used to query the result database, display the detection records of the equipment, and can be queried according to date and result type; the statistical interface is used to query the database to count the number of qualified and unqualified tests within a limited time, and draw bar charts according to units such as month / week / day.

[0013] In the technical solution provided by the present invention, the system uses a structural frame as a supporting body, and the system includes an input device, which includes a plurality of photoelectric switches, an input roller, a fuel tank template and a template lifting mechanism; a detection device, which includes a collaborative robot, a first acquisition camera to a fourth acquisition camera, an illumination light source, a camera structure, an industrial computer, a PLC, a wireless bridge, a first display and a second display; an output device, which includes a transfer lifting mechanism, a transfer conveyor belt, an entry-limiting grating, an alarm, a qualified product temporary storage area and a unqualified product temporary storage area; the two temporary storage areas are located on both sides of the input direction, and the output direction is Perpendicular to the input direction; the oil tank profiling and transfer lifting mechanism are powered by a pneumatic circuit and controlled by a PLC; a structural support device, the structural support device includes a structural frame, a supporting platform at the bottom of the frame and a locked movable foot; a pneumatic circuit, the pneumatic circuit includes a pneumatic valve group, a first pneumatic slide rail group, and a second pneumatic slide rail group. The system solves the problems of being unable to freely select the detection and collection position and being unable to achieve automatic continuous detection, improves the accuracy and scalability of the detection, and overcomes the difficulty of being unable to trace the cause of the problem in the detection of the oil tank, which can reduce the number of on-site personnel and improve the inherent safety level of the production process. BRIEF DESCRIPTION OF THE DRAWINGS

[0014] In order to more clearly illustrate the technical solutions of the embodiments of the present invention, the drawings required for use in the embodiments will be briefly introduced below. Obviously, the drawings described below are only some embodiments of the present invention. For ordinary technicians in this field, other drawings can be obtained based on these drawings without paying creative work.

[0015] Figure 1 A schematic diagram of the structure of a visual intelligence system provided by an embodiment of the present invention; Figure 2 A schematic diagram of the structure of another visual intelligence system provided by an embodiment of the present invention.

[0016] Numbers in the figure: 1-input roller, 2-oil tank backing, 3-backing lifting mechanism, 4-collaborative robot, 5-first acquisition camera, 6-second acquisition camera, 7-third acquisition camera, 8-fourth acquisition camera, 9-industrial computer, 10-PLC, 11-first display, 12-second display, 13-transfer lifting mechanism, 14-transfer conveyor belt, 15-entry restriction grating, 16-qualified product temporary storage area, 17-unqualified product temporary storage area, 18-structural frame, 19-support platform, 20-locking movable foot, 21-pneumatic valve group, 22-first pneumatic slide rail group, 23-second pneumatic slide rail group, 24-robot controller, 25-anti-touch net, 111-trigger photoelectric switch, 112-deceleration photoelectric switch and 113-in-place photoelectric switch. DETAILED DESCRIPTION

[0017] In order to make the purpose, technical solution and advantages of the embodiments of the present invention clearer, the technical solution in the embodiments of the present invention will be clearly and completely described below in conjunction with the drawings in the embodiments of the present invention. Obviously, the described embodiments are part of the embodiments of the present invention, not all of the embodiments. Based on the embodiments of the present invention, all other embodiments obtained by ordinary technicians in this field without creative work are within the scope of protection of the present invention.

[0018] It should be clear that the described embodiments are only part of the embodiments of the present invention, not all of the embodiments. Based on the embodiments of the present invention, all other embodiments obtained by ordinary technicians in this field without creative work are within the scope of protection of the present invention.

[0019] The terms used in the embodiments of the present invention are only for the purpose of describing specific embodiments, and are not intended to limit the present invention. The singular forms "a", "said" and "the" used in the embodiments of the present invention are also intended to include plural forms, unless the context clearly indicates other meanings.

[0020] It should be understood that the term "and / or" used in this article is only a description of the association relationship of associated objects, indicating that there can be three relationships. For example, A and / or B can represent: A exists alone, A and B exist at the same time, and B exists alone. In addition, the character " / " in this article generally indicates that the associated objects before and after are in an "or" relationship.

[0021] The word "if" as used herein may be interpreted as "at the time of" or "when" or "in response to determining" or "in response to detecting", depending on the context. Similarly, the phrases "if it is determined" or "if (stated condition or event) is detected" may be interpreted as "when it is determined" or "in response to determining" or "when detecting (stated condition or event)" or "in response to detecting (stated condition or event)", depending on the context.

