Cigarette packet appearance detection system and detection method

Abstract

The invention discloses a cigarette packet appearance detection system and method, and the system comprises a detection unit which comprises two cameras and a black box with a reflector, and the two cameras are respectively disposed above and below the two sides of a conveying belt unit; the trigger unit comprises a trigger grating, and the trigger grating is controlled to start and stop through a trigger grating controller and a trigger grating EMV box so as to trigger the camera to take a picture; the control and rejection unit comprises a machine storage program controller, an FPI-IPC and a rejection air cylinder, the FPI-IPC receives images of the camera and sends signals to the machine storage program controller, and the machine storage program controller controls the rejection air cylinder to act so as to reject unqualified cigarette packets. According to the invention, the limitation that only five-surface image information can be acquired in cigarette packet appearance detection is avoided, so that the overall quality of the cigarette packet is more reliable and stable, the occurrence of quality accidents is reduced, and the production efficiency is improved.

Description

Technical Field

[0001] The present invention relates to the field of automatic control technology, and in particular to a cigarette package appearance detection system and detection method. Background Art

[0002] The cigarette packaging process is the core link in the cigarette manufacturing process. It is the process of packaging cigarettes rolled by cigarette machines into cigarette packs and cigarette strips. Through tracking the production process, it is found that more than 85% of unqualified products come from the cigarette pack forming process. The main reasons are as follows: First, the cigarette pack forming process is complicated and has many uncertain factors, which are specifically manifested in the involvement of many auxiliary materials and unstable auxiliary materials, differences in incoming cigarette materials, and wear of equipment parts; second, in the folding process of the cigarette pack, there are many intersections of the cigarette pack, which can easily cause damage to the cigarette pack; finally, a large amount of latex is used in the production process, and the overflow or leakage of glue in the channel will affect the formation of the cigarette pack after drying. This requires us to add cigarette pack appearance inspection during the production process and remove unqualified cigarette packs in time to prevent them from flowing into subsequent production processes and causing quality accidents.

[0003] The existing technology is to arrange a small package appearance inspection device on the cigarette package conveyor belt channel, and use machine vision inspection technology to inspect the appearance quality of cigarette packages. The cigarette package appearance quality inspection system uses machine vision inspection technology, and the system is mainly composed of a CCD camera, a light-emitting diode lighting lamp, a 24V power supply, an image acquisition card, an industrial computer and machine vision software. The light-emitting diode lighting lamp provides sufficient light source for the system's image acquisition, the CCD camera is responsible for converting the optical signal into an electrical signal, and the image acquisition card converts the electrical signal converted by the CCD into an image data stream in a certain format, which is transmitted to the machine vision software in the industrial computer, and the acquired image data is analyzed and processed, and the defect information is sent to the PLC of the packaging machine. After the PLC receives the defect instruction from the industrial computer, it sends a control instruction to the rejection mechanism of the packaging machine, and the defective cigarette packages are rejected under the action of the rejection cylinder.

[0004] This set of machine vision inspection technology can only collect image information of the five sides of the cigarette pack, because the side position of the cigarette pack (QR code side) is completely in contact with and covered by the conveyor belt of the cigarette pack drying channel, which makes it impossible for the camera to collect image information on this side. In actual production, after tracking, it was found that the quality defects of cigarette packs occurred randomly on the six sides of the cigarette packs. The limitations of hardware conditions increase the probability of quality accidents, which in turn affects the material consumption cost of the unit and the effective operation rate of the production equipment, and will also increase the workload of the unit operators. Summary of the invention

[0005] The technical problem to be solved by the present invention is to provide a cigarette package appearance detection system and detection method, which solves the problem that cigarette package appearance detection cannot collect image information of the six surfaces of the cigarette package.

[0006] The technical problem to be solved by the present invention is achieved through the following technical solutions:

[0007] A cigarette package appearance detection system, comprising:

[0008] A detection unit, comprising two cameras and a black box with a reflector, wherein the two cameras are respectively installed above and below the two sides of the conveyor unit, and are used to capture the upper and lower images of the cigarette packs passing on the conveyor unit, and the cameras are provided with flashlights, and the black box with the reflector is used to cover the detection section between the two cameras without light leakage;

[0009] A trigger unit, which includes a trigger grating, wherein the trigger grating is started and stopped by a trigger grating controller and a trigger grating EMV box to trigger the camera to take pictures;

[0010] A control and rejection unit includes a machine stored program controller, an FPI-IPC and a rejection cylinder. The FPI-IPC receives the image from the camera and sends a signal to the machine stored program controller. The machine stored program controller controls the action of the rejection cylinder to reject unqualified cigarette packs.

