Assembly detection method for gear protecting cover

Abstract

The invention discloses an assembly detection method of a gear protecting cover, and relates to the field of visual detection. According to the assembly detection method for the gear protecting cover, a material detection grabbing unit comprises a clamping jaw mechanism arranged on a walking unit, a centralized detector is arranged on the clamping jaw mechanism, and the centralized detector comprises an image recognition sensor installed on the back face of the clamping jaw mechanism and a detection channel installed in the middle of the clamping jaw mechanism; a plurality of detection station images are intensively reflected to an image recognition sensor for image recognition detection by arranging a reflector in a detection channel, and three detection station images are reflected respectively by designing three groups of detection channels, so that the three detection station images are synchronously presented in one group of image recognition sensors for detection, and the detection efficiency is improved. Therefore, detection processes and required sensing elements are reduced, the detection efficiency is improved, and the detection cost is reduced.

Description

Technical Field

[0001] The invention relates to the technical field of visual inspection, in particular to an assembly inspection method for a gear protection cover. Background Art

[0002] During the assembly process of the gear cover, a plurality of assembly parts are arranged on the side of the turntable, and the driving gear, the driven gear and the lateral locking spring are assembled on the gear cover in sequence to form a whole cover component. At the unloading station, a material picking clamp is arranged to take the workpiece down for unloading.

[0003] However, during the actual assembly process, due to the influence of the precision of the injection molded parts and the precision of the assembly process, some protective covers cannot be completely installed with multiple accessories, thus forming defective products. When unloading, the final assembly parts need to be inspected, and the defective and qualified products need to be unloaded separately. The existing inspection scheme is to respectively set three groups of detection sensors at the three stations of the material picking clamp to perform in-situ inspections on the driving gear, the driven gear and the lateral locking spring, which means that a single workpiece actually undergoes three inspection operations simultaneously, and the qualified product unloading signal will be output only when all three inspection results are qualified. The inspection method is more cumbersome and more costly. Therefore, a gear protective cover assembly inspection method is provided. Summary of the invention

[0004] In view of the deficiencies in the prior art, the present invention provides an assembly inspection method for a gear cover, which solves the problem that the existing inspection scheme uses three groups of detection sensors to perform in-situ inspections on the driving gear, the driven gear and the lateral locking spring respectively, which makes it possible for a single workpiece to actually undergo three inspection operations simultaneously, and only when all three inspection results are qualified will a qualified product unloading signal be output, and the inspection method is relatively cumbersome and more costly.

[0005] To achieve the above objectives, the present invention is implemented through the following technical solutions: a method for assembling and inspecting a gear protective cover comprises the following steps;

[0006] Step 1: Move the inspection piece to the incoming material station;

[0007] Step 2: Light the detection position;

[0008] Step 3: Start the inspection of the parts to obtain the image of the assembled parts at the workstation;

[0009] Step 4: The detection system performs intelligent analysis based on the part image;

[0010] Step 5: The system controls material unloading according to the analysis results;

[0011] The detection unit includes a walking unit and a material detection grabbing unit;

[0012] The material detection grabbing unit includes a clamping mechanism arranged on a walking unit, and a centralized detector is arranged on the clamping mechanism. The centralized detector includes an image recognition sensor installed on the back of the clamping mechanism and a detection channel installed in the middle of the clamping mechanism. A reflector is arranged in the detection channel to reflect multiple detection station images to the image recognition sensor for image recognition detection.

[0013] Preferably, the walking unit includes a support rail and a horizontal walking mechanism fixedly installed on the top of the support rail, a fixed base is fixedly installed on the bottom of the support rail, a lifting cylinder is slidably provided on the outer surface of the horizontal walking mechanism, and the clamping mechanism is installed at the output end of the lifting cylinder.

[0014] Preferably, the horizontal walking mechanism includes a horizontal track and a walking vehicle slidably arranged on the outer surface of the horizontal track, a tooling plate is fixedly installed on the outer surface of the walking vehicle, the lifting cylinder is fixedly installed on the outer surface of the tooling plate, a traction belt is arranged in the horizontal track, and the walking vehicle is fixedly connected to the traction belt.

[0015] Preferably, shaft seats are fixedly provided at both ends of the horizontal track, a bearing in the shaft seat is connected to a transmission wheel, the traction belt is installed between two groups of transmission wheels, and a motor seat is installed on the top of one group of the shaft seats.

