Automatic point inspection and calibration system and method thereof

Abstract

The invention discloses an automatic point inspection and calibration system and a method thereof, and relates to the technical field of industrial automation and quality control, the system comprises a calibration sample hole disc which is provided with micropores and is used for simulating pinhole defects on the surface of a strip; the sample hole disc driving device is arranged at the bottom of the pinhole detection device and can drive the calibration sample hole disc to move to the position where the strip pinhole detection device is located. The pinhole detection visual detection device is arranged on the pinhole detection device and can collect micropores in the calibration sample hole disc; the data processing and control system can receive image signals of the pinhole detection visual detection device, carry out image processing and analysis and carry out point inspection and calibration on the pinhole detection device. By adopting the automatic point inspection and calibration system and the automatic point inspection and calibration method, the detection parameters of the pinhole detection device can be automatically calibrated.

Description

Technical Field

[0001] The present invention relates to the technical field of industrial automation and quality control, and in particular to an automatic spot inspection and calibration system and method thereof. Background Art

[0002] In the production process of aluminum foil and other strip materials, the pinhole detection device is an indispensable quality inspection tool. It can monitor the pinhole defects on the surface of the strip material in real time to ensure product quality.

[0003] However, the pinhole detection device itself may also cause a decrease in detection accuracy or malfunction due to long-term use, environmental factors or equipment aging, or even false detection or missed detection. Therefore, it is urgent to design a technical solution that can automatically calibrate the detection parameters of the pinhole detection device. Summary of the invention

[0004] The object of the present invention is to provide an automatic spot inspection and calibration system and method thereof to solve the problems existing in the above-mentioned prior art and to automatically calibrate the detection parameters of a pinhole detection device.

[0005] To achieve the above object, the present invention provides the following solutions:

[0006] The present invention provides an automatic spot inspection and calibration system, comprising:

[0007] A calibration sample hole plate, which is provided with micro-holes to simulate pinhole defects on the surface of the strip;

[0008] The sample hole plate driving device is arranged at the bottom of the pinhole detection device, and can drive the calibration sample hole plate to move to the position where the material pinhole detection is located;

[0009] A pinhole detection visual inspection device, which is arranged on the pinhole detection device and can collect micro-holes on the calibration sample well plate;

[0010] The data processing and control system can receive the image signal of the pinhole detection visual inspection device, and perform image processing, analysis, spot inspection and calibration of the pinhole detection device.

[0011] The present invention aims to confirm whether the current state of a pinhole detection device is normal, and to update internal parameters of the pinhole detection device when factors related to the pinhole detection device change.

[0012] In terms of spot inspection, the present invention comprehensively checks the detection measurement range, detection signal status, detection capability, detection performance index, and consistency of repeated detection results of the pinhole detection device. Through this series of inspections, it is ensured that the functions of the pinhole detection device are operating normally and meet the design requirements.

[0013] In terms of calibration, the present invention confirms the lateral pixel ratio parameters of the pinhole detection device, and calculates the two-dimensional projection of the light spot corresponding to the non-physical object of the tiny target, so as to obtain the deviation between the lateral and longitudinal measured dimensions and the actual dimensions of the micropore target on the calibration sample plate. The calculation method is based on the processing computer, which is a mature technology and will not be described in detail. At the same time, the present invention also performs calculation parameter correction on the measurement deviation of the micropore area (especially the non-occupied state in the edge pixels). In addition, when multiple cameras are used in combination, the system can calculate and correct the overlap of the measurement area. In particular, for the case where the measured micropore target is smaller than one pixel, the system can process the light spot projection mapping, and calibrate and correct the relevant calculation parameters such as the length, width, and area of ​​the micropore target.

[0014] The automatic spot inspection and calibration system of the present invention ensures the accuracy and reliability of the pinhole detection device through the two major functions of spot inspection and calibration, and improves the precision and stability of the online detection process.

[0015] Preferably, the sample well plate driving device includes a lifting module, the lifting module is provided with an in-and-out module, and the calibration sample well plate is horizontally arranged on the in-and-out module; the lifting module can lift the in-and-out module and the calibration sample well plate to a position at the same height as the material, and the in-and-out module can drive the calibration sample well plate to move horizontally to a pinhole detection position with the material; a rotating motor is provided at the bottom of the calibration sample well plate, and the rotating motor can drive the calibration sample well plate to rotate.