[0011] Preferably, in the above technical solution, the camera is a line-by-line scanning camera with a 1 / 2-inch chip and a Gigabit Ethernet interface, the two cameras are camera A and camera B, and the camera housing A below the camera A and the camera housing B above the camera B are fixedly mounted on the lower side wall and the upper side wall of the conveyor belt unit by pins.

[0012] Preferably, the above technical solution further includes: an LED controller, wherein the LED controller is used to control the light source of the flash A of camera A and the flash B of camera B.

[0013] Preferably, in the above technical solution, the trigger grating includes a transmitter and a receiver, the receiver is arranged on the side of the belt pair of the conveyor belt unit in an oblique staggered manner, and the transmitter is located on the opposite side of the receiver, and the transmitter is used to emit a light beam to the receiver, and when the edge of the output cigarette pack causes the light beam to be interrupted, the trigger grating triggers the flash and the camera to take pictures.

[0014] Preferably, in the above technical solution, the control and rejection unit also includes: a touch screen and a data matrix scanner, the touch screen is connected to the FPI-IPC, the touch screen is used to provide a user interface so that the operator can set the detection parameters and monitor the detection process; the data matrix scanner is used to scan the data matrix on the cigarette pack passing through the conveyor belt unit, and transmit the scanning results to the FPI-IPC for processing.

[0015] Preferably, in the above technical solution, the control and rejection unit also includes: a rejection device triggers the grating, and when the FPI-IPC identifies that a passing cigarette pack is unqualified, the rejection device triggers the grating to send a signal to the machine storage program controller, and the machine storage program controller turns on the control valve of the rejection cylinder to start the rejection of unqualified cigarette packs.

[0016] Preferably, in the above technical solution, the control and rejection unit also includes: a detection grating, which is arranged at the output port position of the conveyor belt unit, and the detection grating is used to detect whether the cigarette packs identified as unqualified have been rejected. If not, the detection grating sends a signal to the machine storage program controller, and then the machine stops running.

[0017] Preferably, in the above technical solution, the black box with a reflector includes a reflector, and the reflector is used to help illuminate the cigarette pack passing by and prevent the influence of light superposition on the opposite camera.

[0018] A method for performing cigarette package appearance inspection using a cigarette package appearance inspection system comprises the following steps:

[0019] S1, cigarette packet detection trigger: when the cigarette packet passes through the conveyor belt unit (4) and reaches the position of the triggering grating, the transmitter of the triggering grating emits a light beam, and if the receiver detects that the light beam is interrupted, the photo taking program is triggered;

[0020] S2, triggering photography: when the receiver detects that the light beam is interrupted, it immediately sends a trigger signal to the system, and the LED controller controls the flash to light up, and at the same time triggers camera A and camera B to take photos to capture the image of the cigarette package;

[0021] S3, image data acquisition and analysis: The images captured by the camera are transmitted to the FPI-IPC, and the FPI-IPC analyzes the image data;

[0022] S4. Rejection of unqualified cigarette packages: If the FPI-IPC determines that the cigarette package is unqualified, it sends a rejection instruction to the machine stored program controller, and the machine stored program controller activates the rejection cylinder to perform the rejection action and remove the unqualified cigarette package from the production line.

[0023] Preferably, in the above technical solution, step S3 also includes: a data matrix scanner scans the data matrix on the cigarette pack to obtain information about the cigarette pack, and transmits the scanning result to the FPI-IPC for processing, and the FPI-IPC combines the image processing result and the data matrix information to make a comprehensive judgment on the quality of the cigarette pack; step S4 also includes: when the FPI-IPC recognizes that the passed cigarette pack is unqualified, the rejection device triggers the grating to send a signal to the machine storage program controller, and the machine storage program controller connects the control valve of the rejection cylinder to start the rejection of unqualified cigarette packs; step S4 also includes step S5: confirming whether the cigarette pack has been successfully rejected: if the cigarette pack is not rejected, the detection grating located at the output port will send a feedback signal to the machine storage program controller, and then the machine stops running.