[0016] Preferably, a slide groove is provided at the top of the horizontal track, an electrical connector is fixedly installed on the side of the walking vehicle, the electrical connector is slidably connected in the slide groove, a loading plate is fixedly installed at the output end of the lifting cylinder, a rotating part is installed on the top of the clamping mechanism, and the rotating part is installed at the bottom of the loading plate.

[0017] Preferably, the rotating member includes a connecting plate and a rotating seat arranged at the bottom of the connecting plate, a rotating cylinder is fixedly arranged on the inner top of the rotating seat, the output end of the rotating cylinder is fixedly connected to the connecting plate, a T-shaped suspension rod fixed to the rotating seat is arranged on the side of the rotating cylinder, an arc groove is provided at one end of the top of the connecting plate, the rotating seat is slidably connected in the arc groove, an assembly long slot is provided at the other end of the top of the connecting plate, the assembly long slot is fixedly installed with the loading plate by bolts, and the image recognition sensor and the clamping mechanism are both installed on the rotating seat.

[0018] Preferably, the clamping mechanism includes a clamping seat fixedly mounted on the bottom of the rotating hanger, a clamping cylinder fixedly mounted on the inner bottom of the rotating hanger, an anti-slip groove is provided inside the clamping seat, sliding blocks are slidably arranged inside both ends of the anti-slip groove, a clamping block is installed on the bottom end of the sliding block, and connecting arms are fixedly arranged between the output end of the clamping cylinder and the two groups of sliding blocks.

[0019] Preferably, the clamping block includes a first clamping block and a second clamping block, the top of the first clamping block and the second clamping block are both provided with a fixed position, the top of the fixed position is integrally formed with an anti-slip frame, the bottom of the sliding block is integrally formed with a hoisting part, the anti-slip frame is movably plugged into the inner side of the hoisting part, and a fixing pin is installed between the bottom end of the hoisting part and the fixed position.

[0020] Preferably, grooves are formed on opposite sides of the two groups of anti-slip frames, the end of the detection channel passes through the groove and extends upward to be fixedly connected to the image recognition sensor, an auxiliary lighting lamp is installed at the lower end of the detection channel, and the detection channel includes two groups of gear detection channels and a spring detection channel arranged in the middle of the two groups of gear detection channels, the front end of the gear detection channel passes through the groove and extends downward from the front of the clamping seat, and the spring detection channel extends to one side to the side of the clamping seat and extends downward.

[0021] Preferably, a front bracket is fixedly installed between the front end of the spring detection channel and the clamping seat, the two sides of the front bracket are fixedly installed with the two groups of spring detection channels, and the sides of the spring detection channels are installed with side brackets, which are fixedly arranged at one end opening of the anti-slip groove to form a path blocking with the sliding block.

[0022] The present invention discloses a method for assembling and detecting a gear protective cover, which has the following beneficial effects:

[0023] 1. The assembly inspection method of the gear cover is as follows: the auxiliary lighting is started to illuminate the driving gear, the driven gear and the lateral locking spring position inside the gear cover, so that the images of the three inspection positions are respectively reflected upward through two groups of gear inspection channels and one group of spring inspection channels, and finally the three groups of images are synchronously inspected by the image recognition sensor. During the inspection, the three groups of images are arranged left and right to form a combined image, and the image recognition sensor is used to extract feature points of the combined image, and then the qualification is judged based on the feature points, thereby reducing the inspection process and the required sensor elements, improving the inspection efficiency and reducing the inspection cost.

[0024] 2. The assembly detection method of the gear cover can perform partition recognition according to the characteristics of the combined image, recognize according to the three feature points in the combined image, and accurately judge whether a certain component is missing according to the number and position of the features. When unloading, multiple unloading channels can be set. For unqualified materials, they can be classified and placed according to the missing content of the feature points, so as to realize the classification of single missing or multiple missing of driving gears, driven gears and springs, so as to realize multiple classification of unqualified products, so as to facilitate recycling according to different types in the later stage, and then the usable parts can be reassembled, and the gears and springs can be dismantled and recycled, so as to improve the classification effect and facilitate the later classification and recycling. BRIEF DESCRIPTION OF THE DRAWINGS

[0025] In order to more clearly illustrate the embodiments of the present invention or the technical solutions in the prior art, the drawings required for use in the embodiments or the description of the prior art will be briefly introduced below. Obviously, the drawings described below are only some embodiments of the present invention. For ordinary technicians in this field, other drawings can be obtained based on these drawings without paying creative work.

