Refill quality detection system
The refill quality detection system addresses low accuracy in existing methods by using X-ray imaging and linear array cameras to automate the inspection of both transparent and opaque pen refills, enhancing detection efficiency and accuracy.
Patent Information
- Application Number
- CN202311120203.X
- Authority / Receiving Office
- CN · China
- Patent Type
- Applications(China)
- Current Assignee / Owner
- Filing Date
- 2023-09-01
- Publication Date
- 2025-01-03
AI Technical Summary
Existing pen refill quality inspection methods, particularly for non-transparent oil tubing refills, suffer from low detection accuracy and efficiency due to visual inspection methods, leading to unqualified products and user experience issues, and existing machine vision systems are limited in their applicability to both transparent and opaque refills.
A refill quality detection system incorporating a refill transport module, filler detection module with X-ray imaging, and pen tip detection module, utilizing X-ray sources and array detectors for transparent and opaque refills, along with linear array cameras for pen tip inspection, to accurately measure ink and tail plug oil volumes and pen tip quality.
The system enhances detection accuracy and efficiency, enabling simultaneous inspection of transparent and opaque refills, reducing labor costs and improving the quality of pen refill production by automating the detection process.
Smart Images
Figure CN119237329A_ABST
Abstract
Description
Technical Field
[0001] The present application relates to the field of pen refill quality detection, and in particular to a pen refill quality detection system. Background Art
[0002] At present, the mainstream pen factories in China produce more than 40 billion refills annually. Although the refill filling technology is very advanced, there are always about 0.2% of the refills whose ink and tail plug oil filling volume does not meet the requirements. These unqualified products will directly affect the service life of the refills or cause the risk of ink leakage.
[0003] The method currently used in the industry mainly relies on skilled technical workers. For transparent oil tubing refills, the refills are placed in a mold marked with a fixed scale, and visual inspection is used to detect indicators such as the oil in the tail plug of the refill and the amount of ink injected, and unqualified refills are selected. For non-transparent oil tubing refills, the refills are placed under strong light, and visual inspection is used to detect the oil in the tail plug of the refill and the amount of ink injected from the tail of the refill, and unqualified refills are selected. It can be understood that the manual visual inspection method is less efficient in detecting the quality of refills, and it is very easy to cause visual fatigue to the inspectors, resulting in a decrease in the accuracy of judgment. Especially for the inspection of non-transparent oil tubing refills, the visual inspection method from the tail of the refill has a low detection accuracy, and can only screen out half-tube or even empty refills, and cannot be accurately calculated, resulting in the outflow of unqualified products, affecting the user experience.
[0004] In recent years, with the advancement of artificial intelligence technology, intelligent detection technology based on machine vision has achieved remarkable development in all walks of life. Specifically for the quality inspection of refills in the stationery industry, by using suitable industrial array cameras, lenses, light sources, industrial computers, etc. to build an image acquisition system on the production line, and with certain algorithms, the detection of the amount of ink and tail plug oil injected into the refills can be achieved. However, this visual inspection method can only be used to detect refills with transparent oil tubing. For refills with non-transparent oil tubing, it is not possible to intuitively use industrial cameras to take pictures for visual inspection. The method of simulating manual inspection is to shoot from the tail end of the refill. Due to the high speed of the production line and the up and down shaking of the chain, the imaging is extremely unstable, resulting in a high misjudgment rate. How to realize a quality inspection system that is compatible with transparent and opaque oil tubing refills has become a key factor restricting the actual implementation of the refill quality inspection project. Summary of the invention
[0005] In view of this, the present invention provides a refill quality detection system, the purpose of which is to be compatible with transparent and non-transparent refill detection and improve the efficiency and accuracy of refill quality detection.
[0006] In order to solve the above technical problems, this application adopts the following technical solutions:
[0007] A refill quality detection system comprises a refill transport module, a filler detection module, a nib detection module and a screening module, wherein the refill transport module comprises a code generator, the refill transport module is used to carry the refills to be detected through the filler detection module and the nib detection module, and generate code values corresponding to the sequence of the refills to be detected through the code generator; the filler detection module is used to record the code values, and detect the filler of the corresponding refill to be detected according to the code values and generate corresponding filler detection information; the nib detection module is used to record the code values, and detect the nib of the corresponding refill to be detected according to the code values and generate corresponding nib detection information; the screening module is used to screen qualified refills and / or screen out unqualified refills according to the filler detection information and the nib detection information.
[0008] Furthermore, the filler detection module includes a filler image acquisition module and a filler image analysis module, wherein the filler image acquisition module is used to record the coding value and acquire the refill filler image of the refill to be detected corresponding to the coding value; the filler image analysis module is used to generate corresponding filler detection information of the refill to be detected based on the refill filler image of the refill to be detected.