[0022] The present invention provides a visual intelligent system for detecting the welding quality of automobile fuel tanks, such as Figure 1 and Figure 2 As shown, the system uses a structural frame 18 as a supporting body, and the system includes: An input device includes a plurality of photoelectric switches, an input roller 1, a fuel tank mold 2 and a mold lifting mechanism 3; a detection device includes a collaborative robot 4, a first acquisition camera 5 to a fourth acquisition camera 8, an illumination light source, a camera structure, an industrial computer 9, a PLC 10, a wireless network bridge, a first display 11 and a second display 12; an output device includes a transfer and lifting mechanism 13, a transfer conveyor belt 14, an entry limiting grating 15, an alarm, a qualified product temporary storage area 16 and a failed product temporary storage area 17; the two temporary storage areas are located on both sides of the input direction, and the output direction is perpendicular to the input direction; the fuel tank mold 2 and the transfer and lifting mechanism 13 are powered by a pneumatic circuit and controlled by a PLC 10; a structural support device includes a structural frame 18, a support platform 19 at the bottom of the frame and a locking movable foot 20; a pneumatic circuit includes a pneumatic valve group 21, a first pneumatic slide rail group 22, and a second pneumatic slide rail group 23.

[0023] In the embodiment of the present invention, the photoelectric switch includes a trigger photoelectric switch 111, a deceleration photoelectric switch 112 and an in-position photoelectric switch 113; the trigger photoelectric switch 111 is used to detect whether the oil tank is about to be input into the detection system, and the detection system starts the input roller 1 after receiving the trigger signal, and the input roller 1 accelerates at this time; the deceleration photoelectric switch 112 is used to send a deceleration signal to the detection system when the oil tank is about to be transported to the detection position, so as to decelerate the running speed of the input roller 1; the detection system obtains the in-position signal sent by the in-position photoelectric switch 113, and when it is determined that the oil tank is in position, the input roller 1 is stopped immediately to make the oil tank stop at the detection position; the trigger photoelectric switch 111 is fixed to the two support rods on one side of the oil tank entry device by bolts, and its height is flush with the entry height of the oil tank, and it is a beam-type photoelectric switch; the deceleration photoelectric switch 112 and the in-position photoelectric switch 113 are reflective photoelectric switches, which are fixed under the input roller 1 by bolts, and are The system direction is arranged in sequence at the interval of the cylinder of the input roller 1; the input roller 1 is installed on the structural frame 18 by bolts, and the height is 1 / 3 from the bottom surface; the oil tank backing form is used to support the oil tank to ensure that the oil tank is in a fixed state during the detection process. The supporting structure contour of the oil tank backing form 2 is designed according to the oil tank contour and is divided into two parts, front and rear, according to the input direction of the oil tank; similarly, the backing form lifting mechanism 3 is divided into two parts, front and rear, according to the input direction of the oil tank. The two oil tank backing forms are respectively fixed on the backing form lifting mechanism 3, positioned by pins, and fixed by bolts; the backing form lifting mechanism 3 is fixed to the first pneumatic slide rail group 22 by bolts and is located below the input roller 1; the backing form lifting mechanism 3 is used to lift the backing form, and the backing form lifting mechanism 3 lifts the oil tank backing form 2 so that the oil tank no longer contacts the input roller 1, and relies on gravity to make the oil tank fall into the backing form; when the backing form lifting mechanism 3 falls, the highest point of the oil tank backing form 2 is lower than the highest point of the input roller 1 to avoid affecting the movement of the oil tank.

[0024] In the embodiment of the present invention, the cylinder spacing of the input roller 1 is slightly narrower in the front and rear of the input direction and slightly wider in the middle. The wider spacing position is used for the oil tank mold 2 and the transfer load to be lifted from between the rollers.