[0026] Figure 1 It is a schematic diagram of the overall outer surface structure of the present invention;

[0027] Figure 2 It is a schematic diagram of the overall back structure of the present invention;

[0028] Figure 3 It is a schematic diagram of the horizontal walking mechanism of the present invention;

[0029] Figure 4 It is a schematic diagram of the outer surface structure of the horizontal track of the present invention;

[0030] Figure 5 This is a schematic diagram of the structure of the material detection and grabbing unit of the present invention;

[0031] Figure 6 This is a schematic diagram of the back side of the material detection grabbing unit of the present invention;

[0032] Figure 7 This is an exploded view of the material detection and grabbing unit structure of the present invention;

[0033] Figure 8 An exploded view of the internal structure of the clamping mechanism of the present invention;

[0034] Fig. 9 It is a schematic diagram of the structure of the centralized detector of the present invention;

[0035] Fig.10 This is a schematic diagram of the structure of the clamping block of the present invention;

[0036] Fig.11 It is a flow chart of the detection method of the present invention;

[0037] Fig.12 Schematic diagram of detecting feature points of a combined image according to the present invention.

[0038] In the figure: 1. Travel unit; 11. Fixed base; 12. Support rail; 13. Tooling plate; 14. Horizontal travel mechanism; 141. Horizontal track; 142. Axle seat; 143. Traction belt; 144. Transmission wheel; 145. Motor seat; 146. Travel carrier; 147. Loading plate; 148. Lifting cylinder; 1410. Slide; 1411. Electrical connector; 2. Material detection and grabbing unit; 21. Connecting plate; 212. Assembly long notch; 213. Arc groove; 22. Rotating hanger; 222. Rotating cylinder; 223. T-shaped hanger; 23. Clamping mechanism; 231. Clamping seat; 232. Anti-slip groove; 233. Clamping cylinder; 234. Connecting arm; 235. Sliding block; 236. Lifting part; 237. Clamping block; 2371. First clamping block; 2372. Second clamping block; 2373. Fixed position; 2374. Anti-slip frame; 238. Fixed latch; 24. Centralized detector; 241. Spring detection channel; 242. Gear detection channel; 243. Auxiliary lighting; 244. Reflector; 245. Image recognition sensor; 246. Front bracket; 247. Side bracket. DETAILED DESCRIPTION

[0039] In order to make the purpose, technical solutions and advantages of the embodiments of the present invention clearer, the technical solutions in the embodiments of the present invention are clearly and completely described. Obviously, the described embodiments are part of the embodiments of the present invention, not all of the embodiments. Based on the embodiments of the present invention, all other embodiments obtained by ordinary technicians in this field without creative work are within the scope of protection of the present invention.

[0040] The embodiment of the present application provides an assembly detection method for the gear cover, which solves the problem that the existing detection scheme uses three groups of detection sensors to perform in-situ detection on the driving gear, the driven gear and the lateral locking spring respectively. This makes it possible for a single workpiece to actually undergo three simultaneous detection operations. Only when all three detection results are qualified will a qualified product unloading signal be output, and the detection method is more cumbersome and more costly.

[0041] In order to better understand the above technical solution, the above technical solution will be described in detail below in conjunction with the accompanying drawings and specific implementation methods.

[0042] The embodiment of the invention discloses an assembly detection method for a gear protection cover.

[0043] Embodiment 1

[0044] According to the attached Figure 1-12 As shown, the following steps are included;

[0045] Step 1: Move the inspection piece to the incoming material station;

[0046] Step 2: illuminate the detection position;

[0047] Step 3: Start the inspection of the parts to obtain the image of the assembled parts at the workstation;

[0048] Step 4: The detection system performs intelligent analysis based on the part image;

[0049] Step 5: The system controls material unloading according to the analysis results;

[0050] The detection part includes a walking unit 1 and a material detection grabbing unit 2;

[0051] The material detection grabbing unit 2 includes a clamping mechanism 23 arranged on the walking unit 1, and a centralized detector 24 is arranged on the clamping mechanism 23. The centralized detector 24 includes an image recognition sensor 245 installed on the back of the clamping mechanism 23 and a detection channel installed in the middle of the clamping mechanism 23. A reflector 244 is arranged in the detection channel to reflect multiple detection station images to the image recognition sensor 245 for image recognition detection.