[0009] Furthermore, the filling image acquisition module includes an X-ray source component and an X-ray array detector, the X-ray source component is used to irradiate the filling of the pen core to be inspected; the X-ray array detector is used to determine the amount of X-rays irradiated by the X-ray source component on the filling of the pen core to be inspected, and according to the amount of X-rays of the filling of the pen core to be inspected, collect the image of the filling of the pen core to be inspected corresponding to the coding value.
[0010] Furthermore, the filling image analysis module includes a segmentation detection unit and a detection judgment unit, wherein the segmentation detection unit is used to segment the refill filling image to determine the ink segmentation map of the refill to be detected and the tail plug oil segmentation map of the refill to be detected; the detection judgment unit determines the ink length of the refill to be detected and the tail plug oil length of the refill to be detected according to the ink segmentation map and the tail plug oil segmentation map, and judges whether the refill filling of the refill to be detected is qualified based on the comparison of the ink length and the tail plug oil length of the refill to be detected with a preset parameter threshold.
[0011] Furthermore, the filling image analysis module also includes an image processing module, which is used to mark the pen refills to be detected in the pen refill image according to preset marking rules, and the marking is used to determine the arrangement order of the pen refills to be detected.
[0012] Furthermore, the detection and judgment unit calculates the length of the minimum circumscribed rectangle of the ink in the Y direction as the ink length according to the ink segmentation map, and calculates the length of the maximum inscribed rectangle of the tail plug oil in the Y direction as the tail plug oil length according to the tail plug oil segmentation map.
[0013] Furthermore, the pen tip detection module includes a pen tip image acquisition module and a pen tip image analysis module, wherein the pen tip image acquisition module is used to record the coding value and acquire the pen tip image of the pen refill to be detected corresponding to the coding value; the pen tip image analysis module is used to generate corresponding pen tip detection information of the pen refill to be detected based on the pen tip image of the pen refill to be detected.
[0014] Furthermore, the pen tip image acquisition module includes a linear array camera and a linear scanning strip light source. The linear array camera is arranged above the pen core transmission module, and is used to acquire the pen tip image of the pen core to be detected; the linear scanning strip light source is arranged above the pen core transmission module, and is used to provide light illumination for the linear array camera to acquire the pen tip image of the pen core to be detected.
[0015] Furthermore, the pen tip image analysis module includes a pen tip detection unit, which is used to determine the pen tip data of the pen refill to be detected based on the pen tip image, and judge whether the pen tip of the pen refill to be detected is qualified based on the comparison of the pen tip data and a preset pen tip parameter threshold, wherein the pen tip data includes the pen tip length and the degree of ink contamination of the pen tip.
[0016] Furthermore, the screening module includes a processor and a sorter. The processor is used to determine the information of the pen refill to be detected based on the filling detection information of the filling detection module and the pen tip detection information of the pen tip detection module; the sorter is used to receive the information of the pen refill to be detected sent by the processor, and screen qualified pen refills and / or screen out unqualified pen refills based on the information of the pen refill to be detected.
[0017] It can be seen from the above technical solution that the advantages and positive effects of the refill quality detection system proposed in this application are:
[0018] The pen refill to be inspected is carried by the pen refill conveying module and moved to the filling detection module and the pen tip detection module. The filling detection module and the pen tip detection module respectively detect different positions of the pen refill, which can effectively improve the accuracy of detecting the pen refill to be inspected, and can be applicable to transparent, translucent and opaque pen refills at the same time, with wide versatility. The screening module further screens qualified pen refills and / or screens out unqualified pen refills according to the filling detection information obtained by the filling detection module and the pen tip detection information obtained by the pen tip detection module, thereby realizing automatic detection of pen refills. Compared with the existing technology, it saves labor costs and improves the detection efficiency and accuracy of pen refills. BRIEF DESCRIPTION OF THE DRAWINGS
[0019] The above content and the following specific embodiments of the present invention will be better understood when read in conjunction with the accompanying drawings. It should be noted that the accompanying drawings are only examples of the technical solutions claimed for protection.
[0020] Figure 1 It is a structural block diagram of a refill quality detection system provided by an embodiment of the present application;
[0021] Figure 2 is a structural block diagram of a filling material detection module provided in an embodiment of the present application;
[0022] Figure 3 This is an X-ray pen core imaging effect diagram provided by an embodiment of the present application;
[0023] Figure 4 is a marking diagram of a refill image provided by an embodiment of the present application;
[0024] Figure 5 This is a measurement diagram of the refill ink and tail plug oil size provided in an embodiment of the present application;
[0025] Figure 6 is a structural block diagram of a pen tip detection module provided in an embodiment of the present application;
[0026] Figure 7 It is a schematic diagram of a refill quality inspection device provided in one embodiment of the present application.