[0016] Preferably, it also includes a transverse moving linear module, a transverse guide rail is provided at the bottom of the pinhole detection device, the transverse moving linear module is movably connected to the transverse guide rail, and the lifting module is arranged on the transverse moving linear module; the transverse moving linear module can drive the lifting module, the entry and exit module and the calibration sample hole plate to move at a uniform speed along the axial direction of the material conveying roller.

[0017] Preferably, the lifting module includes a first guide plate connected to the horizontal linear moving module, a vertically arranged first linear guide is provided on the outer side of the first guide plate, a first slider is provided on the first linear guide, and the outer side of the first slider is connected to the entry and exit module; a first drive motor is provided on the first guide plate, and the first drive motor is used to drive the first slider to move up and down along the first linear guide.

[0018] Preferably, the entry and exit module includes a second guide plate fixedly connected to the first slider, a horizontally arranged second linear guide is provided on the top of the second guide plate, a second slider is provided on the second linear guide, and the top of the second slider is connected to the calibration sample well plate; a second drive motor is provided on the second guide plate, and the second drive motor is used to drive the second slider to move horizontally forward and backward along the second linear guide.

[0019] Preferably, the pinhole detection device includes a mounting frame, with material conveying rollers at both ends of the mounting frame, wherein a synchronous encoder wheel is provided above the end of one of the material conveying rollers, and the synchronous encoder wheel is connected to an encoder; the mounting frame includes a left side plate and a right side plate, and the left side plate and the right side plate are connected above by a top plate.

[0020] Preferably, the pinhole detection visual inspection device includes a camera and a light source; the camera is arranged on the top plate, a left light source adjustment plate is connected to the bottom of the left plate, a right light source adjustment plate is provided at the bottom of the right plate, the light source is horizontally arranged between the left light source adjustment plate and the right light source adjustment plate, and the light source is located below the pinhole detection position of the material strip.

[0021] Preferably, the data processing and control system includes a data line acquisition card, a processing computer and the encoder; the data line acquisition card can receive the image signal of the camera, and the processing computer can perform image processing and analysis, and inspect and calibrate the pinhole detection device according to the image aperture measurement value.

[0022] Preferably, the processing computer can automatically determine the outer boundary of the calibration sample well plate imaging and perform flat field correction according to the signal state; and the processing computer can automatically eliminate interference signals.

[0023] The present invention also provides an automatic spot inspection and calibration method, comprising the following steps:

[0024] Step 1: System startup and initialization;

[0025] Step 2: Enter the automatic inspection and calibration state; when the pinhole detection device reaches the inspection and maintenance cycle time point, or the operator finds that it has an abnormal response, it automatically or manually switches to the automatic inspection and calibration state; the material is automatically withdrawn from the production area to make room for the calibration sample hole plate;

[0026] Step 3: The sample well plate driving device moves the calibration sample well plate to the position where the material pinhole detection is located;

[0027] Step 4: The calibration sample well plate rotates to simulate the linear transmission state of the material, and the camera collects images at the same time;

[0028] Step 5: Image processing and analysis: The processing computer receives the image signal from the camera, performs image processing and analysis, calculates the pore size of the micropores through an algorithm, and compares it with the actual size;

[0029] Step 6: parameter adjustment and calibration; if the aperture measurement deviation is found to be out of range, the aperture measurement parameters are adjusted automatically or manually; the steps of image acquisition, processing and analysis are repeated until the aperture measurement deviation is within the allowable range;

[0030] Step 7, lateral movement and multi-point detection: The lateral movement linear module is started to drive the calibration sample well plate to move at a uniform speed along the axis direction of the material conveying roller. During the movement, steps 4 to 6 are repeated evenly at different positions according to the set spacing;

[0031] Step eight, system reset and state switching; after all position points are automatically inspected and calibrated, the calibration sample well plate is withdrawn to the initial position; the state of the pinhole detection device is switched to the online production detection state.

[0032] Compared with the prior art, the present invention has achieved the following technical effects:

[0033] The automatic spot inspection and calibration system of the present invention is independent of the pinhole detection device and does not interfere with the normal operation of the pinhole detection device. By calibrating the sample hole plate to simulate the micropore defects that may appear on the surface of the material belt, and using the sample hole plate driving device to move the calibration sample hole plate to the detection position where the material belt was originally located, the current state of the pinhole detection device can be automatically inspected, and according to the standard sample hole, the system can automatically calibrate the measurement size deviation, realize continuous correction of the deviation until it converges to the target range, and improve the accuracy of detection. BRIEF DESCRIPTION OF THE DRAWINGS

[0034] 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 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.

