Control method and device for neat sleeving detection of multi-size workbins

Abstract

The invention relates to the field of industrial material neat sleeving detection, and provides a control method and device for automatically achieving neat sleeving performance detection of multi-size workbins. According to the device, an X-axis servo sliding rail is matched with a servo sliding table to transfer a material box, a detection position is composed of a two-dimensional gantry servo truss and a visual detection system, symmetrically-distributed strip-shaped light sources are fixed to the two ends of a gantry truss stand column, and an area-array camera is carried at the Z-axis tail end of the truss; by controlling the horizontal axis Y and the vertical axis Z of the gantry truss and combining the X axis of the servo sliding table, complete image acquisition of the workbins with various sizes is realized; detecting the image to obtain a conclusion whether the materials in the material box are neat or not; when the detection result is correct, the servo sliding table conveys the material box to a discharging position; and when the detection result is abnormal, the servo sliding table sends the material box back to the feeding position and prompts an operator to carry out reinspection. According to the invention, a three-axis servo motion control system is combined with a visual detection algorithm, so that neat detection of materials in a multi-size material box is realized, and the system is an important component of digital assembly.

Description

Technical Field

[0001] The invention relates to the field of industrial material complete set detection, in particular to a control method and device for automatic complete set detection of multi-size material boxes, which is used for complete set detection before installation in a digital assembly workshop. Background Art

[0002] The digital assembly unit of large precision components of aero engines contains rectangular boxes of various sizes and specifications. The inside of the boxes uses customized linings, and the materials are placed in order according to the shape of the linings, such as Figure 1 As shown. The material boxes are classified into more than 20 types according to the material content. When all the material boxes are complete, the digital assembly of the large precision component can be implemented.

[0003] At present, the inspection method of material boxes is manual inspection, which verifies the materials of more than 20 kinds of material boxes by hand and eye, and cannot guarantee the authenticity and accuracy of the complete set inspection. For the complete set inspection of multiple batches of material boxes, it is easy to have serious problems such as mixing materials from different batches, mixing incomplete components, and losing small materials. Summary of the invention

[0004] Aiming at the problem of material integrity detection in multi-size bins, the present invention provides a control method and device for integrity detection of multi-size bins using a three-axis servo motion control system combined with a visual detection algorithm. A long-distance servo slide is used to realize the transportation and transfer of bins, and a gantry servo truss and a visual acquisition system are used to automatically realize integrity detection of multi-size bins.

[0005] The technical solution adopted by the present invention to achieve the above-mentioned purpose is:

[0006] A control device for detecting the complete set of material boxes of multiple sizes comprises: a slide rail is provided on the X-axis of a measuring coordinate system, a servo slide is provided on the slide rail, a material unloading rolling table is provided at one end of the slide rail, a pneumatic push rod that can slide freely along the Y-axis direction is provided on the servo slide, a material box sensor is provided at one end of the pneumatic push rod, and a cache sensor is provided on the top of the material unloading slide; it also comprises a two-dimensional gantry truss of Y and Z axes, the gantry truss is arranged above the slide rail, symmetrically distributed strip light sources are fixed at both ends of the gantry truss columns, and an area array camera is carried at the end of the Z axis of the truss.

[0007] The utility model also comprises a PLC control system for controlling the movement of each actuator and the on and off of the strip light source.

[0008] It also includes industrial computers and displays.

[0009] The industrial computer is connected to the area array camera via a gigabit network port and is used for image acquisition, complete set detection, result output and image storage of the material box;

[0010] The display is used to display the detection results.

[0011] A method for detecting the complete set of material boxes of multiple sizes comprises the following steps:

[0012] 1) Place the material box containing the material on the servo slide and detect it through the material box sensor;

[0013] 2) When the material box sensor detects the existence of the material box, the servo slide moves the material box to the X-axis detection position, and the gantry truss moves the Y-axis and Z-axis to the photo taking position of the material box;

[0014] 3) When the three servo axes move into position, the two strip light sources are automatically turned on, the light sources evenly illuminate the material box, and the camera is used to take photos and samples;

[0015] 4) Check the collected pictures to determine whether the material box is complete, turn off the strip light source, move the Y and Z axes of the gantry truss to the original position, and wait for the next complete detection;

[0016] 5) If the materials in the material box are fully loaded, the servo slide moves the material box to the roller table, and the pneumatic push rod automatically pushes the material box to the unloading roller table and retracts it to its original position. After the push rod retracts to its original position, the servo slide automatically returns to its initial position and waits for the subsequent full loading detection; if the materials in the material box are not fully loaded, the servo slide directly returns to its initial position automatically.