[0025] In the embodiment of the present invention, the collaborative robot 4 is fixed to the top center of the structural frame 18 by bolts, and the robot controller 24 is placed on the bottom platform of the structural frame 18; the collaborative robot 4 is installed upside down and is used to operate the collaborative robot 4 to move according to the set moving route and point. After the robot controller 24 receives the moving instruction, the collaborative robot 4 drives the light source and the first acquisition camera 5 to the acquisition position, and when all position detections are completed, the collaborative robot 4 moves to the initial position; the detection position is set according to the structure and size of the oil tank, and the lighting source is used to provide lighting for the acquisition; the first acquisition camera 5 to the fourth acquisition camera 8 are used to realize image acquisition of the target position of the oil tank detection; the second acquisition camera 6 to the fourth acquisition camera 8 fixed at the fixed position of the structural frame 18 and the first acquisition camera 5 fixed to the end of the collaborative robot 4 through the camera structure are all fixed by bolts; the industrial computer 9 is fixed to the support platform at the bottom of the frame by bolts. The industrial computer 9 receives the image captured by the camera, completes image detection, recognition and measurement, summarizes the overall quality of the oil tank, and determines the output direction of the oil tank; the PLC 10 is fixed to the support platform 19 at the bottom of the frame by bolts, and is located on the opposite side of the oil tank input position; the wireless bridge includes a transmitting end and a receiving end, the transmitting end is placed on the industrial computer 9, and has four antennas; the receiving end is fixed to the end of the collaborative robot 4 by bolts, and has two antennas, and the wireless bridge plays the role of wirelessly transmitting the robot camera image to the industrial computer 9; the first display 11 and the second display 12 are both touch screen displays, the first display 11 is fixed by bolts, and is mounted on the anti-touch net 25 above the installation position of the PLC 10, close to the qualified product temporary storage area 16, and the second display 12 is fixed by bolts, and is mounted above the side of the unqualified product temporary storage area 17, away from the anti-touch net 25 on the tank input side.

[0026] In the embodiment of the present invention, the transfer conveyor belt 14 and the transfer lifting mechanism 13 are divided into two parts, front and rear, according to the oil tank input direction. The transfer conveyor belt 14 is used to output the inspected oil tanks to two types of temporary storage areas, and the transfer and conveying direction is perpendicular to the input roller 1; the transfer lifting mechanism 13 is connected to the transfer conveyor belt 14 by bolts at the top, and is connected to the second pneumatic slide rail group 23 at the bottom by bolts. The two parts of the transfer lifting mechanism 13 can be simultaneously driven to be lifted up or driven to fall down by the second pneumatic slide rail group 23, and drive the transfer conveyor belt 14 to move in the vertical direction; the entry limiting grating 15 is installed on the structural frame on one side of the qualified product temporary storage area 16 by bolts, and is a reverse-beam type; the alarm is used Receive system detection result signals and abnormal signals, and activate sound and light alarms; the qualified product temporary storage area 16 is a telescopic conveyor roller structure with railings on both sides and the rear end to prevent the oil tank from falling. When the oil tank is to be moved into the qualified product temporary storage area 16, it will be started together with the transfer conveyor belt 14, and the length will be adjusted according to the expected temporary storage quantity. Up to 4 mailboxes can be temporarily stored; the qualified product temporary storage area 16 communicates with the system structure frame 18 through cables and draws power; the unqualified product temporary storage area 17 is a bucket-shaped structure, which is fixed to the system structure frame 18 by bolts; there is space to temporarily store one oil tank. If it has been temporarily stored, subsequent unqualified products will no longer be transferred and will need to be emptied before they can be temporarily stored again.

[0027] In the embodiment of the present invention, the structural frame 18 is a rectangular parallelepiped structure. Except for the side of the qualified product temporary storage area 16, the upper and lower 1 / 3 parts of the other three sides are closed with anti-touch nets 25, and the middle 1 / 3 position is vacant, which is used as the space for the oil tank to enter and exit. There is no anti-touch net 25 on the side of the qualified product temporary storage area 16, and the input roller 1 restricts the entry of personnel; the support platform 19 at the bottom of the frame is used to support the industrial computer 9, the robot controller 24 and the PLC 10. The whole machine frame is welded with 100 square tubes to ensure the stability of the whole frame, and aluminum profiles are used inside to make the whole machine lightweight.

[0028] In the embodiment of the present invention, the pneumatic valve group 21 is fixed by bolts to the structural frame 18 at about 1 / 3 below the side opposite to the oil tank input position. The first pneumatic slide rail group 22 includes two pneumatic slide rails, denoted as A and B, which are respectively connected to the mold lifting mechanism 3 by bolts, and are fixed to the center of the bottom support platform 19 of the frame by bolts; the second pneumatic slide rail group 23 includes two pneumatic slide rails, denoted as C and D, which are respectively connected to the transfer lifting mechanism 13 by bolts, and are fixed to the center of the bottom support platform 19 of the frame by bolts; the second pneumatic slide rail group 23 is located on the inner side of the first pneumatic slide rail group 22, and is arranged as ACDB in the order of the oil tank input, and the four pneumatic slide rails are arranged in a straight line.