[0027] The reference numerals are described as follows:
[0028] Pen refill quality detection system 100;
[0029] Pen core transmission module 10;
[0030] Filling material detection module 20;
[0031] Filling material image acquisition module 210;
[0032] Filler image analysis module 220;
[0033] Image processing unit 2201;
[0034] Segmentation detection unit 2202;
[0035] Detection and judgment unit 2203;
[0036] Pen tip detection module 30;
[0037] Pen tip image acquisition module 310;
[0038] Pen tip image analysis module 320;
[0039] Image processing unit 3201;
[0040] Pen tip detection unit 3202;
[0041] Screening module 40;
[0042] Pen refill quality testing equipment 200;
[0043] Conveying device 1;
[0044] Pen refill 2 to be tested;
[0045] Industrial computer 5;
[0046] Display 6;
[0047] Linear array camera 31;
[0048] Linear array lens 32;
[0049] Line scanning light source 33;
[0050] X-ray source assembly 41;
[0051] X-ray array detector 42;
[0052] Proximity switch 71;
[0053] Protective lead room 72;
[0054] Air-cooled refrigeration device 73. DETAILED DESCRIPTION
[0055] The detailed features and advantages of the present invention are described in detail in the specific implementation modes below, and the contents are sufficient to enable any person skilled in the art to understand the technical contents of the present invention and implement them accordingly. Moreover, according to the description, claims and drawings disclosed in this specification, those skilled in the art can easily understand the relevant objects and advantages of the present invention.
[0056] It should be noted that in this specification, similar reference numerals and letters denote similar items in the following drawings, and therefore, once an item is defined in one drawing, it does not need to be further defined and explained in the subsequent drawings.
[0057] In the description of this embodiment, it should be noted that the terms "upper", "lower", "inner", "bottom", etc. indicate orientations or positional relationships based on the orientations or positional relationships shown in the accompanying drawings, or are the orientations or positional relationships in which the product is usually placed when in use. They are only for the convenience of describing the present invention and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, be constructed and operated in a specific orientation, and therefore cannot be understood as a limitation on the present invention.
[0058] In order to make the objectives, technical solutions and advantages of the present invention more clear, the embodiments of the present invention will be further described in detail below with reference to the accompanying drawings.
[0059] Please refer to Figure 1 As shown, Figure 1: is a structural block diagram of a refill quality detection system 100. The refill quality detection system 100 includes a refill transport module 10, a filler detection module 20, a pen tip detection module 30 and a screening module 40. Among them, the refill transport module 10 includes a code generator, and the refill transport module 10 is used to carry the refills to be detected through the filler detection module 20 and the pen tip detection module 30, and generate code values corresponding to the order of the refills to be detected through the code generator. The filler detection module 20 is used to record the code value, and detect the filler of the corresponding refill to be detected according to the code value and generate corresponding filler detection information. The pen tip detection module 30 is used to record the code value, and detect the pen tip of the corresponding refill to be detected according to the code value and generate corresponding pen tip detection information. The screening module 40 is used to screen qualified refills and / or filter out unqualified refills according to the filler detection information and the pen tip detection information.
[0060] An encoder is a device that compiles and converts signals or data into a signal form that can be used for communication, transmission and storage. In an exemplary embodiment, an encoder can be used to generate a code value corresponding to the order of the pen core to be detected, so that the code value can be used as a basis for subsequent identification of the pen core to be detected. Using the code value of the pen core to be detected as the only basis for identifying the pen core to be detected avoids missed detection and misscreening under high-speed detection.
[0061] It can be understood that the pen refill to be inspected is carried by the pen refill conveying module 10 and moved to the filling detection module 20 and the pen tip detection module 30. The filling detection module 20 and the pen tip detection module 30 respectively detect different positions of the pen refill, which can effectively improve the accuracy of detecting the pen refill to be inspected, and can be applicable to transparent, translucent and opaque pen refills at the same time, and has wide versatility. The screening module 40 further screens qualified pen refills and / or screens out unqualified pen refills according to the filling detection information obtained by the filling detection module 20 and the pen tip detection information obtained by the pen tip detection module 30, thereby realizing automatic detection of pen refills. Compared with the existing technology, it saves labor costs, improves the detection efficiency of pen refills, and the detection results are more objective.