[0017] While the complete set detection is in progress, the buffer sensor always detects whether the material box on the unloading roller table is full. When the buffer material box accumulates to the position of the sensor, the ongoing complete set detection is stopped and the operator is prompted to remove the qualified material box. After taking it away, the sensor is no longer blocked and the system continues to run.

[0018] In the step 1), after the material box sensor detects, the material box label needs to be scanned to obtain the material box type, and the material box is moved to the detection position of the X-axis that matches the size of its type according to the type of the material box.

[0019] In the step 5), when it is determined that the materials in the material box are not complete, the operator is prompted to re-inspect the incomplete material box, and after the re-inspection is completed, the completeness test is performed again.

[0020] The present invention has the following beneficial effects and advantages:

[0021] 1. An independent QR code label is affixed to the outside of the material box to uniquely identify the material batch and material box type.

[0022] 2. Use automated methods to conduct complete testing, ensuring the testing process and consistency.

[0023] 3. The image acquisition of all material boxes is completed while using camera detection, making product assembly traceable. BRIEF DESCRIPTION OF THE DRAWINGS

[0024] Figure 1 This is a schematic diagram of the material box (including lining);

[0025] Figure 2 It is a complete set of detection and control system layout diagram;

[0026] Figure 3 It is a diagram of the implementation steps of an example of the present invention. DETAILED DESCRIPTION

[0027] The present invention is further described in detail below in conjunction with the accompanying drawings and embodiments.

[0028] The system of the present invention comprises the following components:

[0029] 1) X-axis servo slide

[0030] 2) Servo slide pneumatic push rod

[0031] 3) Material box sensor

[0032] 4) Y and Z axis two-dimensional gantry truss

[0033] 5) Area Array Camera

[0034] 6) Strip light source

[0035] 7) Unloading roller table

[0036] 8) Cache Sensor

[0037] 9)PLC control system (including button box)

[0038] 10) Industrial computers and displays

[0039] like Figure 2 As shown, the system is divided into three areas: loading position, detection position, and unloading position. The servo slide of the loading position realizes the transfer of the material box through the X-axis, and the slide is equipped with a material box in-place sensor and a pneumatic push rod; the detection position is composed of a two-dimensional gantry servo truss and a visual inspection system. The two ends of the gantry truss column are fixed with symmetrically distributed strip light sources, and the end of the truss Z-axis is equipped with an array camera; the unloading position is composed of an unloading roller table to realize the unloading cache of multiple material boxes. One end of the roller table is equipped with a cache sensor to detect whether the material box of the unloading roller table is full. The specific operation process of the complete set detection is described as follows:

[0040] like Figure 3 As shown, first, place the material box containing the material at the upper left corner of the servo slide, and press it horizontally against the material box sensor. The sensor indicator light turns green and the presence of the material box is detected. Use a handheld barcode scanner to scan the material box label, and the display shows the material box type. Click the Start Job button to execute the complete set detection process for the material box.

[0041] In the second step, the servo slide moves the material box to the X-axis detection position corresponding to the material box type. At the same time, the gantry truss moves the Y-axis and Z-axis to the photo taking position of the material box. After waiting for the three servo axes to move into place, the two strip light sources are automatically turned on. The light sources evenly illuminate the material box for camera photo sampling.

[0042] In the third step, after the image is collected, a visual inspection of the corresponding material box type is performed to draw a conclusion on whether the set is complete. At this time, the strip light source is turned off, and the Y and Z axes of the gantry truss are moved to their original positions, waiting for the next complete set inspection.