[0029] In the embodiment of the present invention, PLC10 is used to control the alarm, the transfer conveyor belt 14, the input roller 1, the output roller, the gas valve of the oil tank mold 2, and the collaborative robot 4; PLC10 is connected to the collaborative robot 4 through protocol communication, and is connected to the system master control device through TCP communication, so as to read the robot status signal in real time and forward it to the system master control device; PLC10 controls the descent of the mold lifting mechanism 3, the start and stop of the input roller 1, and the position movement of the collaborative robot 4 by receiving the data sent by the system master control device; PLC10 reads the status of its controlled hardware equipment and the signals triggered by multiple photoelectric switches, and sends them to the system to realize real-time monitoring of the status by the system master control device; PLC10 is connected to the production site MES control system through a network cable, and the MES control system receives the read signal sent by PLC10, reads the current oil tank detection result, and completes the upload of the detection result.

[0030] In the embodiment of the present invention, the system further comprises: a robot control device and a detection and identification device; The robot control device runs in the robot controller 24 and is used to receive the control signal sent by the PLC 10 and control the movement mode, movement speed and movement route of the collaborative robot 4; The detection and identification device has an independent operable interface, which includes a collection and detection module and a first communication module; The acquisition and detection module adopts machine vision and deep learning technology, including image noise reduction, image enhancement, gamma correction, image rotation, template matching, strength segmentation, serial communication, and TCP communication functions; the acquisition and detection module receives images from the first acquisition camera 5 to the fourth acquisition camera 8, and based on the robot position signal obtained by the first communication module, enables corresponding preprocessing algorithms and detection and recognition algorithms for different targets to detect the similarity, size, position, and height of weldments; the detection and recognition device is connected to the second communication module of the system master control device through the first communication module, receives its signal and performs corresponding operations; after the target detection of a single fuel tank is completed, the detection and recognition device automatically summarizes all results, stores them locally, and sends the results to the system master control device.

[0031] In the embodiment of the present invention, the system master control device includes a second communication module and a human-computer interaction module; The second communication module realizes communication interconnection with PLC10 and the detection and identification device based on TCP, and realizes transparent transmission of TCP results to PLC10; the second communication module sends the position of the collaborative robot 4 to the detection and identification device, triggers the corresponding position detection operation of the detection and identification device, receives the next target position, and forwards it to PLC10; receives the oil tank detection result, enters the result into the database, and then forwards it to PLC10; the second communication module sends the target position signal to PLC10, receives the robot's current position signal, and forwards it to the first communication module of the detection and identification device; the second communication module sends the control signal of the hardware device and receives the system operation status signal; The human-computer interaction module has a switchable display interface, which includes a signal interface, an operation interface, an alarm interface, a history record interface and a statistical interface; the display interface is used to display all system states, including photoelectric switch signals, transfer and backing position, motor start and stop, robot position, detection status, detection tank model, detection task batch, date, and detection results; the operation interface includes operation buttons, automatic or manual equipment state switching, roller, backing or transfer control cases, communication test cases, and robot reset cases; the alarm interface is used to display the alarm records of the equipment; the history record interface is used to query the result database, display the detection records of the equipment, and can be queried according to date and result type; the statistical interface is used to query the database to count the number of qualified and unqualified tests within a limited time, and draw bar charts according to units such as month / week / day.

[0032] In the embodiment of the present invention, after the test is completed, the system will summarize all the test results to form the final quality result, which includes NG and OK. If it is OK, it will be transferred to the qualified roller area on the left for temporary storage. The roller area can temporarily store multiple oil tanks; if it is NG, it will be transferred to the funnel area on the right for temporary storage. The funnel area can only temporarily store one oil tank; if the oil tank result is NG and there is already an oil tank in the funnel area, or the oil tank in the qualified product area is full, no transfer will be performed, and the system will alarm to remind manual processing.

[0033] The oil tank flows out from the welding line to the detection system. After the photoelectric switch of the detection system detects the oil tank, the delay waits for the oil tank to stop steadily, and then the collaborative robot 4 drives the camera to start taking pictures for detection. After the detection is completed, the detection results are uploaded to the MES system. If the detection result is qualified, the indicator light is green, and the oil tank flows into the buffer area, waiting for packaging and storage. If the detection is unqualified, the detection result indicator light is red and the buzzer alarm reminds the assembler to take out the oil tank and the quality inspector will re-inspect the oil tank. The system master control device is the main body, which transfers the status signal and the detection result signal. At the same time, it has three result storage methods: local storage, database storage, and MES system upload. The detection and recognition device has an independent operable interface, and can pre-configure different preprocessing and detection algorithms according to different target requirements, and trigger them through fixed signals when in use. The algorithms that can be pre-configured in the detection and recognition device include image noise reduction, image enhancement, gamma correction, image rotation, template matching, strength segmentation, etc. According to the different positions of the target in the image and different target features, the appropriate algorithm is selected for logical combination to highlight the key contour and improve the accuracy of recognition. The detection routes pre-configured by the detection and identification device can be expanded according to site needs.