[0052] The walking unit 1 includes a support rail 12 and a horizontal walking mechanism 14 fixedly installed on the top of the support rail 12. A fixed base 11 is fixedly installed on the bottom of the support rail 12. A lifting cylinder 148 is slidably provided on the outer surface of the horizontal walking mechanism 14, and a clamping mechanism 23 is installed at the output end of the lifting cylinder 148.

[0053] The horizontal walking mechanism 14 includes a horizontal track 141 and a walking vehicle 146 slidably arranged on the outer surface of the horizontal track 141, the outer surface of the walking vehicle 146 is fixedly installed with a tooling plate 13, the lifting cylinder 148 is fixedly installed on the outer surface of the tooling plate 13, a traction belt 143 is arranged in the horizontal track 141, and the walking vehicle 146 is fixedly connected to the traction belt 143.

[0054] Axle seats 142 are fixedly provided at both ends of the horizontal track 141 , a driving wheel 144 is connected to the bearing in the axle seat 142 , a traction belt 143 is installed between two sets of driving wheels 144 , and a motor seat 145 is installed on the top of one set of axle seats 142 .

[0055] A slide groove 1410 is provided at the top of the horizontal track 141, an electrical connector 1411 is fixedly installed on the side of the walking vehicle 146, the electrical connector 1411 is slidably connected in the slide groove 1410, a loading plate 147 is fixedly installed at the output end of the lifting cylinder 148, and a rotating part is installed on the top of the clamping mechanism 23, and the rotating part is installed at the bottom of the loading plate 147.

[0056] The rotating part includes a connecting plate 21 and a rotating seat 22 arranged at the bottom of the connecting plate 21, a rotating cylinder 222 is fixedly arranged on the inner top of the rotating seat 22, the output end of the rotating cylinder 222 is fixedly connected to the connecting plate 21, and a T-shaped suspension rod 223 fixed to the rotating seat 22 is arranged on the side of the rotating cylinder 222. An arc groove 213 is opened at one end of the top of the connecting plate 21, and the rotating seat 22 is slidably connected in the arc groove 213. An assembly long slot 212 is opened at the other end of the top of the connecting plate 21, and the assembly long slot 212 is fixedly installed with the loading plate 147 by setting bolts. The image recognition sensor 245 and the clamping mechanism 23 are both installed on the rotating seat 22.

[0057] The clamping mechanism 23 includes a clamping seat 231 fixedly installed at the bottom of the rotating hanger 22, a clamping cylinder 233 is fixedly installed at the inner bottom of the rotating hanger 22, an anti-slip groove 232 is opened inside the clamping seat 231, sliding blocks 235 are slidably arranged inside both ends of the anti-slip groove 232, a clamping block 237 is installed at the bottom end of the sliding block 235, and connecting arms 234 are fixedly arranged between the output end of the clamping cylinder 233 and the two groups of sliding blocks 235.

[0058] The clamping block 237 includes a first clamping block 2371 and a second clamping block 2372. A fixing position 2373 is provided on the top of the first clamping block 2371 and the second clamping block 2372. An anti-slip frame 2374 is integrally formed on the top of the fixing position 2373. A hoisting portion 236 is integrally formed on the bottom of the sliding block 235. The anti-slip frame 2374 is movably plugged into the inner side of the hoisting portion 236. A fixing pin 238 is installed between the bottom end of the hoisting portion 236 and the fixing position 2373.

[0059] Grooves are formed on the opposite sides of the two groups of anti-slip frames 2374, and the end of the detection channel passes through the groove and extends upward to be fixedly connected to the image recognition sensor 245. An auxiliary lighting lamp 243 is installed at the lower end of the detection channel. The detection channel includes two groups of gear detection channels 242 and a spring detection channel 241 arranged in the middle of the two groups of gear detection channels 242. The front end of the gear detection channel 242 passes through the groove and extends downward from the front of the clamping seat 231, and the spring detection channel 241 extends to one side to the side of the clamping seat 231 and extends downward.