[0062] It should be noted that the pen refill to be inspected may be first inspected by the filling material inspection module 20 and then by the pen tip inspection module 30 when being carried by the pen refill transport module 10, or may be first inspected by the pen tip inspection module 30 and then by the filling material inspection module 20. In addition, according to actual needs, the inspection may be performed by the filling material inspection module 20 or the pen tip inspection module 30 alone, and the present application does not limit the inspection order of the pen refill to be inspected.
[0063] In one embodiment, the refill conveying module 10 may be a conveying chain, which carries the refill to be inspected through the filling material inspection module 20 and the pen tip inspection module 30 .
[0064] Please refer to Figure 2 The filling material detection module 20 may include a filling material image acquisition module 210 and a filling material image analysis module 220. The filling material image acquisition module 210 is used to record the code value and acquire the filling material image of the pen core to be detected corresponding to the code value, and the filling material image analysis module 220 is used to generate the corresponding filling material detection information of the pen core to be detected according to the filling material image of the pen core to be detected.
[0065] In one embodiment, the filling image acquisition module 210 may include an X-ray source component 41 and an X-ray array detector 42. The X-ray source component 41 is used to irradiate the filling of the pen core to be detected, and the X-ray array detector 42 is used to determine the amount of X-rays irradiated by the X-ray source component 41 on the filling of the pen core to be detected, and according to the amount of X-rays of the filling of the pen core to be detected, the image of the filling of the pen core to be detected corresponding to the coding value is acquired.
[0066] The basic principle of X-rays being able to image products is mainly based on two points: 1. X-rays have penetrating, absorbable, fluorescent and photosensitive effects. 2. The inherent density or thickness differences of the product's organizational structure.
[0067] like Figure 3 As shown, since the ink inside the pen core has a higher density than the tail plug oil, when the X-ray passes through the pen core, the ink absorbs more X-rays than the silicone oil used as the tail plug oil. Therefore, the amount of X-rays reaching the X-ray array detector 42 (i.e., the X-ray receiving device) is different. After receiving different amounts of X-rays, the fluorescent screen on the X-ray array detector 42 uses the photosensitive effect to form a black and white contrast image.
[0068] It can be understood that by utilizing the imaging principle that when X-rays penetrate liquids of different densities, the attenuation degree varies accordingly, the X-ray source assembly 41 and the X-ray array detector 42 can be used in combination with transparent and opaque oil tubing refills to determine the image of the refill filling of the refill to be tested, and has a wide range of applications.
[0069] The filling image analysis module 220 may include a segmentation detection unit 2202 and a detection judgment unit 2203. The segmentation detection unit 2202 is used to segment the refill image and determine the ink segmentation map of the refill to be detected and the tail plug oil segmentation map of the refill to be detected. The detection judgment unit 2203 determines the ink length of the refill to be detected and the tail plug oil length of the refill to be detected according to the ink segmentation map and the tail plug oil segmentation map, and determines whether the refill filling of the refill to be detected is qualified by comparing the ink length and the tail plug oil length of the refill to be detected with the preset parameter threshold.
[0070] In one embodiment, the filling image analysis module 220 may further include an image processing unit 2201. The image processing module 2201 may be used to mark the refills to be detected in the refill image according to a preset marking rule, and the marking is used to determine the arrangement order of the refills to be detected.
[0071] Considering that in actual production, due to problems such as material jamming or lack of material in the equipment, the number of refills passing through the refill quality detection system 100 in one production cycle may not match the preset number, it is necessary to confirm the arrangement order of the refills passing through the refill quality detection system 100 so that the result signal sent to the PLC (Programmable Logic Controller) corresponds to the actual refill situation. The refill transmission module 10 has mechanical actions of acceleration and deceleration and stopping within one production cycle, which easily leads to stretching problems at both ends of the captured image, and the position of the refill in the image is not fixed due to mechanical motion errors.
[0072] Please refer to Figure 3 and Figure 4 , the refill conveying module 10 may be a conveying chain, and a single chain section in the conveying chain may carry two refills. The preset marking rule may be based on the existence of a link gap between every two chains in the conveying chain, and the image processing module 2201 marks the link gap in the refill filling image. A rectangular bright spot mark is marked between the chains below every two refills in the image, and the arrangement order of the refills is determined by using the mark of the rectangular bright spot.
[0073] Furthermore, when annotating the image of the refill, the mark of the rectangular bright spot can be used as a reference point to annotate the ink, tail plug oil pixel points and refill positioning points of each refill in the image.
[0074] In one embodiment, the image processing unit 2201 may also be used to pre-process the image of the refill.
[0075] Since X-ray imaging is affected by voltage, the higher the voltage, the brighter the image, and the lower the voltage, the darker the image. In the actual production process, the voltage has a jump problem, resulting in unstable imaging. Therefore, the image processing unit 2201 can pre-process the image of the refill by calibrating the brightness and contrast from an algorithmic perspective, so that the features of the refill image are more obvious and convenient for subsequent processing.