[0035] Figure 1 A schematic diagram of the installation position of the automatic inspection and calibration system in one or more embodiments of the present invention;

[0036] Figure 2 A side view of an automatic inspection and calibration system in one or more embodiments of the present invention.

[0037] In the figure: 1-left side plate, 2-right side plate, 3-left light source adjustment plate, 4-right light source adjustment plate, 51-first camera, 52-second camera, 6-light source, 7-encoder, 8-synchronous encoder wheel, 9-material conveying roller, 10-material conveying, 11-calibrated sample well plate, 12-in and out module, 13-lifting module, 14-lateral moving linear module. DETAILED DESCRIPTION

[0038] 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.

[0039] The object of the present invention is to provide an automatic spot inspection and calibration system and method thereof to solve the problems existing in the above-mentioned prior art and to automatically calibrate the detection parameters of a pinhole detection device.

[0040] In order to make the above-mentioned objects, features and advantages of the present invention more obvious and easy to understand, the present invention is further described in detail below with reference to the accompanying drawings and specific embodiments.

[0041] Pinhole detection devices are mainly used to detect pinhole defects on the surface of products such as foils; the pinhole detection devices known to the inventors are mostly based on machine vision technology, and detect pinholes through industrial cameras and image processing software. However, the pinhole detection device itself may also cause a decrease in detection accuracy or malfunction due to long-term use, environmental factors or equipment aging, and even false detection or missed detection. Therefore, in order to ensure the working precision and accuracy of the pinhole detection device, it is necessary to regularly inspect and calibrate it to reduce its error; based on this, the present invention provides an automatic inspection and calibration system, such as Figure 1 and Figure 2 As shown, it includes a calibration sample well plate 11, a sample well plate driving device, a pinhole detection visual inspection device and a data processing and control system. The calibration sample well plate 11 is provided with microholes. In one embodiment, a plurality of standard microholes of 5μm, 10μm, 20μm and 50μm can be set as needed; it is used to simulate pinhole defects on the surface of the strip 10; the sample well plate driving device is arranged at the bottom of the pinhole detection device, which has a laser ranging sensor, and can drive the calibration sample well plate 11 to move to the position where the pinhole detection of the strip 10 is located according to the data of the laser ranging sensor; the pinhole detection visual inspection device is arranged on the pinhole detection device, and can collect the microholes on the calibration sample well plate 11; the data processing and control system can receive the image signal of the pinhole detection visual inspection device, and perform image processing, analysis, spot inspection and calibration of the pinhole detection device.

[0042] The technical solution of the present invention is an automatic spot inspection and calibration system tailored for the pinhole detection device, which is a key component to ensure the efficient and accurate operation of the pinhole detection device. The present invention is based on a data processing and control system, and through the spot inspection function of different detection positions of the pinhole detection device, it comprehensively and systematically verifies the current state of the pinhole detection device. The spot inspection process not only covers the confirmation of the detection measurement range, but also includes the stability of the detection signal state, the adequacy of the detection capability, and the compliance of the detection performance indicators. More importantly, it verifies the consistency of the detection results by repeatedly testing the physical object of the calibration sample plate, thereby ensuring the reliability and accuracy of the pinhole detection device in practical applications.

[0043] The calibration function is another core of the present invention. When the pinhole detection device changes due to any factors, its internal parameters need to be updated accordingly to maintain the detection accuracy. The automatic spot inspection and calibration system undertakes this important task. It confirms the lateral pixel ratio parameters of the pinhole detection device through the computer software of the data processing and control system to ensure the accuracy of the measurement results. At the same time, the present invention can also deal with the two-dimensional projection problem of the non-physical corresponding light spot of the tiny target. The deviation between the lateral and longitudinal measured dimensions and the actual dimensions of the micro-hole target is accurately calculated by the processing computer, and the relevant calculation parameters are used for correction. The processing computer adopts a computer, and its calculation method is a mature technology and will not be repeated. In addition, for the measurement deviation of the micro-hole area (especially the non-occupied state in the edge pixels), the present invention can also provide accurate calculation parameters for correction. When multiple cameras are used in combination, the present invention can also calculate and correct the overlap of the measurement area to ensure the consistency and accuracy of the overall measurement.