[0024] The above technical solution of the present invention has the following beneficial effects:

[0025] The present invention avoids the limitation that cigarette package appearance detection can only collect five-surface image information through a cigarette package appearance detection system and detection method, making the overall quality of the cigarette package more reliable and stable, reducing the occurrence of quality accidents, saving production costs, and improving production efficiency. BRIEF DESCRIPTION OF THE DRAWINGS

[0026] The accompanying drawings, which are incorporated in and constitute a part of the specification, illustrate embodiments of the invention and, together with the description, serve to explain the principles of the invention.

[0027] Figure 1 This is a structural diagram of the cigarette package appearance inspection system of this application;

[0028] Figure 2 Schematic diagram of triggering the grating.

[0029] Figure 3 This is a structural diagram of the camera.

[0030] Figure 4 This is the internal structure diagram of camera B.

[0031] Among them: 1-LED controller, 2-trigger grating controller, 3-trigger grating EMV box, 4-conveyor unit, 5-camera A, 6-camera housing A, 7-touch screen, 8-data matrix scanner, 9-machine storage program controller, 10-FPI-IPC, 11-reject cylinder, 12-reject device trigger grating, 13-camera B, 14-camera housing B, 15-flash B, 16-trigger grating, 17-black box with reflector, 18-flash A. DETAILED DESCRIPTION

[0032] Various exemplary embodiments of the present invention will now be described in detail with reference to the accompanying drawings. It should be noted that the relative arrangement of components and steps, numerical expressions and numerical values ​​set forth in these embodiments do not limit the scope of the present invention unless otherwise specifically stated.

[0033] like Figure 1 As shown, a cigarette package appearance detection system includes: an LED controller 1, a trigger grating controller 2, a trigger grating EMV box 3 (EMV: electromagnetic compatibility), a conveyor belt unit 4, a camera A5, a camera housing A6, a touch screen 7, a data matrix scanner 8, a machine storage program controller 9, an FPI-IPC 10 (an industrial computer for cigarette package appearance detection with an operating interface), a rejection cylinder 11, a rejection device trigger grating 12, a camera B13, a camera housing B14, a flash B15, a trigger grating 16, a black box with a reflector 17, and a flash A18.

[0034] One end of the LED controller 1 is connected to the power supply device, and the other end is connected to the camera A5 and the camera B13 respectively. The LED controller 1 is used to control the flashlight B15 and the flashlight A18 of the two cameras. The flashlight is used as a light source to shoot images for the two cameras.

[0035] The trigger grating controller 2 and the trigger grating EMV box 3 are connected to the trigger grating 16. The trigger grating controller 2 is used to control the start and stop of the trigger grating 16 to ensure that the camera is triggered to take pictures at the right time. The trigger grating EMV box 3 ensures that the trigger grating 16 meets industrial standards in terms of electromagnetic compatibility to prevent electromagnetic interference from affecting the stability and accuracy of the system. When the cigarette package reaches the predetermined detection position, the trigger grating controller 2 will send a signal to trigger the camera to take pictures, thereby capturing the image of the cigarette package for subsequent appearance quality inspection. The trigger grating controller 2 and the trigger grating EMV box 3 jointly ensure that the cigarette package can be accurately and timely captured when passing through the detection system, providing a basis for subsequent image processing and quality inspection.

[0036] The conveyor belt unit 4 is used to convey cigarette packets, and ensures the transportation of cigarette packets through the coordinated action of a transmission device, a control device, etc.

[0037] The cameras are CCD cameras, including camera A5 and camera B13. The bottom of camera A5 is fixedly connected to camera housing A6, and the top of camera B13 is fixedly connected to camera housing B14. Camera housing A6 and camera housing B14 are both fixedly mounted on the lower side wall and upper side wall of the conveyor belt unit 4 and fixed with pins.

[0038] like Figure 2As shown, the trigger grating 16 is used to start the camera A5 and the camera B13 to take pictures. The trigger grating 16 includes a control device, an electromagnetic compatibility box, a transmitter 164 and a receiver 166. The receiver 166 is arranged behind the belt pair 163 in an oblique staggered manner, and the transmitter 164 is located on the opposite side, which is used to emit a red light beam to the receiver 166. When the edge of the output cigarette package 165 causes the light beam to be interrupted, the trigger grating 16 triggers the flashlight B15, the flashlight A18 and the camera A5 and the camera B13 to take pictures. The cable of the receiver 166 is located on the conveyor belt.

