Electrode cap detection equipment based on machine vision technology

Abstract

The invention relates to the field of detection equipment, and particularly discloses machine vision technology-based electrode cap detection equipment, which comprises at least one vision sensor, a first detection port, a second detection port and a light source, the first detection port and the second detection port are independently arranged, the first detection port allows an electrode cap to be closed and opened at the first detection port, and the second detection port allows an electrode cap to be opened and closed at the second detection port. The two second detection ports are formed in the two ends of the detection cavity respectively, one second detection port detects the end face of one electrode cap, the light source emits light rays to the electrode caps, and the receiving end of the visual sensor receives the light rays reflected by the electrode caps. The size and the centering state of the electrode cap are detected in the first detection port, and the end surface defect of the electrode cap is detected in the second detection port, so that the comprehensive detection of the electrode cap is realized, the size, the centering state and the surface defect condition of the electrode cap are accurately obtained, the detection item of the electrode cap is perfected, and the detection accuracy and comprehensiveness are improved.

Description

Technical Field

[0001] The present invention relates to the field of detection equipment, in particular to optical detection equipment. Background Art

[0002] During the welding process, the jaws of the welding equipment will perform an opening / closing action. Therefore, in the current industry, the length between the electrode caps is generally measured indirectly through the motion control mechanism of the welding equipment, and the length between the electrode caps is used as the basis for evaluating whether the electrode caps need to be replaced. Generally speaking, when the equipment replaces a new electrode cap, the static pole arm remains stationary, and the moving pole arm moves forward to close the jaws of the welding clamp. At this time, the actual position of the moving pole arm can be calculated by the control system; after the electrode cap is cut and ground, the moving pole arm closes the jaws again, and the new moving pole arm position is calculated. After subtracting these two positions, the total wear of the two electrode caps can be obtained, and whether to replace the electrode caps can be determined based on the total wear. However, there are many factors that affect the welding quality and whether the electrode caps need to be replaced, such as the length, centering, and end face defects of each electrode cap. This measurement scheme cannot fully reflect the actual status of the electrode caps, and there are obvious shortcomings in the following aspects:

[0003] ① The length of the electrode caps of the moving pole arm and the static pole arm cannot be measured separately: the existing detection scheme can only measure the total wear of the two electrode caps, but cannot detect the length of each of the two electrode caps separately. In actual welding operations, the two electrode caps are likely to have different wear amounts. Judging the life of the electrode caps by the total wear amount may result in false detection.

[0004] ② The alignment of the electrode cap cannot be detected: Ideally, the axes of the two electrode caps should coincide, but in reality, there is always a certain deviation between the axes of the electrode caps. If the deviation is too large, it will affect the welding quality. The existing solution cannot detect this situation.

[0005] ③ Unable to detect defects on the end face of the electrode cap: After multiple welding, the flatness and cleanliness of the end face of the electrode cap will change, thus affecting the welding quality. If necessary, a new electrode cap needs to be replaced. The existing detection scheme cannot detect these defects.

[0006] The technical problem to be solved by the present application is: how to design a measurement method that can comprehensively measure the actual state of the electrode cap. Summary of the invention

[0007] In order to overcome the deficiencies of the prior art, an object of the present invention is to provide an electrode cap detection device based on machine vision technology.

[0008] The technical solution adopted by the present invention is: an automatic electrode cap detection device based on machine vision technology, including at least one visual sensor, a first detection port, a second detection port and a light source, the first detection port and the second detection port are independently set, the first detection port allows the electrode cap to be closed and opened at the first detection port, the two second detection ports are respectively set at the two ends of the detection chamber, one second detection port performs end face detection on an end face of an electrode cap, the light source emits light to the electrode cap, and the receiving end of the visual sensor receives the light reflected from the electrode cap.

[0009] In some embodiments, the light source includes a backlight source and a side light source, the backlight source illuminates the side surface of the electrode cap, and the side light source illuminates the end surface of the electrode cap.

[0010] In some embodiments, a spectroscope is included, and two spectroscopes are both tiltedly arranged in the detection chamber, one spectroscope corresponds to an end face of an electrode cap, the spectroscope is arranged on the path of light reflected by the electrode cap, the receiving end of the visual sensor receives the light reflected from the spectroscope, and the side light source is arranged between the two spectroscopes.