[0044] It is particularly worth mentioning that the present invention also has the ability to process spot projection mapping when the micro-hole target being measured is smaller than one pixel. This is a mature technology, so it will not be described in detail. Through the precise calculation method in mature and known computer software, the relevant calculation parameters such as the length, width, and area of ​​the micro-hole target can be calibrated and corrected, thereby further improving the detection accuracy and reliability of the pinhole detection device. In summary, the automatic spot inspection and calibration system of the present invention provides strong support for the pinhole detection device with its comprehensive spot inspection function and precise calibration capability, ensuring the normal and accurate online detection process.

[0045] In one embodiment, the pinhole detection device includes a mounting frame, and belt conveying rollers 9 are provided at both ends of the mounting frame, wherein a synchronous encoder wheel 8 is provided above the end of one of the belt conveying rollers 9, and the synchronous encoder wheel 8 is connected to an encoder 7, which can realize the detection of the conveying rate of the belt 10; the mounting frame includes a left side plate 1 and a right side plate 2, and the left side plate 1 and the right side plate 2 are connected above by a top plate, and a laser ranging sensor can be set at the bottom of the top plate, which can detect the distance between it and the belt or the calibration sample hole plate 11, so as to facilitate the determination of the image acquisition distance of the camera; the pinhole detection visual detection device includes a camera and a light source 6; in this embodiment, two cameras are set on the top plate, namely a first camera 51 and a second camera 52, and the left side plate 1 A left light source adjustment plate 3 is connected to the bottom by bolts, a right light source adjustment plate 4 is connected to the bottom of the right side plate 2 by bolts, and a plurality of mounting holes are arranged on the left side plate 1 and the right side plate 2. Therefore, by adjusting the left light source adjustment plate 3 to be connected to different mounting holes of the left side plate 1, and the right light source adjustment plate 4 to be connected to different mounting holes of the right side plate 2, the height position of the light source 6 can be adjusted; the light source 6 can be an LED lamp tube, which is horizontally arranged between the left light source adjustment plate 3 and the right light source adjustment plate 4, and the light source 6 is located below the pinhole detection position of the strip 10, which is used to provide a light source 6 to illuminate the bottom of the strip or the calibration sample hole plate 11, so that the pinhole is clearer, which is convenient for the first camera 51 and the second camera 52 to collect the pinhole image.

[0046] When the pinhole detection device is working, the material strip 10 enters the pinhole detection device from the bottom of the material conveying roller 9 at one end, and then is conveyed out through the upper part of the material conveying roller 9 at the other end. During this period, the first camera 51 and the second camera 52 on the top plate of the pinhole detection device collect image information of the material strip 10 and transmit it to the data processing and control system to detect its pinhole defects. The pinhole detection device and its working principle are mature technologies and are not described in detail. When the pinhole detection device reaches the inspection and maintenance cycle time point, or the operator finds that it has an abnormal response, the system switches to the automatic inspection and calibration state, removes the material strip 10, and starts the automatic inspection and calibration system of the present invention. The calibration sample hole plate 11 simulates the detection object in the actual production process, and performs a comprehensive inspection and calibration on the pinhole detection device to ensure that it is in an accurate detection and measurement state.