[0034] The system of the present invention realizes docking with production equipment, automatically obtains fuel tanks, and automatically outputs fuel tanks after the detection is completed; it improves the automation level of automobile fuel tank welding quality detection, realizes the preservation of detection results and traceability query of detection records; by adopting contour matching in machine vision technology and target detection technology in deep learning, the accuracy of fuel tank detection is improved, and the quality problems of different targets can be accurately detected; by building an expandable system platform, if additional detection items are to be added to the detection of a fuel tank, quick expansion and rapid configuration of the detection algorithm can be performed, and the newly configured detection target acquisition position is incorporated into the original collaborative robot point concentration without affecting the original detection. By configuring a detachable template jacking structure, the template replacement can be quickly realized. Combined with the rapid configuration of the system detection solution, the system can quickly complete the mode switching from type A fuel tank detection to type B fuel tank detection. The software detection algorithm is directional configured for the target, which can improve the effect of target detection. The detection accuracy of the specific position of a specific target is higher than that of the detection algorithm with general configuration.

[0035] The detection table of the system of the present invention is connected to the oil tank production line. After the oil tank flows out from the welding line, it enters the detection table through the input roller 1. After reaching the specified position, the photoelectric switch 111 is triggered to customize the input roller 1; after the triggering, the mold lifting mechanism 3 is started to lift the oil tank to the detection position; thereafter, the detection system automatically starts the detection, first starting from the fixed camera position, and visually collecting the image of the mold situation to identify whether the mold is accurately dropped; if the mold drop fails, it is immediately transferred and an alarm is given for abnormal mold failure; if the mold is successful, the image is collected and identified by the fixed camera, and the mobile collaborative robot 4 drives the camera to the first detection position. After completing image collection, transmission, and identification, the collaborative robot 4 is moved to the second detection position, and all position detections are completed in turn. Then the collaborative robot 4 is moved back to its original position and the detection results of all positions are summarized; and the oil tank is output in a direction perpendicular to the input through the transmission roller. If missing parts or abnormal dimensions are detected, they are transferred to the unqualified product temporary storage area 17, and an alarm signal is issued thereafter. If all are qualified, they are transferred to the qualified product temporary storage area 16 without an alarm. The advantages are that it can freely select the detection and collection location according to the structure of the oil tank and realize automatic continuous detection. Through deep learning and machine vision technology, the accuracy of detection is greatly improved, and the scalability of the system is improved, so that the system can detect more than one type of oil tank without making major changes. The system can save the entire detection process and realize the traceability of the detection link.

[0036] The system of the present invention can automatically capture images and conduct visual inspection of the welding quality of welding machine accessories on the oil tank, and can configure different detection algorithms according to the different detection requirements of the oil tank. It can freely adjust the angle and position of the collaborative robot, set different robot movement routes, and achieve clear target image acquisition. The image acquisition position covers the complete surface of the oil tank, and the system can comprehensively detect the quality of each part of the oil tank; contour matching and deep learning target detection are applied to weld detection to complete weld quality detection; product barcode information is recognized by the camera, and the data of each detection part and the photos taken are saved in the local computer environment in the form of folders.

[0037] During the test process, for the original manual inspection method, the test time was 6 months, the total number of inspected oil tanks exceeded 20,000, a total of 2 different signals, and about 200 defective products were detected. After on-site manual review, the defective product detection rate was 100%. The system can surround the inspection of all targets on the oil tank structure, and can trace back the inspection results of the defective position after the inspection. In addition, the two types of oil tanks are produced alternately, and their inspection is achieved by quickly replacing the prototype hardware and adjusting the system settings, saving a lot of manual workload.

[0038] The system can highlight the features of each target in a targeted manner, improve the accuracy of detection, and increase the scalability of the system and improve the detection capability. Before pre-configuration, the general algorithm can detect 10 detection items of the original A model, with an average accuracy of about 80% and a detection rate of 92%; after pre-configuration, the system is upgraded to 19 items for A model and 20 items for B model, with an average accuracy of more than 95% and a detection rate of 100%.