[0039] like Figure 3 and Figure 4 As shown, camera A5 and camera B13 are used to capture images of cigarette packets passing by. The two CCD cameras are progressive scan cameras with 1 / 2-inch chips and Gigabit Ethernet interfaces, and are fixed in the camera housing by pins and bolts. The object 55 of the CCD camera is located behind the lighting device (such as flash lamp A18 and flash lamp B15), and the glass plate 56 is used to protect the object 55 of the CCD camera.

[0040] The black box 17 with reflectors is used to cover the detection section between the cameras without light leakage. The black box 17 is a two-piece steel plate housing that covers the detection section between the housings of the upper and lower cameras and the belt pair, which can effectively prevent the influence of external light when shooting. The reflectors in the black box 17 are used to help illuminate the cigarette packs passing by and prevent the influence of light superposition on the opposite camera.

[0041] FPI-IPC10 is used for setting up the cigarette package inspection system. It has a network card and I / O circuit board installed inside. The software system operation interface for monitoring and controlling cigarette package inspection runs on the FPI-IPC. In addition, the FPI-IPC also communicates with the machine storage program controller 9 through a network connection. The FPI-IPC 10 is connected to an uninterruptible power supply (UPS) and the UPS works in conjunction with the battery module to ensure the necessary safe and stable operation of the FPI-IPC10.

[0042] The reject cylinder 11 is used to reject cigarette packs identified as unqualified by FPI-IPC10. When FPI-IPC10 identifies that the cigarette packs passing through are unqualified, the reject device triggers the grating 12 to send a signal to the machine's stored program controller 9, and the machine stored program controller 9 turns on the control valve of the reject cylinder 11. The control valve keeps the reject cylinder 11 in the upper initial position through compressed air. When controlled by the machine stored program controller 9, the control valve switches the compressed air, and the reject cylinder 11 performs its working stroke and knocks out the unqualified cigarette packs. There is no back pressure on the reject cylinder 11 during the switching, so the reject stroke can be completed quickly; after the rejection, the control valve switches the compressed air again, and the reject cylinder 11 moves back to the initial position.

[0043] There is a grating at the output port to detect whether the cigarette packs identified as unqualified have been rejected. If not, the grating at the output port sends a signal to the machine stored program controller 9, and then the machine stops running.

[0044] The present invention provides a cigarette package appearance detection system and detection method, which can accurately collect image information of six surfaces of a cigarette package when detecting the appearance of the cigarette package.

[0045] The present invention can accurately identify and remove unqualified products during the production process of the packaging unit, prevent unqualified cigarette packages from flowing into the next production process, and effectively protect the quality of the product.

[0046] Although the present invention has been disclosed as above by the embodiments, it is not intended to limit the present invention. Any person skilled in the art may make various choices and modifications without departing from the spirit and scope of the present invention. Therefore, the protection scope of the present invention is limited by the claims and their equivalents.

Claims

1. A cigarette package appearance detection system, characterized in that: include: A detection unit, comprising two cameras and a black box (17) with a reflective plate, wherein the two cameras are respectively installed above and below the two sides of the conveyor belt unit (4) and are used to capture the upper and lower images of the cigarette packs passing on the conveyor belt unit (4), and the cameras are provided with flashlights, and the black box (17) with the reflective plate is used to cover the detection section between the two cameras without light leakage; A trigger unit, comprising a trigger grating (16), wherein the trigger grating (16) is started and stopped by a trigger grating controller (2) and a trigger grating EMV box (3) to trigger a camera to take pictures; A control and rejection unit comprises a machine stored program controller (9), an FPI-IPC (10) and a rejection cylinder (11), wherein the FPI-IPC (10) receives images from the camera and sends a signal to the machine stored program controller (9), and the machine stored program controller (9) controls the action of the rejection cylinder (11) to reject unqualified cigarette packs.

2. The cigarette package appearance detection system according to claim 1, characterized in that: The camera is a progressive scan camera with a 1 / 2 inch chip and a Gigabit Ethernet interface. The two cameras are camera A (5) and camera B (13). The camera housing A (6) below the camera A (5) and the camera housing B (14) above the camera B (13) are fixedly mounted on the lower side wall and the upper side wall of the conveyor belt unit (4) by pins.