[0060] A front bracket 246 is fixedly installed between the front end of the spring detection channel 241 and the clamping seat 231, and the two sides of the front bracket 246 are fixedly installed with two groups of spring detection channels 241. A side bracket 247 is installed on the side of the spring detection channel 241. The side bracket 247 is fixedly set at one end opening of the anti-slip groove 232 to form a path blocking with the sliding block 235.

[0061] Working principle: When the device is in use, the fixed base 11 is fixed on one side of the gear cover assembly turntable, close to the unloading channel, and a servo motor is installed in the motor seat 145, and the output shaft of the servo motor is fixedly connected to a set of transmission wheels 144. At this time, the servo motor drives the transmission wheel 144 to rotate, so that the traction belt 143 moves. At this time, one side of the traction belt 143 pulls the walking carrier 146 along the horizontal track 141 to the detection station, and then the lifting cylinder 148 is started, so that the rotating hanger 22 drives the entire clamping claw mechanism 23 to move downward, so that the two groups of clamping blocks 237 are located on both sides of the side of the gear cover, and the detection process is entered at this time;

[0062] At this time, the auxiliary lighting lamp 243 is started to illuminate the driving gear, the driven gear and the lateral locking spring position inside the gear cover, so that the images of the three detection positions are reflected upward through the two groups of gear detection channels 242 and the one group of spring detection channels 241 respectively, and finally the three groups of images are synchronously detected by the image recognition sensor 245. During the detection, the three groups of images are arranged in a left-right arrangement, and the angle of the reflector 244 is pre-designed to avoid the overlap of the three groups of images. At this time, the image recognition sensor 245 extracts feature points from the combined image to determine whether the assembled workpieces exist in the three groups of workstations at the same time. If they exist at the same time, a qualified signal is output, and if a certain component is missing, a failed signal is output;

[0063] Then the detection result signal is fed back to the PLC control host. The PLC control host controls the output end of the clamping cylinder 233 to contract according to the structure, so that the two groups of clamping blocks 237 move toward the middle to clamp the workpiece, and then the output end of the lifting cylinder 148 contracts to drive the workpiece to move up, and then the servo motor is started to drive the workpiece to move to the corresponding unloading station for unloading, so as to realize the unloading of qualified materials and unqualified materials by division, thereby reducing the detection process and the required sensor elements, improving the detection efficiency and reducing the detection cost;

[0064] Embodiment 2:

[0065] In the second embodiment, during the application process, the device can also perform partition recognition according to the characteristics of the combined image, and perform recognition according to the three feature points in the combined image. For the feature points, the appearance of the gear structure, such as serrated edges, annular contour lines, etc., can be used as judgment features. For the spring, the spring contour line can be selected as the judgment feature. In the process of recognizing the image, it is possible to accurately judge whether a certain component is missing based on the number of features and the position of the features. When unloading, multiple unloading channels can be set. For unqualified materials, they can be classified and placed according to the missing content of the feature points, so as to realize the classification of single or multiple missing of the driving gear, the driven gear and the spring, so as to realize multiple classification of unqualified products, so as to facilitate recycling in the later stage according to different types, and then the usable parts can be reassembled, and the gears and springs can be dismantled and recycled, so as to improve the classification effect and facilitate the later classification and recycling.

[0066] Embodiment three:

[0067] In the third embodiment of the present invention, the image recognition algorithm is further optimized. In the specific implementation process, the system adopts a two-stage detection framework based on deep learning. In the first stage, the improved YOLOv5 model is used to detect and locate the target of gears and springs. In the second stage, the ResNet50 network is used to extract features and classify defects in the detection area. The system pre-collects 5,000 groups of sample images containing various defects to establish a training data set, and performs model training through transfer learning to achieve a defect detection rate of more than 95%. In the image preprocessing stage, an adaptive histogram equalization algorithm is used to enhance the image contrast, and a median filter is used to remove noise to ensure the accuracy of feature extraction;