[0039] In the technical solution provided by the present invention, the system uses a structural frame as a supporting body, and the system includes an input device, which includes a plurality of photoelectric switches, an input roller, a fuel tank template and a template lifting mechanism; a detection device, which includes a collaborative robot, a first acquisition camera to a fourth acquisition camera, an illumination light source, a camera structure, an industrial computer, a PLC, a wireless bridge, a first display and a second display; an output device, which includes a transfer lifting mechanism, a transfer conveyor belt, an entry-limiting grating, an alarm, a qualified product temporary storage area and a non-qualified product temporary storage area; the two temporary storage areas are located On both sides of the input direction, the output direction is perpendicular to the input direction; the oil tank profiling and transfer lifting mechanism are powered by a pneumatic circuit and controlled by a PLC; a structural support device, the structural support device includes a structural frame, a supporting platform at the bottom of the frame and a locked movable foot; a pneumatic circuit, the pneumatic circuit includes a pneumatic valve group, a first pneumatic slide rail group, and a second pneumatic slide rail group. The system solves the problems of being unable to freely select the detection and collection position and being unable to achieve automatic continuous detection, improves the accuracy and scalability of the detection, and overcomes the difficulty of being unable to trace the cause of the problem in the detection tank.

[0040] Those skilled in the art can clearly understand that, for the convenience and brevity of description, the specific working processes of the systems, devices and units described above can refer to the corresponding processes in the aforementioned method embodiments and will not be repeated here.

[0041] The above description is only a preferred embodiment of the present invention and is not intended to limit the present invention. Any modifications, equivalent substitutions, improvements, etc. made within the spirit and principles of the present invention should be included in the scope of protection of the present invention.

Claims

1. A visual intelligent system for detecting the welding quality of automobile fuel tanks, characterized in that: The system is supported by a structural frame 18 and includes: An input device, the input device comprising a plurality of photoelectric switches, an input roller (1), a fuel tank template (2) and a template lifting mechanism (3); a detection device, the detection device comprising a collaborative robot (4), a first acquisition camera (5) to a fourth acquisition camera (8), an illumination light source, a camera structure, an industrial computer (9), a PLC (10), a wireless network bridge, a first display (11) and a second display (12); an output device, the output device comprising a transfer lifting mechanism (13), a transfer conveyor belt (14), an entry limiting grating (15), an alarm, a qualified product A temporary storage area (16) and a temporary storage area for defective products (17); the two temporary storage areas are located on both sides of the input direction, and the output direction is perpendicular to the input direction; the oil tank backing mold (2) and the transfer and lifting mechanism (13) are powered by a pneumatic circuit and controlled by a PLC (10); a structural support device, the structural support device includes a structural frame (18), a support platform (19) at the bottom of the frame, and a locking movable foot (20); a pneumatic circuit, the pneumatic circuit includes a pneumatic valve group (21), a first pneumatic slide rail group (22), and a second pneumatic slide rail group (23).

2. The system according to claim 1, characterized in that The photoelectric switch comprises a trigger photoelectric switch (111), a deceleration photoelectric switch and an in-position photoelectric switch (113); the trigger photoelectric switch (111) is used to detect whether the oil tank is about to be input into the detection system, and the detection system starts the input roller (1) after receiving the trigger signal, and the input roller (1) is accelerated at this time; the deceleration photoelectric switch (112) is used to send a deceleration signal to the detection system when the oil tank is about to be transported to the detection position, so as to decelerate the running speed of the input roller (1); the detection system obtains the in-position signal sent by the in-position photoelectric switch (113), and when it is determined that the oil tank is in position, the input roller (1) is immediately stopped, so that the oil tank stops at the detection position; the trigger photoelectric switch (111) is fixed to two support rods on one side of the oil tank entry device by bolts, and its height is flush with the oil tank entry height, and is a reflection type photoelectric switch; the deceleration photoelectric switch (112) and the in-position photoelectric switch (113) are reflection type photoelectric switches, fixed to the bottom of the input roller (1) by bolts, and arranged in sequence according to the direction in which the oil tank enters the detection system. The input roller (1) is installed on the structural frame (18) by bolts, and the height is 1 / 3 of the distance from the bottom surface; the fuel tank backing mold is used to support the fuel tank to ensure that the fuel tank is in a fixed state during the inspection process. The supporting structure profile of the fuel tank backing mold (2) is designed according to the fuel tank profile and is divided into two parts, front and rear, according to the fuel tank input direction; similarly, the backing mold lifting mechanism (3) is divided into two parts, front and rear, according to the fuel tank input direction. The two fuel tank backing molds are respectively fixed on the backing mold lifting mechanism (3) and are connected by The pin is positioned and fixed by bolts; the mold jacking mechanism (3) is fixed to the first pneumatic slide rail group (22) by bolts and is located below the input roller (1); the mold jacking mechanism (3) is used to lift the mold, and the mold jacking mechanism (3) lifts the oil tank mold (2) so that the oil tank no longer contacts the input roller (1), and relies on gravity to make the oil tank fall into the mold; when the mold jacking mechanism (3) falls, the highest point of the oil tank mold (2) is lower than the highest point of the input roller (1) to avoid affecting the movement of the oil tank.