[0011] In some embodiments, a reflector is included, and two reflectors are both tiltedly arranged in the detection chamber, one reflector corresponds to an end face of an electrode cap, a side light source is arranged between the reflector and the electrode cap, the reflector is arranged on the path of light reflected by the electrode cap, and the receiving end of the visual sensor receives the light reflected from the reflector.

[0012] In some embodiments, the backlight source and the visual sensor are respectively disposed on opposite upper and lower sides of the first detection port.

[0013] In some embodiments, a plane mirror is included, a receiving end of the visual sensor faces an end away from the first detection port or the second detection port, and the plane mirror is disposed in front of the receiving end of the visual sensor.

[0014] In some embodiments, the visual sensor is disposed directly below a position between the first detection zone and the second detection zone.

[0015] In some embodiments, the backlight source is disposed above or below the electrode cap.

[0016] The beneficial effects of the present invention are:

[0017] The electrode cap detection equipment based on machine vision technology detects the size and centering status of the electrode cap at the first detection port and detects the end face defects of the electrode cap at the second detection port, thereby realizing comprehensive detection of the electrode cap and accurately obtaining the size, centering status and surface defects of the electrode cap, thereby improving the detection items of the electrode cap and enhancing the detection accuracy and comprehensiveness. BRIEF DESCRIPTION OF THE DRAWINGS

[0018] Figure 1 It is a schematic diagram of the overall structure of Example 1;

[0019] Figure 2 This is a schematic structural diagram of the first detection port of Example 1;

[0020] Figure 3 It is a structural schematic diagram of the second detection port of Example 1;

[0021] Figure 4 A schematic diagram of the structure in which the first detection port and the second detection port are arranged vertically;

[0022] Figure 5 A schematic diagram of a structure in which a first detection port and a second detection port are arranged opposite to each other;

[0023] Figure 6 It is a structural schematic diagram of Example 2;

[0024] Figure 7 It is a structural schematic diagram of Example 3;

[0025] Figure 8 It is a structural schematic diagram of Example 4;

[0026] Fig. 9 It is a structural schematic diagram of Example 5;

[0027] Fig.10 It is a structural schematic diagram of Example 6;

[0028] Fig.11 It is a structural schematic diagram of Example 7;

[0029] Fig.12 is a schematic structural diagram of Example 8;

[0030] The numbers and names in the figure correspond to each other as follows: 1. Shell; 2. First visual sensor; 3. Second visual sensor; 4. Backlight source; 5. Side light source; 6. Beam splitter; 10. First plane mirror; 11. Second plane mirror; 12. Reflective plane mirror; 16. Common visual sensor; 17. Common plane mirror. DETAILED DESCRIPTION

[0031] The following will be combined with the drawings in the embodiments of the present invention to clearly and completely describe the technical solutions in the embodiments of the present invention. Obviously, 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.

[0032] The present invention provides multiple technical solutions:

[0033] Example 1

[0034] See also Figure 1-Figure 3 , an electrode cap detection device based on machine vision technology, comprising a first visual sensor 2, a second visual sensor 3, a first detection port, a second detection port, a backlight source 4, a side light source 5 and a spectroscope 6. The first visual sensor 2 takes pictures of two electrode caps in a closed state and an open state to obtain two side views of the electrode caps; when the two electrode caps are in an open state, the second visual sensor 3 takes pictures of the end faces of the two electrode caps to obtain two end face views of the electrode caps.

[0035] The first detection port is an open slot, which is directly connected to the external space. The two electrode caps are closed and opened at the first detection port. The backlight source 4 and the first visual sensor 2 are respectively arranged on the upper and lower sides of the first detection port. The first visual sensor 2 takes a picture of the side of the electrode cap in the first detection port to collect an image. The backlight source 4 illuminates the electrode cap in the first visual sensor 2, so that the first visual sensor 2 can obtain a clear shadow image of the electrode cap. The shadow image is then transmitted to the learning model for analysis and processing, so that the size and neutrality of the electrode cap can be calculated.