[0076] The segmentation detection unit 2202 can pass the pre-processed refill image into the pre-trained instance segmentation model to realize the identification and positioning of the ink and tail plug oil of each refill. By analyzing the collected refill image, the refill detection task can be defined as an instance segmentation task, and LabelMe is used for image annotation. Then, the instance segmentation model Solov2 is used to perform instance segmentation on the processed refill image through transfer learning, and the ink and tail plug oil pixel points corresponding to each refill in the refill image are obtained, and the ink segmentation map of the refill to be detected and the tail plug oil segmentation map of the refill to be detected are determined.
[0077] It should be noted that the specific process of passing an image into an instance segmentation model for segmentation is well known to those skilled in the art and will not be described in detail here.
[0078] The detection and judgment unit 2203 can calculate the length of the minimum circumscribed rectangle of the ink in the Y direction as the ink length according to the ink segmentation map, and calculate the length of the maximum inscribed rectangle of the tail plug oil in the Y direction as the tail plug oil length according to the tail plug oil segmentation map.
[0079] In one embodiment, please refer to Figure 5 The detection and judgment unit 2203 can calculate the length of the minimum circumscribed rectangle of the ink image in the Y direction as the actual ink length, calculate the length of the maximum inscribed rectangle of the tail plug oil in the Y direction as the actual tail plug oil length, and then compare the measured dimensions of the ink and tail plug oil of the pen with the pre-stored standard dimensions of the ink and tail plug oil. Those that exceed the upper and lower limits of the threshold are defective products.
[0080] Please refer to Figure 6 The pen tip detection module 30 includes a pen tip image acquisition module 310 and a pen tip image analysis module 320. The pen tip image acquisition module 310 is used to record the code value and collect the pen tip image of the pen core to be detected corresponding to the code value, and the pen tip image analysis module 320 is used to generate the corresponding pen tip detection information of the pen core to be detected according to the pen tip image of the pen core to be detected.
[0081] The pen tip image acquisition module 310 includes a line array camera 31 and a line scanning light source 33. The line array camera 31 is arranged above the pen core conveying module 10, and is used to acquire the pen tip image of the pen core to be detected. The line scanning light source 33 is arranged above the pen core conveying module 10, and is used to provide light illumination when the line array camera 31 acquires the pen tip image of the pen core to be detected.
[0082] It can be understood that the image formed by the line array camera 31 is in the shape of a "line". Although it is also a two-dimensional image, it is extremely long, which can reach a length of several K pixels, while the width is only a few pixels. The object to be detected usually moves at a uniform speed, and the line array camera 31 is used to continuously scan it line by line to achieve the purpose of uniform detection of its entire surface.
[0083] In this embodiment, since the pen refills to be inspected run at a uniform speed along with the chain, and 20 pen refills are produced in one cycle (the production quantity in one cycle during normal production), the imaging effect of using the linear array camera 31 is better.
[0084] In one embodiment, the line array camera 31 includes a line array lens 32, which can be placed directly above the conveyor chain through a fixed bracket. The line scanning light source 33 is placed obliquely above the pen refill to be inspected at an angle of about 45° through a fixed bracket to provide stable lighting for the pen refill to be inspected. The line array camera 31 synchronously collects images of the pen tips of 20 pen refills to be inspected passing directly below the line array camera 31 during the movement of the chain.
[0085] It can be understood that the pen refill to be inspected is transported by the pen refill conveying module 10 and continuously scanned line by line by the line array camera 31, so as to achieve the purpose of uniformly inspecting the entire surface of the pen refill to be inspected. The line array camera 31 has high requirements for light brightness, and the pen refill to be inspected is illuminated by the line scanning light source 33, which facilitates the subsequent image processing of the pen tip.
[0086] The pen tip image analysis module 320 includes a pen tip detection unit 3202. The pen tip detection unit 3202 is used to determine the pen tip data of the pen refill to be detected based on the pen tip image, and to judge whether the pen tip of the pen refill to be detected is qualified based on the comparison of the pen tip data and the preset pen tip parameter threshold, wherein the pen tip data includes the pen tip length and the degree of ink contamination of the pen tip.
[0087] In one embodiment, the pen tip image analysis module 320 may further include an image processing unit 3201. The image processing unit 3201 may pre-process the pen tip image collected by the pen tip image collection system by adjusting brightness and contrast, and then cut and segment the processed pen tip image to extract the pen tip image of each pen refill. Exemplarily, the pen tip images may be extracted one by one by slicing the matrix.