[0047] In order to prevent the device of the present invention from interfering with the normal operation of the pinhole detection device, and to enable the device to be moved to the original detection position of the strip 10 in time when the pinhole detection device fails, so as to perform spot inspection and calibration, the structure of the sample well plate driving device of the present embodiment includes a transverse moving linear module 14, a transverse guide rail is provided at the bottom of the pinhole detection device, and a transverse slider of the transverse moving linear module 14 is movably connected to the transverse guide rail. The transverse slider can realize the sliding of the transverse slider along the transverse guide rail through a driving motor and a lead screw nut pair. The lead screw is arranged in parallel with the transverse guide rail, the nut on the lead screw is connected to the transverse slider, and one end of the lead screw is connected to the driving motor, so as to realize the above-mentioned function; further, the first guide plate of the lifting module 13 is arranged on the slider of the transverse moving linear module 14; a vertically arranged first linear guide rail is provided on the outer side of the first guide plate, a first slider is provided on the first linear guide rail, and the outer side of the first slider is connected to the in-and-out module 12; a first driving motor is provided on the first guide plate, and the first driving motor is a linear motor for driving the first slider to move up and down along the first linear guide rail. The lead screw nut pair can also be used here to realize this function. The entry and exit module 12 includes a second guide plate fixedly connected to the first slider, a horizontally arranged second linear guide is provided on the top of the second guide plate, a second slider is provided on the second linear guide, and the top of the second slider is connected to the calibration sample well plate 11; a second drive motor is provided on the second guide plate, and the second drive motor is a linear motor, which is used to drive the second slider to move horizontally back and forth along the second linear guide; the lifting module 13 can raise the entry and exit module 12 and the calibration sample well plate 11 to the same height as the material belt 10, and the entry and exit module 12 can drive the calibration sample well plate 11 to move horizontally to the pinhole detection position of the material belt 10; a rotating motor is provided at the bottom of the calibration sample well plate 11, and the rotating motor can drive the calibration sample well plate 11 to rotate, so as to simulate the transmission state of the material belt 10.

[0048] The data processing and control system of the present embodiment includes a data line acquisition card, a processing computer and an encoder 7; the data line acquisition card can receive the image signals of the first camera 51 and the second camera 52, the processing computer can perform image processing and analysis, and spot check and calibrate the pinhole detection device according to the image aperture measurement value; the processing computer processes the collected sample hole image, extracts the sample hole size information, compares the measurement result with the standard sample hole size, calculates the size deviation, and continuously corrects the deviation according to intelligent calculation methods such as visual spot projection and nonlinear dynamic optimization until it converges to the target range. The processing computer cooperates with the PLC control system to realize the switching of the working state between the device of the present invention and the pinhole detection device, and control the movement of each module of the device of the present invention; the processing computer automatically records the data of each spot check and calibration, including the detection time, detection result, calibration parameters, etc.; according to the detection result and calibration result, it provides corresponding feedback and prompt information, such as qualified detection, calibration required, etc. After each spot check and calibration, it automatically shuts down or enters the initialization standby state and waits for startup. The mature software built into the processing computer can automatically determine the outer boundary of the calibration sample well plate 11 imaging, and perform flat field correction according to the signal state to ensure that the detected pinhole size is consistent with the measured size at the edge and away from the edge area. The mature software built into the processing computer is equipped with an automatic identification function for micro-hole detection interference, which can automatically eliminate interference signals and ensure the authenticity, stability and effectiveness of the automatic inspection and calibration process.

[0049] The present invention also provides an automatic spot inspection and calibration method, comprising the following steps:

[0050] Step 1: System startup and initialization;

[0051] Step 2: Enter the automatic inspection and calibration state; when the pinhole detection device reaches the inspection and maintenance cycle time point, or the operator finds that it has an abnormal response, it automatically or manually switches to the automatic inspection and calibration state; the material belt 10 automatically withdraws from the production area to make room for the calibration sample hole plate 11;

[0052] Step 3: The sample well plate driving device moves the calibration sample well plate 11 to the position where the pinhole detection of the material belt 10 is located;

[0053] Step four, the rotating motor controls the calibration sample well plate 11 to rotate, simulating the linear transmission state and linear transmission speed of the material 10. The rotating motor adopts a stepper motor or a servo motor. The stepper motor or the servo motor moves and drives the controller connected to it to send a pulse signal to the first camera 51 and the second camera 52. After the camera receives the pulse signal, it waits for the automatic calibration start signal. When the processing computer determines that the rotation speed of the calibration sample well plate 11 reaches the specified speed based on the data of the controller, the automatic calibration start signal is sent through the PLC control system, and the camera collects the image.