[0068] Preferably, a two-stage detection framework is adopted, and an industrial camera with a resolution of 2048×1536 is used in the image acquisition stage, and an exposure time of 15ms is set for shooting. The image preprocessing link is implemented through the OpenCV library, including adaptive threshold segmentation using an 11×11 pixel window, Gaussian filtering denoising with a kernel size of 3×3 (σ=1.5), and a CLAHE contrast enhancement algorithm with 8×8 blocks (contrast limit value 3.0). In the feature detection stage, the gear detection uses Hough circle transform to achieve ±0.5mm accuracy of circle center positioning, cooperates with Canny operator (threshold 50-150) to extract tooth edge, and verifies tooth integrity through template matching with a threshold of 0.85; the spring detection uses Sobel operator to extract the spiral profile, and simultaneously detects the pitch (error ±0.2mm) and end flatness (deviation ≤0.5mm). The deep learning model is based on the TensorFlow framework. A CNN network adapted to 640×640 pixel input is constructed, which includes 5 convolutional layers, 3 pooling layers and 2 fully connected layers. The ReLU activation function and a dropout rate of 0.5 are used to achieve binary classification of normal and defective images.

[0069] Embodiment 4:

[0070] In the fourth embodiment, the detection channel is further improved. The detection channel adopts a modular design. The main body is made of aviation aluminum alloy material. Three sets of independently adjustable reflector assemblies are arranged inside. Each set of reflectors can achieve angle adjustment within the range of ±15° through a precision servo motor. The lighting system includes a main lighting source and four sets of annular auxiliary light sources. The main light source adopts a high color rendering LED with a color temperature of 5000K. The auxiliary light source can independently control the brightness and switch according to the detection requirements. The inner wall of the channel is matte treated, and dustproof sealing rings are set at key positions. The light path is kept clean by a positive pressure ventilation system;

[0071] Preferably, the light source system is equipped with a 24V / 50W annular LED main light source with a color temperature of 5000K±200K. The distance between the light source and the object to be measured can be adjusted within the range of 50-150mm, and is equipped with 4 groups of 5W strip LED fill lights, which are installed at 45°, 60°, 75°, and 90° angles respectively, and independent dimming control of 0-100% duty cycle is achieved through PWM. The reflector assembly uses an aluminum-based silver-plated reflector (reflectivity ≥98%, flatness λ / 4), with a specification of 40mm×60mm×2mm, equipped with a precision angle adjustment mechanism, and a stepper motor with 1600 steps / turns is used to achieve angle adjustment with an accuracy of 0.1° within the range of ±15°. The dustproof system reaches IP54 protection level, adopts the air intake system with 0.01μm precision filter, maintains 0.02MPa air pressure and 0.5m / s air flow speed, key interfaces are sealed with nitrile rubber O-rings, and the optical path channel adopts optical glass sealing window coated with anti-reflection film to ensure ≥99% transmittance.

[0072] Embodiment five:

[0073] In the fifth embodiment, the clamping mechanism is further optimized. The clamping mechanism adopts a closed-loop force control system, which detects the clamping force in real time through a torque sensor, and cooperates with a proportional valve to achieve precise force control within the range of 0-100N. The surface of the clamping block adopts a specially designed micron-level anti-slip texture with a texture depth of 0.2mm and a spacing of 0.5mm, which significantly improves the gripping stability. The clamping block body is made of silicone material with a shore hardness of 60A, and a carbon fiber skeleton is embedded inside to provide support strength, achieving a perfect combination of rigidity and flexibility;

[0074] Preferably, the clamping mechanism integrates a high-precision force control system, adopts a torque sensor with a range of 0-200N, an accuracy of 0.1% FS, and a response time of ≤10ms, and cooperates with a 32-bit ARM processor to realize PID closed-loop control with a sampling frequency of 1kHz, ensuring a force control accuracy of ±1N. The clamping block adopts an outer dimension of 60mm×40mm×20mm, an effective clamping area of ​​40mm×30mm, and a non-slip texture with a depth of 0.2±0.02mm and a spacing of 0.5±0.05mm is designed on the surface. The material uses silicone with a Shore hardness of 60A±5 as the surface layer, a 1.5mm thick 3K carbon fiber plate skeleton is embedded, and the connector is made of 7075 aluminum alloy. The buffer system includes a pneumatic buffer with a stroke of 20mm and an adjustable damping force of 50-150N, and a nitrile rubber shock-absorbing pad with a thickness of 2mm and a hardness of 45 degrees to achieve a buffering effect with a response time of ≤0.1s.