[0088] In this embodiment, since the pen tip image is acquired by using a line array camera 31, and the line array camera 31 has high requirements for light brightness and the overall imaging is dark, the brightness and contrast of the pen tip image can be adjusted from an algorithmic perspective to make the features of the pen tip image more obvious, which is convenient for subsequent model prediction.
[0089] In one embodiment, the pen tip detection unit 3202 can use a deep learning image classification model to determine the ink contamination of the pen tip of the pen refill to be detected. The pen tip detection unit 3202 analyzes the collected pen tip images, defines the pen tip contamination detection task as an image multi-classification task, and divides the pen tip images into good, dirty, no pen tip and other types, and then uses the image classification model MobileNetV3 to perform multi-classification detection on the processed pen tip images through transfer learning.
[0090] In another embodiment, pen tip detection can also use a binary image method, setting the pen tip background image pixels to white (1), the ink contaminated area to black (0), and then calculating the number of black (0) pixels, and comparing the black (0) pixels with the upper and lower limits of the standard threshold to determine whether there is pen tip contamination.
[0091] In addition, by passing the pen tip image into a trained deep learning target detection model, the pen tip contamination area in the image can be marked to determine whether there is pen tip contamination.
[0092] The screening module 40 includes a processor and a sorter. The processor is used to determine the information of the pen refill to be detected based on the filling detection information of the filling detection module 20 and the pen tip detection information of the pen tip detection module 30. The sorter is used to receive the information of the pen refill to be detected sent by the processor, and screen qualified pen refills and / or filter out unqualified pen refills based on the information of the pen refill to be detected.
[0093] In one embodiment, the filling material detection module 20 further includes a result statistics unit and a result transmission unit. The result statistics unit is used to perform result statistics according to the detection result of the detection judgment unit 2203, and store the result in a database. The result transmission unit is used to send the detection result of the result statistics unit to the PLC, and the PLC sends a control signal to the processor according to the detection result, and the processor sends a control signal to the sorter, and the sorter screens qualified refills and / or screens out unqualified refills.
[0094] In one embodiment, the pen tip detection module 30 further includes a result statistics unit and a result transmission unit. The specific implementation process can refer to the description of the result statistics unit and the result transmission unit in the filling material detection module 20, which will not be repeated here.
[0095] The detection results of the filling detection module 20 may include the total production, the number of good products, the number of inks that are too long, the number of inks that are too short, the number of tail plug oils that are too long, and the number of tail plug oils that are too short. They can be stored locally in the form of Excel to facilitate the subsequent production site to view real-time data, trace back defective problems, and improve production quality.
[0096] The detection results of the pen tip detection module 30 may include the total number of production, the total number of good products, the total number of defective products, and the number of defective items of each component (pen tip contamination, no pen tip), which can be stored locally in the form of Excel to facilitate the subsequent production site to view real-time data, trace defective problems, and improve production quality.
[0097] In one embodiment, the result transmission unit packages the code value of the refill to be tested and the refill detection result (in binary form, good products are 1, bad products are 0) and sends them to the PLC. The result transmission method can be serial communication, network socket communication or other communication methods, which are not limited in this example.
[0098] In one embodiment, the sorter may include a solenoid valve sorting device. When the pen refill to be tested passes through the solenoid valve sorting device, the PLC makes a judgment based on the received signal. If any of the output results of the pen tip contamination detection station and the pen refill ink tail plug oil injection amount detection station corresponding to the same coding value (the same pen refill) is a defective product, the pen refill to be tested can be judged as an unqualified product. At this time, the solenoid valve sorting device is notified to sort it into a defective product collection box.
[0099] It should be noted that the image classification detection model involved in the pen tip detection module 30 and the filling detection module 20 needs to be determined after testing according to the specific detection task (such as the amount of data, the complexity of the tested pattern, the complexity of the defect type, etc.), and a model should not be selected as the baseline for all classification detection tasks for transfer learning. Similarly, the instance segmentation detection model can also use other target detection models as the basic model for transfer learning, such as the MaskR-CNN detection model, so this is not limited to this in the present exemplary embodiment.
[0100] In addition, since most of the testing equipment at the production site is offline, the result statistics unit in this example stores the test results locally in the form of Excel. With the automation, intelligence and progress of the workshop, the collected data can be stored in the cloud synchronously, and the unified management of multiple devices, multiple production lines and even multiple factories can be achieved, and an intelligent defect traceability system can be established to facilitate product problem tracing, make the production process more transparent, and facilitate production management.