[0054] The first camera 51 and the second camera 52 of this embodiment are both line scanning cameras; the acquisition speed of the first camera 51 and the second camera 52 is controlled by the pulse signal generated by the motor controller when the stepper motor or the servo motor moves. When the stepper motor or the servo motor drives the calibration sample well plate 11 to rotate, the motor controller generates a pulse signal to synchronously drive the line trigger acquisition operation of the first camera 51 and the second camera 52. In the process, in order to match the pulse signal with the line trigger acquisition frequency of the camera, the diameter of the calibration sample well plate 11 can be recalculated and designed, the rotating motor model of the calibration sample well plate 11 can be replaced, or the trigger signal pulse frequency converter inside the camera can be replaced, so that the pulse signal is synchronized with the line trigger acquisition frequency of the camera. This is a mature technology and will not be elaborated on; when the rotation speed of the calibration sample well plate 11 does not match the actual speed of the material 10, it can be adjusted by the frequency division and frequency multiplication parameters configured by the camera. The camera is connected to the processing computer through a wire, and the collected image data can be transmitted to the processing computer;

[0055] Step 5: Image processing and analysis: The processing computer receives the image signal from the camera, performs image processing and analysis, calculates the pore size of the micropores through an algorithm, and compares it with the actual size;

[0056] Step 6: parameter adjustment and calibration; if the aperture measurement deviation is found to be out of range, the aperture measurement parameters are adjusted automatically or manually; the steps of image acquisition, processing and analysis are repeated until the aperture measurement deviation is within the allowable range, at which point the automatic spot check and calibration of the current position is completed;

[0057] Step 7, lateral movement and multi-point detection; the lateral movement linear module 14 is started to drive the calibration sample well plate 11 to move at a uniform speed along the axial direction of the belt conveyor roller 9. During the movement, steps 4 to 6 are repeated evenly at different positions according to the set spacing; when the calibration sample well plate 11 moves to the overlapping area, the first camera 51 and the second camera 52 can detect two identical calibration holes at the same time, and the software in the processing computer will automatically determine that the micropores appear in the first camera 51 and the second camera 52 at the same time. At this time, the position of the lateral movement linear module 14 is recorded as position A, and the position A is used as the position B. The calculation starts from the position, and the transversely moving linear module 14 continues to move in translation until the software determines that the situation in which the micropores are synchronously detected by the first camera 51 and the second camera 52 disappears. At this time, the position B of the transversely moving linear module 14 is calculated, and the position difference between position B and position A is the overlap amount. This method is not limited by the number of cameras. Combined with the calibration position information that appears at the same time, it can automatically measure and give the overlap amount calculation. After the automatic calibration action is completed, when switching to the online detection process, the calibration parameter value of the overlap amount will be automatically updated to the configuration parameters of the pinhole detection device and put into use.

[0058] Step eight, system reset and state switching; after all position points are automatically inspected and calibrated, the processing computer controls the PLC controller to drive the calibration sample well plate 11 to withdraw to the initial position; the state of the pinhole detection device is switched to the online production detection state, at which time the strip 10 can be normally transmitted again, and the pinhole detection of the strip 10 can be performed; at this time, the square wave pulse signal generated by the synchronous encoder wheel 8 driving the encoder 7 controls the operation of the first camera 51 and the second camera 52. At this time, the acquisition speed of the first camera 51 and the second camera 52 is determined by the movement speed of the synchronous encoder wheel 8. Since the synchronous encoder wheel 8 has the same speed as the strip 10, it is determined by the movement speed of the strip 10.

[0059] The present invention applies optical visual detection technology to the auxiliary inspection and calibration of the pinhole detection device. The detection object (such as aluminum foil) of the pinhole detection device is simulated by rotating the calibration sample well plate 11, and the standard micropore image on the calibration sample well plate 11 is automatically photographed by a camera. Then, the computer system processes and analyzes the image, determines the size of the measurement hole, and compares it with the preset standard size. If it is found that the deviation exceeds the allowable range, the computer system automatically calibrates the detection parameters of the pinhole detection device to ensure that it is always in an accurate detection state. Optical visual detection technology is a technology that uses optical principles to perform non-contact detection of objects. It captures the image of the object through a camera, and then uses an image processing algorithm to analyze and process the image, thereby realizing the measurement and judgment of parameters such as object size, shape, and defects. This technology has the advantages of non-contact, high precision, and high speed. It has been widely used in the field of industrial automation and is a mature technology, so it will not be described in detail.

[0060] The present invention can significantly improve the detection accuracy and stability of the pinhole detection device, reduce the cases of false detection and missed detection. At the same time, it realizes automatic operation and reduces the cost and risk of manual intervention. In addition, through the functions of flat field correction and automatic interference identification, the accuracy and reliability of the system are further improved.

[0061] The present invention uses specific examples to illustrate the principles and implementation methods of the present invention. The above examples are only used to help understand the method and core ideas of the present invention. At the same time, for those skilled in the art, according to the ideas of the present invention, there will be changes in the specific implementation methods and application scope. In summary, the content of this specification should not be understood as limiting the present invention.