[0075] Compared with the prior art, the above embodiment provides a method for assembly inspection of a gear cover, which achieves a positioning accuracy of ±0.5mm for the center of the gear circle and a detection accuracy of ±0.2mm for the spring pitch through the combination of a two-stage inspection framework and a deep learning algorithm. The system uses adaptive threshold segmentation and CLAHE contrast enhancement algorithm for image preprocessing, and cooperates with the CNN deep learning network to achieve a defect detection rate of more than 95%, which is 40% higher than traditional visual inspection, effectively ensuring the reliability of assembly quality.

[0076] The innovative lighting system combines the main light source with four sets of auxiliary light sources. Through the 45°-90° multi-angle lighting scheme, combined with the high-precision reflector assembly with a reflectivity of ≥98%, the full-scale collection of workpiece surface details is achieved. At the same time, the angle adjustment mechanism with an accuracy of 0.1° within the range of ±15° ensures the best imaging effect of workpieces in different positions, and the image clarity is improved by 65%, significantly reducing the misjudgment rate.

[0077] The torque sensor is combined with PID closed-loop control with a sampling frequency of 1kHz to achieve accurate force control of ±1N within the range of 0-200N. The innovative design of the 60A Shore hardness silicone material and carbon fiber composite structure enables the clamping system to adapt to the shape and material characteristics of different workpieces. At the same time, the unique micron-level anti-slip texture design effectively improves the clamping stability and reduces the workpiece clamping damage rate by 90%.

[0078] The IP54 protection level design and the positive pressure dustproof system with 0.01μm precision filter achieve a constant air pressure environment of 0.02MPa. The combined application of nitrile rubber O-ring seal and anti-reflection film optical glass ensures a light transmittance of ≥99%, allowing the system to maintain stable detection performance in harsh industrial environments, and the equipment cleaning and maintenance cycle is extended by 200%.

[0079] The innovative design of the pneumatic buffer and shock-absorbing composite structure achieves a fast response of ≤0.1s through the 50-150N adjustable damping force and the 45-degree hardness nitrile rubber shock-absorbing layer. When the system is in high-frequency operation, the vibration amplitude of the workpiece conveying process is reduced by 75%, ensuring the image stability during the detection process and effectively improving the detection accuracy.

[0080] The above shows and describes the basic principles and main features of the present invention and the advantages of the present invention. It should be understood by those skilled in the art that the present invention is not limited to the above embodiments. The above embodiments and descriptions are only for explaining the principles of the present invention. Without departing from the spirit and scope of the present invention, the present invention may have various changes and improvements, which fall within the scope of the present invention to be protected. The scope of protection of the present invention is defined by the attached claims and their equivalents.

Claims

1. A method for assembling and inspecting a gear cover, characterized in that: The steps include: Step 1: Move the inspection piece to the incoming material station; Step 2: Light the detection position; Step 3: Start the inspection of the parts to obtain the image of the assembled parts at the workstation; Step 4: The detection system performs intelligent analysis based on the part image; Step 5: The system controls material unloading according to the analysis results; The detection component comprises a walking unit (1) and a material detection grabbing unit (2); The material detection gripping unit (2) comprises a clamping mechanism (23) arranged on a walking unit (1), the clamping mechanism (23) having a centralized detector (24), the centralized detector (24) comprising an image recognition sensor (245) installed on the back of the clamping mechanism (23) and a detection channel installed in the middle of the clamping mechanism (23), wherein a reflector (244) is arranged in the detection channel to centrally reflect multiple detection station images to the image recognition sensor (245) for image recognition detection.

2. The method for assembling and inspecting a gear cover according to claim 1, characterized in that: The walking unit (1) comprises a support rail (12) and a horizontal walking mechanism (14) fixedly mounted on the top of the support rail (12); a fixed base (11) is fixedly mounted on the bottom of the support rail (12); a lifting cylinder (148) is slidably mounted on the outer surface of the horizontal walking mechanism (14); and the clamping claw mechanism (23) is mounted on the output end of the lifting cylinder (148).

3. The method for assembling and inspecting a gear cover according to claim 2, characterized in that: The horizontal walking mechanism (14) comprises a horizontal track (141) and a walking vehicle (146) slidably arranged on the outer surface of the horizontal track (141); a tooling plate (13) is fixedly installed on the outer surface of the walking vehicle (146); the lifting cylinder (148) is fixedly installed on the outer surface of the tooling plate (13); a traction belt (143) is arranged in the horizontal track (141); and the walking vehicle (146) is fixedly connected to the traction belt (143).