[0036] The two second detection ports are respectively arranged at the two ends of the detection chamber, the detection chamber is a columnar body, and the two electrode caps perform end face detection at the second detection ports. Two spectroscopes 6 are arranged in the detection chamber, one spectroscope 6 corresponds to one detection end face, the direction in which the spectroscope 6 is arranged and the direction in which the electrode cap extends form an angle of 40-50 degrees, a side light source 5 is arranged between the two spectroscopes 6, the direction in which the side light source 5 is arranged and the direction in which the electrode cap extends form an angle of 80-100 degrees, the side light source 5 provides light to the two spectroscopes 6, and the second visual sensor 3 is arranged directly below the side light source 5. When working, the light emitted by the side light source 5 passes through the spectroscope 6 and shines on the end face of the electrode cap, and the light reflected by the end face of the electrode cap shines back on the surface of the spectroscope 6 and enters the second visual sensor 3 after being reflected by the spectroscope 6. The second visual sensor 3 takes pictures of the end faces of the two electrode caps through the spectroscope 6 to obtain the end face images, and then transmits the end face images to the learning model for analysis and processing, and calculates the surface defect states of the two electrode caps respectively.

[0037] See 4 and Figure 5 The first detection port and the second detection port can be arranged side by side, up and down, or symmetrically according to the requirements. The first visual sensor 2 and the second visual sensor 3 can be arranged according to the specific positions of the first detection port and the second detection port.

[0038] In order to match the size of the electrode cap, the height of the first detection port in this embodiment is within the range of 20mm-100mm, the depth is 20mm-100mm, and the center of the second detection chamber is located within the middle 1 / 3 of the first detection port.

[0039] Example 2

[0040] Another embodiment of an electrode cap detection device based on machine vision technology is different from the embodiment 1 in that: Figure 6 , the side light source 5 is arranged between the spectroscope 6 and the electrode cap, and the angle between the side light source 5 and the spectroscope 6 is 40-50 degrees. The side light source 5 emits light to the end faces of the electrode caps on both sides, and the light reflected from the end faces of the electrode caps enters the receiving end of the second visual sensor 3 through the reflection of the spectroscope 6. The spectroscope 6 can be replaced with a reflector, which can reduce the brightness loss of the light source and reduce the influence of the top reflected light on the imaging, thereby achieving a better imaging effect than the spectroscope 6. This embodiment has a better lighting effect around the end faces of the electrode caps, and it is easier to detect defects far away from the center of the end faces.

[0041] Example 3

[0042] Another embodiment of an electrode cap detection device based on machine vision technology is different from the embodiment 1 in that: Figure 7 The side light source 5 is arranged between the reflector and the second visual sensor 3, and the angle between the side light source 5 and the spectroscope 6 is 40-50 degrees. The light emitted by the side light source 5 is emitted to the electrode cap at the detection end face, and the light reflected from the end face of the electrode cap enters the receiving end of the second visual sensor 3 through the reflection of the spectroscope 6. The spectroscope 6 can be replaced by a reflector, which can reduce the brightness loss of the light source and avoid the influence of top reflection.

[0043] Example 4

[0044] Another embodiment of an electrode cap detection device based on machine vision technology is different from the embodiment 1 in that: Figure 8 In order to reduce the height of the machine, the first visual sensor 2 and the second visual sensor 3 collect images of the electrode caps in the first detection port and the second detection port through a plane mirror. The plane mirror is arranged in front of the receiving end of the first visual sensor 2 and the second visual sensor 3. The first visual sensor 2 corresponds to the first plane mirror 10, and the second visual sensor 3 corresponds to the second plane mirror 11. The first detection port and the second detection port are arranged behind the first visual sensor 2 and the second visual sensor 3.

[0045] Example 5

[0046] Another embodiment of an electrode cap detection device based on machine vision technology is different from the embodiment 1 in that: Fig. 9, the beam splitter 6 is removed, two second visual sensors 3 are provided, and the receiving ends of the two second visual sensors 3 are respectively facing the corresponding electrode cap end faces, and this embodiment does not require a complex optical path. The two visual sensors can be arranged in parallel and in opposite directions or in the same straight line.