[0101] The design of the refill quality detection system 100 based on machine vision can use Python as the development language, PaddlePaddle as the deep learning development framework, and combine the open source visual function library OpenCV and the GUI graphical user interface library PYQT5 to write a program to realize the functions required by the standardized detection system. The entire software interface can include an image display area, a basic menu area, a detection result display area, a software button operation area, and other parts. The detection system can not only realize the real-time display function of image acquisition and the function of automatically determining whether the refill is qualified, but also realize the function of setting some basic parameters in the menu area.
[0102] Please refer to Figure 7 The present application also provides a refill quality inspection device. The refill quality inspection device includes a conveying device 1, a linear array camera 31, a linear array lens 32, a line scanning light source 33, an X-ray source assembly 41, an X-ray array detector 42, an industrial computer 5, a display screen 6, a proximity switch 71, a protective lead room 72 and an air-cooled refrigeration device 73. The linear array lens 32 is mounted on the linear array camera 31 to collect the image of the pen tip, and the X-ray source assembly 41 and the X-ray array detector 42 cooperate to collect the image of the filling.
[0103] The conveying device 1 can be a conveying chain, on which the pen refill 2 to be inspected is placed. When the pen refill 2 to be inspected passes through the inspection area, the linear array camera 31 and the linear array lens 32 are placed directly above the chain through a fixed bracket, and the line scanning light source 33 is placed obliquely above the pen refill to be inspected at an angle of about 45° through a fixed bracket to provide stable lighting for the pen refill to be inspected. The linear array camera 31 synchronously collects the image of the pen tip passing directly below the linear array camera 31 during the movement of the chain.
[0104] It is understandable that X-rays are a type of electromagnetic wave with high penetration and high energy, which has certain radiation hazards, and radiation safety considerations should be given top priority. The protective lead room 72 adopts a three-layer structure design of steel-lead-steel. The lead layer can block the diffusion of X-rays and play a role in isolating the equipment box from the external environment. In addition, the front and rear doors of the protective lead room are designed with safety locks by installing proximity switches 71. When the front and rear doors of the protective lead room are closed normally, the detection equipment can work, otherwise the X-ray component should automatically cut off the operation immediately and send out an alarm signal.
[0105] In addition, since the X-ray generation process is formed by the high-speed moving electron beam hitting the anode target of the X-ray tube, and 99% of the energy in this process will be dissipated in the form of heat, heat dissipation is a key factor affecting the service life of the equipment. In this exemplary implementation scheme, an air-cooled refrigeration device 73 is used. During operation, the refrigerant absorbs heat and vaporizes in the protective lead room. The compressor continuously extracts the generated gas from the evaporator and compresses it into high-temperature, high-pressure steam. The refrigerant vapor is sent to the condenser and then exchanges heat with the air. After releasing heat, it condenses into liquid, enters the evaporator after being depressurized by the throttling mechanism, vaporizes again, and absorbs the heat of the cooled object, and the cycle repeats over and over again. Compared with water-cooled refrigerators, air-cooled refrigerators directly use fans to force air flow to take away the heat of the refrigerant, without the need for other auxiliary equipment, and eliminates the need for cooling towers, cooling water pumps, and cooling pipe systems. It has certain advantages in installation, especially in scenarios where the cooling capacity is not required, and its convenient mobility has great advantages.
[0106] The industrial computer 5 is used to send control commands to various devices (such as the conveying device 1, the linear array camera 31, etc.) and receive feedback signals from various devices. The display screen 6 is used to display the test results and test result statistics, which is convenient for the staff to view, trace back the defects, and improve the production quality.
[0107] It should be noted that, although several modules or units of the device for action execution are mentioned in the above detailed description, this division is not mandatory. In fact, according to the embodiments of the present disclosure, the features and functions of two or more modules or units described above can be embodied in one module or unit. On the contrary, the features and functions of one module or unit described above can be further divided into multiple modules or units to be embodied.
[0108] In addition, although the steps of the method in the present disclosure are described in a specific order in the drawings, this does not require or imply that the steps must be performed in this specific order, or that all the steps shown must be performed to achieve the desired results. Additionally or alternatively, some steps may be omitted, multiple steps may be combined into one step, and / or one step may be decomposed into multiple steps, etc.
[0109] The terms and expressions used herein are for descriptive purposes only, and the present invention should not be limited to these terms and expressions. The use of these terms and expressions does not mean to exclude any equivalent features of the illustrations and descriptions (or parts thereof), and it should be recognized that various modifications that may exist should also be included in the scope of the claims. Other modifications, variations and substitutions may also exist. Accordingly, the claims should be deemed to cover all such equivalents.