[0043] Step 4: If the materials in the material box are fully loaded, the servo slide moves the material box to the unloading position. When it reaches the unloading position, the pneumatic push rod automatically pushes the material box to the unloading roller table and retracts it to its original position. After the push rod retracts to its original position, the servo slide automatically returns to the loading position and waits for the subsequent re-loading and full load detection; if the materials in the material box are not fully loaded, the servo slide automatically returns to the loading position and prompts the operator to re-check the material box. After the re-check is completed, you can click the start operation button to re-check the full load.

[0044] During the complete set detection, the buffer sensor always detects whether the material box on the unloading roller table is full. If the buffer material box accumulates to the position of the sensor, the system will automatically stop the ongoing complete set detection and prompt the operator to remove the qualified material box. After removal, the sensor is no longer blocked and the system continues to operate.

[0045] The complete set detection control system of the present invention can realize automatic detection of various types of multi-sized material boxes, and then realize the complete set detection of materials in all material boxes of the component, which is an important component for realizing digital assembly of large components.

Claims

1. A control device for detecting the complete set of material boxes of multiple sizes, characterized in that: include: A slide rail is provided on the X-axis of the measurement coordinate system, a servo slide is provided on the slide rail, a material unloading roller table is provided at one end of the slide rail, a pneumatic push rod which can slide freely along the Y-axis direction is provided on the servo slide, a material box sensor is provided at one end of the pneumatic push rod, and a cache sensor is provided on the top of the material unloading slide; it also includes a Y and Z axis two-dimensional gantry truss, the gantry truss is arranged above the slide rail, symmetrically distributed strip light sources are fixed at both ends of the gantry truss columns, and an area array camera is carried at the end of the Z axis of the truss.

2. A control device for detecting the complete set of multi-size boxes according to claim 1, characterized in that: The utility model also comprises a PLC control system for controlling the movement of each actuator and the on and off of the strip light source.

3. A control device for detecting the complete set of multi-size boxes according to claim 1, characterized in that: It also includes industrial computers and displays. The industrial computer is connected to the area array camera via a gigabit network port and is used for image acquisition, complete set detection, result output and image storage of the material box; The display is used to display the detection results.

4. A method for detecting the complete set of multi-size boxes according to claim 1, characterized in that: The following steps are involved: 1) Place the material box containing the material on the servo slide and detect it through the material box sensor; 2) When the material box sensor detects the existence of the material box, the servo slide moves the material box to the X-axis detection position, and the gantry truss moves the Y-axis and Z-axis to the photo taking position of the material box; 3) When the three servo axes move into position, the two strip light sources are automatically turned on, the light sources evenly illuminate the material box, and the camera is used to take photos and samples; 4) Check the collected pictures to determine whether the material box is complete, turn off the strip light source, move the Y and Z axes of the gantry truss to the original position, and wait for the next complete detection; 5) If the materials in the material box are fully loaded, the servo slide moves the material box to the roller table, and the pneumatic push rod automatically pushes the material box to the unloading roller table and retracts it to its original position. After the push rod retracts to its original position, the servo slide automatically returns to its initial position and waits for the subsequent full loading detection; if the materials in the material box are not fully loaded, the servo slide directly returns to its initial position automatically.

5. A method for detecting the complete set of multi-size boxes according to claim 4, characterized in that: While the complete set detection is in progress, the buffer sensor always detects whether the material box on the unloading roller table is full. When the buffer material box accumulates to the position of the sensor, the ongoing complete set detection is stopped and the operator is prompted to remove the qualified material box. After taking it away, the sensor is no longer blocked and the system continues to run.

6. A method for detecting the complete set of multi-size boxes according to claim 4, characterized in that: In the step 1), after the material box sensor detects, the material box label needs to be scanned to obtain the material box type, and the material box is moved to the detection position of the X-axis that matches the size of its type according to the type of the material box.

7. A method for detecting the complete set of multi-size boxes according to claim 4, characterized in that: In the step 5), when it is determined that the materials in the material box are not complete, the operator is prompted to re-inspect the incomplete material box, and after the re-inspection is completed, the completeness test is performed again.

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