[0047] Example 6

[0048] Another embodiment of an electrode cap detection device based on machine vision technology is different from embodiment 5 in that: Fig.10 , a reflecting plane mirror 12 is added, the receiving end of the second visual sensor 3 is toward another second visual sensor 3, that is, the receiving end of the second visual sensor 3 is toward the electrode cap farther away from it, and a reflecting plane mirror 12 is arranged between the second visual sensor 3 and the electrode cap. The light reflected from the end face of the electrode cap passes through the plane mirror farther away from the electrode cap and then reflects to the receiving end of the second visual sensor 3.

[0049] Example 7

[0050] Another embodiment of an electrode cap detection device based on machine vision technology is different from the embodiment 1 in that: Fig.11 , cancel the first visual sensor 2 and the second visual sensor 3, set a common visual sensor 16, the common visual sensor 16 is set directly below the position between the first detection port and the second detection port, the receiving end of the common visual sensor 16 is toward the position between the first detection port and the second detection port, the number of visual sensors is reduced, and the cost is reduced.

[0051] Example 8

[0052] Another embodiment of an electrode cap detection device based on machine vision technology is different from embodiment 7 in that: Fig.12 The public visual sensor 16 faces away from the first detection port and the second detection port, a plane mirror is arranged in front of the public visual sensor 16, and the receiving end of the public visual sensor 16 faces the plane mirror. The light reflected by the electrode cap enters the receiving end of the public visual sensor 16 through the plane mirror.

[0053] Finally, it should be noted that the above description is only a preferred example of the present invention and is not intended to limit the present invention. Although the present invention has been described in detail with reference to the aforementioned embodiments, those skilled in the art can still modify the technical solutions described in the aforementioned embodiments or replace some of the technical features therein by equivalents. Any modification, equivalent replacement, improvement, etc. made within the spirit and principle of the present invention shall be included in the protection scope of the present invention.

Claims

1. An automatic electrode cap detection device based on machine vision technology, characterized in that: The invention comprises at least one visual sensor, a first detection port, a second detection port and a light source. The first detection port and the second detection port are independently arranged. The first detection port allows the electrode cap to be closed and opened at the first detection port. The two second detection ports are respectively arranged at the two ends of the detection chamber. One of the second detection ports performs end face detection on an end face of the electrode cap. The light source emits light to the electrode cap, and the receiving end of the visual sensor receives light reflected from the electrode cap.

2. The electrode cap detection device based on machine vision technology according to claim 1 is characterized in that: The light source comprises a backlight source (4) and a side light source (5); the backlight source (4) illuminates the side surface of the electrode cap, and the side light source (5) illuminates the end surface of the electrode cap.

3. The electrode cap detection device based on machine vision technology according to claim 2 is characterized in that: It comprises a spectroscope (6), two spectroscopes (6) are both arranged obliquely in a detection chamber, one spectroscope (6) corresponds to an end face of an electrode cap, the spectroscope (6) is arranged on the path of light reflected by the electrode cap, the receiving end of the visual sensor receives the light reflected from the spectroscope (6), and the side light source (5) is arranged between the two spectroscopes (6).

4. The electrode cap detection device based on machine vision technology according to claim 2 is characterized in that: It comprises a reflector, two of which are arranged obliquely in the detection chamber, one of which corresponds to an end face of an electrode cap, the side light source (5) is arranged between the reflector and the electrode cap, the reflector is arranged on the path of light reflected by the electrode cap, and the receiving end of the visual sensor receives the light reflected from the reflector.

5. The electrode cap detection device based on machine vision technology according to claim 1, characterized in that: The backlight source (4) and the visual sensor are respectively arranged on the upper and lower sides opposite to each other of the first detection port.

6. The electrode cap detection device based on machine vision technology according to claim 1, characterized in that: A plane mirror is included. The receiving end of the visual sensor faces an end away from the first detection port or the second detection port. The plane mirror is arranged in front of the receiving end of the visual sensor.

7. The electrode cap detection device based on machine vision technology according to claim 1, characterized in that: The visual sensor is disposed directly below a position between the first detection zone and the second detection zone.

8. The electrode cap detection device based on machine vision technology according to claim 2, characterized in that: The backlight source (4) is arranged just above or just below the electrode cap.

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