[0110] Similarly, it should be pointed out that although the present invention has been described with reference to the current specific embodiments, ordinary technicians in this technical field should realize that the above embodiments are only used to illustrate the present invention, and various equivalent changes or substitutions may be made without departing from the spirit of the present invention. Therefore, as long as the changes and modifications to the above embodiments are within the scope of the essential spirit of the present invention, they will fall within the scope of the claims of the present invention.
Claims
1. A refill quality detection system, characterized in that: It includes a refill transmission module, a filling material detection module, a pen tip detection module and a screening module, wherein: The refill transport module comprises a code generator, the refill transport module is used to carry the refills to be detected through the filling material detection module and the pen tip detection module, and generate code values corresponding to the sequence of the refills to be detected through the code generator; The filling material detection module is used to record the coding value, detect the corresponding filling material of the pen core to be detected according to the coding value, and generate corresponding filling material detection information; The pen tip detection module is used to record the coding value, detect the corresponding pen tip of the pen core to be detected according to the coding value, and generate corresponding pen tip detection information; The screening module is used to screen qualified refills and / or remove unqualified refills according to the filling material detection information and the pen tip detection information.
2. The refill quality detection system according to claim 1, characterized in that: The filler detection module includes a filler image acquisition module and a filler image analysis module, wherein: The filling material image acquisition module is used to record the coding value and acquire the filling material image of the pen core to be tested corresponding to the coding value; The filling material image analysis module is used to generate corresponding filling material detection information of the pen core to be detected according to the pen core filling material image of the pen core to be detected.
3. The refill quality detection system according to claim 2, characterized in that: The filling material image acquisition module includes an X-ray source component and an X-ray array detector. The X-ray source assembly is used to irradiate the filling of the pen core to be tested; The X-ray array detector is used to determine the amount of X-rays irradiated by the X-ray source assembly on the filling of the pen core to be detected, and to collect the image of the filling of the pen core to be detected corresponding to the coding value according to the amount of X-rays of the filling of the pen core to be detected.
4. The refill quality detection system according to claim 2, characterized in that: The filler image analysis module includes a segmentation detection unit and a detection judgment unit, wherein: The segmentation detection unit is used to segment the refill filling image to determine the ink segmentation map of the refill to be detected and the tail plug oil segmentation map of the refill to be detected; The detection and judgment unit determines the ink length of the pen core to be detected and the tail plug oil length of the pen core to be detected according to the ink segmentation map and the tail plug oil segmentation map, and judges whether the pen core filler of the pen core to be detected is qualified according to the comparison between the ink length and the tail plug oil length of the pen core to be detected and the preset parameter threshold.
5. The refill quality detection system according to claim 4, characterized in that: The filling image analysis module also includes an image processing module, which is used to mark the pen refills to be detected in the pen refill filling image according to a preset marking rule, and the marking is used to determine the arrangement order of the pen refills to be detected.
6. The refill quality detection system according to claim 4, characterized in that: The detection and judgment unit calculates the length of the minimum circumscribed rectangle of the ink in the Y direction as the ink length according to the ink segmentation map, and calculates the length of the maximum inscribed rectangle of the tail plug oil in the Y direction as the tail plug oil length according to the tail plug oil segmentation map.
7. The refill quality detection system according to claim 1, characterized in that: The pen tip detection module includes a pen tip image acquisition module and a pen tip image analysis module, wherein: The pen tip image acquisition module is used to record the coding value and acquire the pen tip image of the pen core to be detected corresponding to the coding value; The pen tip image analysis module is used to generate corresponding pen tip detection information of the pen refill to be detected based on the pen tip image of the pen refill to be detected.
8. The refill quality detection system according to claim 7, characterized in that: The pen tip image acquisition module includes a linear array camera and a line scanning strip light source. The linear array camera is arranged above the refill conveying module and is used to collect the image of the pen tip of the refill to be inspected; The line-scanning strip light source is arranged above the refill conveying module, and is used to provide light illumination when the line array camera collects the image of the pen tip of the refill to be detected.
9. The refill quality detection system according to claim 1, characterized in that: The pen tip image analysis module includes a pen tip detection unit, The pen tip detection unit is used to determine the pen tip data of the pen refill to be detected based on the pen tip image, and judge whether the pen tip of the pen refill to be detected is qualified based on the comparison between the pen tip data and a preset pen tip parameter threshold, wherein the pen tip data includes the pen tip length and the degree of ink contamination of the pen tip.
10. The refill quality detection system according to claim 1, characterized in that: The screening module includes a processor and a sorter, The processor is used to determine the information of the pen core to be detected according to the filling material detection information of the filling material detection module and the pen tip detection information of the pen tip detection module; The sorter is used to receive the information of the pen refill to be detected sent by the processor, and screen qualified pen refills and / or filter out unqualified pen refills according to the information of the pen refill to be detected.