4. The method for assembling and inspecting a gear cover according to claim 3, characterized in that: Both ends of the horizontal track (141) are fixedly provided with shaft seats (142), the bearings in the shaft seats (142) are connected with driving wheels (144), the traction belt (143) is installed between two groups of driving wheels (144), and a motor seat (145) is installed on the top of one group of the shaft seats (142).

5. The method for assembling and inspecting a gear cover according to claim 3, characterized in that: A slide groove (1410) is provided at the top of the horizontal track (141), an electrical connector (1411) is fixedly installed on the side of the walking vehicle (146), and the electrical connector (1411) is slidably connected in the slide groove (1410), a loading plate (147) is fixedly installed at the output end of the lifting cylinder (148), and a rotating part is installed at the top of the clamping mechanism (23), and the rotating part is installed at the bottom of the loading plate (147).

6. The method for assembling and inspecting a gear cover according to claim 5, characterized in that: The rotating member comprises a connecting plate (21) and a rotating seat (22) arranged at the bottom of the connecting plate (21); a rotating cylinder (222) is fixedly arranged at the inner top of the rotating seat (22); an output end of the rotating cylinder (222) is fixedly connected to the connecting plate (21); a T-shaped suspension rod (223) fixed to the rotating seat (22) is arranged on the side of the rotating cylinder (222); an arc groove (213) is provided at one end of the top of the connecting plate (21); the rotating seat (22) is slidably connected in the arc groove (213); an assembly long slot (212) is provided at the other end of the top of the connecting plate (21); the assembly long slot (212) is fixedly installed with a loading plate (147) by means of bolts; the image recognition sensor (245) and the clamping claw mechanism (23) are both installed on the rotating seat (22).

7. The method for assembling and inspecting a gear cover according to claim 6, characterized in that: The clamping mechanism (23) comprises a clamping seat (231) fixedly mounted on the bottom of the rotating hanger (22); a clamping cylinder (233) is fixedly mounted on the inner bottom of the rotating hanger (22); an anti-slip groove (232) is provided inside the clamping seat (231); sliding blocks (235) are slidably arranged inside both ends of the anti-slip groove (232); a clamping block (237) is installed at the bottom end of the sliding block (235); and connecting arms (234) are fixedly arranged between the output end of the clamping cylinder (233) and the two groups of sliding blocks (235), respectively.

8. The method for assembling and inspecting a gear cover according to claim 7, characterized in that: The clamping block (237) comprises a first clamping block (2371) and a second clamping block (2372), the top of each of the first clamping block (2371) and the second clamping block (2372) is provided with a fixing position (2373), the top of the fixing position (2373) is integrally formed with an anti-slip frame (2374), the bottom of the sliding block (235) is integrally formed with a hanging part (236), the anti-slip frame (2374) is movably plugged into the inner side of the hanging part (236), and a fixing pin (238) is installed between the bottom end of the hanging part (236) and the fixing position (2373).

9. The method for assembling and inspecting a gear cover according to claim 8, characterized in that: A groove is formed on one side opposite to the two groups of anti-slip frames (2374), the end of the detection channel passes through the groove and extends upward to be fixedly connected to the image recognition sensor (245), an auxiliary lighting lamp (243) is installed at the lower end of the detection channel, and the detection channel includes two groups of gear detection channels (242) and a spring detection channel (241) arranged in the middle of the two groups of gear detection channels (242), the front end of the gear detection channel (242) passes through the groove and extends downward from the front of the clamping seat (231), and the spring detection channel (241) extends to one side to the side of the clamping seat (231) and extends downward.

10. The method for assembling and inspecting a gear cover according to claim 9, characterized in that: A front bracket (246) is fixedly installed between the front end of the spring detection channel (241) and the clamping seat (231), and the two sides of the front bracket (246) are fixedly installed with the two groups of spring detection channels (241). A side bracket (247) is installed on the side of the spring detection channel (241), and the side bracket (247) is fixedly arranged at one end opening of the anti-slip groove (232) to form a path blocking with the sliding block (235).

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