3. The system according to claim 1, characterized in that The collaborative robot (4) is fixed to the top center of the structural frame (18) by bolts, and the robot controller (24) is placed on the bottom platform of the structural frame (18); the collaborative robot (4) is installed upside down and is used to operate the collaborative robot (4) to move according to the set movement route and point position. After receiving the movement instruction, the robot controller (24) operates the collaborative robot (4) to move, and the collaborative robot (4) drives the light source and the first acquisition camera (5) to the acquisition position, and when all position detections are completed, the collaborative robot (4) moves to the initial position; the detection position is set according to the structure and size of the oil tank, and the illumination light source is used to provide lighting for the acquisition; the first acquisition camera (5) to the fourth acquisition camera (8) are used to realize the image acquisition of the target position of the oil tank detection; the second acquisition camera (6) to the fourth acquisition camera (8) fixed at the fixed position of the structural frame (18) and the first acquisition camera (5) fixed to the end of the collaborative robot (4) through the camera structure are all fixed by bolts; the industrial computer (9) is fixed to the support platform ( 19), near the side of the oil tank input position; after receiving the image captured by the camera, the industrial computer (9) completes image detection, recognition, and measurement, summarizes the overall quality of the oil tank, and determines the output direction of the oil tank; the PLC (10) is fixed to the support platform (19) at the bottom of the frame by bolts, and is located on the opposite side of the oil tank input position; the wireless bridge includes a transmitting end and a receiving end, the transmitting end is placed on the industrial computer (9), and has four antennas; the receiving end is fixed to the end of the collaborative robot (4) by bolts, and has two antennas, and the wireless bridge plays a role in wirelessly transmitting the robot camera image to the industrial computer (9); the first display (11) and the second display (12) are both touch screen displays, the first display (11) is fixed by bolts and mounted on the anti-touch net (25) above the installation position of the PLC (10) and near the qualified product temporary storage area (16), and the second display (12) is fixed by bolts and mounted on the anti-touch net (25) above the side of the unqualified product temporary storage area (17), away from the oil tank input side.

4. The system according to claim 1, characterized in that The transfer conveyor belt (14) and the transfer lifting mechanism (13) are divided into two parts, front and rear, according to the direction of oil tank input. The transfer conveyor belt (14) is used to output the oil tanks that have been inspected to two types of temporary storage areas. The transfer conveying direction is perpendicular to the input roller (1). The transfer lifting mechanism (13) is connected to the transfer conveyor belt (14) through bolts at the top and to the second pneumatic slide rail group (23) at the bottom. The two parts of the transfer lifting mechanism (13) can be simultaneously driven to be lifted up or driven to fall down by the second pneumatic slide rail group (23), and drive the transfer conveyor belt (14) to move in the vertical direction. The entry limiting grating (15) is installed on the structural frame on one side of the qualified product temporary storage area (16) through bolts, and is of a reverse-radiation type. The alarm is used The receiving system detection result signal and abnormal signal activates the sound and light alarm; the qualified product temporary storage area (16) is a telescopic conveyor roller structure, with railings on both sides and the rear end to prevent the oil tank from falling. When the oil tank is to be moved into the qualified product temporary storage area (16), it will be started together with the transfer conveyor belt (14), and the length is adjusted according to the expected temporary storage quantity. A maximum of 4 mailboxes can be temporarily stored; the qualified product temporary storage area (16) communicates with the system structure frame (18) through cables and draws power; the unqualified product temporary storage area (17) is a bucket-shaped structure, which is fixed to the system structure frame (18) by bolts; the space temporarily stores one oil tank. If it has been temporarily stored, the subsequent unqualified products will no longer be transferred, and they must be emptied before they can be temporarily stored again.