3. The cigarette package appearance detection system according to claim 2, characterized in that: Also includes: An LED controller (1) is used to control the light sources of a flashlight A (18) of a camera A (5) and a flashlight B (15) of a camera B (13).

4. The cigarette package appearance detection system according to claim 1, characterized in that: The trigger grating (16) comprises a transmitter (164) and a receiver (166), wherein the receiver (166) is arranged on the side of the belt pair (163) of the conveyor belt unit (4) in an oblique and staggered manner, and the transmitter (164) is located on the opposite side of the receiver (166). The transmitter (164) is used to emit a light beam to the receiver (166). When the edge of the output cigarette pack (165) causes the light beam to be interrupted, the trigger grating (16) triggers a flash and a camera to take a picture.

5. The cigarette package appearance detection system according to claim 1, characterized in that: The control and rejection unit further comprises: a touch screen (7) and a data matrix scanner (8); the touch screen (7) is connected to the FPI-IPC (10); the touch screen (7) is used to provide a user interface so that an operator can set detection parameters and monitor the detection process; the data matrix scanner (8) is used to scan the data matrix on the cigarette pack passing through the conveyor unit (4) and transmit the scanning result to the FPI-IPC (10) for processing.

6. The cigarette package appearance detection system according to claim 1, characterized in that: The control and rejection unit further comprises: a rejection device triggering grating (12); when the FPI-IPC (10) identifies that a cigarette pack passing through is unqualified, the rejection device triggering grating (12) sends a signal to the machine stored program controller (9); and the machine stored program controller (9) switches on the control valve of the rejection cylinder (11) to start the rejection of unqualified cigarette packs.

7. The cigarette package appearance detection system according to claim 1, characterized in that: The control and rejection unit further comprises: a detection grating, which is arranged at the output port of the conveyor unit (4), and the detection grating is used to detect whether the cigarette packs identified as unqualified have been rejected. If they have not been rejected, the detection grating sends a signal to the machine storage program controller (9), and then the machine stops running.

8. The cigarette package appearance detection system according to claim 1, characterized in that: The black box (17) with a reflector comprises a reflector, which is used to help illuminate the cigarette packs passing by and prevent the influence of light superposition on the opposite camera.

9. A method for detecting the appearance of a cigarette package using the cigarette package appearance detection system according to any one of claims 1 to 8, characterized in that: The following steps are involved: S1, cigarette packet detection trigger: when the cigarette packet (165) passes through the conveyor belt unit (4) and reaches the position of the triggering grating (16), the transmitter (164) of the triggering grating (16) emits a light beam, and if the receiver (166) detects that the light beam is interrupted, the photographing procedure is triggered; S2, triggering photography: the receiver (166) immediately sends a trigger signal to the system when detecting that the light beam is interrupted, and the LED controller (1) controls the flash to light up, and simultaneously triggers the camera A (5) and the camera B (13) to take photos, thereby capturing the image of the cigarette package; S3, image data acquisition and analysis: the image captured by the camera is transmitted to the FPI-IPC (10), and the FPI-IPC (10) analyzes the image data; S4, rejecting unqualified cigarette packages: If the FPI-IPC (10) determines that the cigarette packages are unqualified, it sends a rejection instruction to the machine stored program controller (9), and the machine stored program controller (9) activates the rejection cylinder (11) to perform the rejection action, thereby rejecting the unqualified cigarette packages from the production line.

10. The method for cigarette package appearance detection by the cigarette package appearance detection system according to claim 9, characterized in that: Step S3 further comprises: a data matrix scanner (8) scans the data matrix on the cigarette package to obtain information of the cigarette package, and transmits the scanning result to the FPI-IPC (10) for processing, and the FPI-IPC (10) combines the image processing result and the data matrix information to make a comprehensive judgment on the quality of the cigarette package; Step S4 also includes: when the FPI-IPC (10) identifies that a cigarette pack passing through is unqualified, the rejection device triggers the grating (12) to send a signal to the machine stored program controller (9), and the machine stored program controller (9) turns on the control valve of the rejection cylinder (11) to start the rejection of the unqualified cigarette pack; Step S4 is followed by step S5: confirming whether the cigarette pack has been successfully rejected: if the cigarette pack has not been rejected, the detection grating located at the output port will send a feedback signal to the machine stored program controller (9), and then the machine will stop running.

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