5. The system according to claim 1, characterized in that The structural frame (18) is a rectangular parallelepiped structure. The upper and lower 1 / 3 of the other three sides, except for the side of the qualified product temporary storage area (16), are closed by anti-touch nets (25). The middle 1 / 3 is left vacant and used as a space for oil tank entry and exit. There is no anti-touch net (25) on the side of the qualified product temporary storage area (16), and personnel entry is restricted by the input roller (1). The support platform (19) at the bottom of the frame is used to support the industrial computer (9), the robot controller (24) and the PLC (10).

6. The system according to claim 1, characterized in that The pneumatic valve group (21) is fixed by bolts to the structural frame (18) at about 1 / 3 below the side opposite to the oil tank input position. The first pneumatic slide rail group (22) includes two pneumatic slide rails, denoted as A and B, which are respectively connected to the mold support lifting mechanism (3) by bolts and fixed to the center of the bottom support platform (19) of the frame by bolts; the second pneumatic slide rail group (23) includes two pneumatic slide rails, denoted as C and D, which are respectively connected to the transfer lifting mechanism (13) by bolts and fixed to the center of the bottom support platform (19) of the frame by bolts; the second pneumatic slide rail group (23) is located inside the first pneumatic slide rail group (22) and is arranged as ACDB in the order of passing the oil tank input. The four pneumatic slide rails are arranged in a straight line.

7. The system according to claim 1, characterized in that The PLC (10) is used to control the alarm, the transfer conveyor belt (14), the input roller (1), the output roller, the gas valve of the oil tank master (2), and the collaborative robot (4); the PLC (10) is connected to the collaborative robot (4) through protocol communication, and is connected to the system master control device through TCP communication, so as to read the robot status signal in real time and forward it to the system master control device; The PLC (10) controls the descent of the mold lifting mechanism (3), the start and stop of the input roller (1), and the movement of the collaborative robot (4) by receiving data sent by the system master control device. The PLC (10) reads the status of its controlled hardware equipment and the signals triggered by multiple photoelectric switches, and sends them to the system to achieve real-time monitoring of the status by the system master control device. The PLC (10) is connected to the MES control system at the production site via a network cable. The MES control system receives the read signal sent by the PLC (10), reads the current oil tank test result, and completes the upload of the test result.

8. The system according to claim 1, characterized in that The system also includes: a robot control device and a detection and identification device; The robot control device runs in the robot controller (24) and is used to receive the control signal sent by the PLC (10) and control the movement mode, movement speed and movement route of the collaborative robot (4); The detection and identification device has an independent operable interface, which includes a collection and detection module and a first communication module; The acquisition and detection module adopts machine vision and deep learning technology, including image noise reduction, image enhancement, gamma correction, image rotation, template matching, image segmentation, serial communication, and TCP communication functions; the acquisition and detection module receives images from the first acquisition camera (5) to the fourth acquisition camera (8), and based on the robot position signal obtained by the first communication module, enables corresponding preprocessing algorithms and detection and recognition algorithms for different targets to detect the similarity, size, position, and height of weldments; the detection and recognition device is connected to the second communication module of the system master control device through the first communication module, receives its signal and performs corresponding operations; after the target detection of a single oil tank is completed, the detection and recognition device automatically summarizes all results, stores them locally, and sends the results to the system master control device.

9. The system according to claim 7 or 8, characterized in that: The system master control device includes a second communication module and a human-computer interaction module; The second communication module realizes communication interconnection with the PLC (10) and the detection and identification device based on TCP, and realizes transparent transmission of the TCP result to the PLC (10); The second communication module sends the position of the collaborative robot (4) to the detection and identification device, triggers the detection and identification device to perform a corresponding position detection operation, receives the next target position, and forwards it to the PLC (10); receives the oil tank detection result, enters the result into a database, and then forwards it to the PLC (10); the second communication module sends a target position signal to the PLC (10), receives a robot current position signal, and forwards it to the first communication module of the detection and identification device; the second communication module sends a hardware device control signal and receives a system operation status signal; The human-machine interaction module has a switchable display interface, which includes a signal interface, an operation interface, an alarm interface, a history record interface and a statistical interface; the display interface is used to display all system states, including photoelectric switch signals, transfer and backing position, motor start and stop, robot position, detection status, detection tank model, detection task batch, date, and detection results; the operation interface includes operation buttons, automatic or manual state switching of the equipment, roller, backing or transfer control cases, communication test cases, and robot reset cases; the alarm interface is used to display the alarm records of the equipment; the history record interface is used to query the result database, display the detection records of the equipment, and can be queried according to date and result type; The statistics interface is used to query the database to count the number of qualified and unqualified tests within a limited time, and to draw a bar chart based on units such as month / week / day.

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