Claims

1. An automatic spot inspection and calibration system, characterized in that: include: A calibration sample hole plate, which is provided with micro-holes to simulate pinhole defects on the surface of the strip; The sample hole plate driving device is arranged at the bottom of the pinhole detection device, and can drive the calibration sample hole plate to move to the position where the material pinhole detection is located; A pinhole detection visual inspection device, which is arranged on the pinhole detection device and can collect micro-holes on the calibration sample well plate; The data processing and control system can receive the image signal of the pinhole detection visual inspection device, and perform image processing, analysis, spot inspection and calibration of the pinhole detection device.

2. The automatic inspection and calibration system according to claim 1, characterized in that: The sample well plate driving device includes a lifting module, on which an in-and-out module is provided, and the calibration sample well plate is horizontally arranged on the in-and-out module; the lifting module can lift the in-and-out module and the calibration sample well plate to a position at the same height as the material, and the in-and-out module can drive the calibration sample well plate to move horizontally to a pinhole detection position with the material; a rotating motor is provided at the bottom of the calibration sample well plate, and the rotating motor can drive the calibration sample well plate to rotate.

3. The automatic inspection and calibration system according to claim 2, characterized in that: It also includes a transverse moving linear module, a transverse guide rail is provided at the bottom of the pinhole detection device, the transverse moving linear module is movably connected to the transverse guide rail, and the lifting module is arranged on the transverse moving linear module; the transverse moving linear module can drive the lifting module, the in-and-out module and the calibration sample hole plate to move at a uniform speed along the axial direction of the material conveying roller.

4. The automatic inspection and calibration system according to claim 3, characterized in that: The lifting module includes a first guide rail plate connected to the horizontal linear moving module, a vertically arranged first linear guide rail is provided on the outer side of the first guide rail plate, a first slider is provided on the first linear guide rail, and the outer side of the first slider is connected to the entry and exit module; a first drive motor is provided on the first guide rail plate, and the first drive motor is used to drive the first slider to move up and down along the first linear guide rail.

5. The automatic inspection and calibration system according to claim 4, characterized in that: The entry and exit module includes a second guide plate fixedly connected to the first slider, a horizontally arranged second linear guide is provided on the top of the second guide plate, a second slider is provided on the second linear guide, and the top of the second slider is connected to the calibration sample well plate; a second drive motor is provided on the second guide plate, and the second drive motor is used to drive the second slider to move horizontally forward and backward along the second linear guide.

6. The automatic inspection and calibration system according to claim 1, characterized in that: The pinhole detection device includes a mounting frame, and belt conveyor rollers are provided at both ends of the mounting frame, wherein a synchronous encoder wheel is provided above the end of one of the belt conveyor rollers, and the synchronous encoder wheel is connected to an encoder; the mounting frame includes a left side plate and a right side plate, and the left side plate and the right side plate are connected above by a top plate.

7. The automatic inspection and calibration system according to claim 6, characterized in that: The pinhole detection visual inspection device includes a camera and a light source; the camera is arranged on the top plate, a left light source adjustment plate is connected to the bottom of the left side plate, a right light source adjustment plate is provided at the bottom of the right side plate, the light source is horizontally arranged between the left light source adjustment plate and the right light source adjustment plate, and the light source is located below the pinhole detection position of the material strip.

8. The automatic inspection and calibration system according to claim 7, characterized in that: The data processing and control system includes a data line acquisition card, a processing computer and the encoder; the data line acquisition card can receive the image signal of the camera, and the processing computer can perform image processing and analysis, and inspect and calibrate the pinhole detection device according to the image aperture measurement value.

9. The automatic inspection and calibration system according to claim 8, characterized in that: The processing computer can automatically determine the outer boundary of the calibration sample well plate imaging and perform flat field correction according to the signal state; and the processing computer can automatically eliminate interference signals.

10. An automatic spot inspection and calibration method, characterized in that: The steps include: Step 1: System startup and initialization; Step 2: Enter the automatic inspection and calibration state; when the pinhole detection device reaches the inspection and maintenance cycle time point, or the operator finds that it has an abnormal response, it automatically or manually switches to the automatic inspection and calibration state; the material is automatically withdrawn from the production area to make room for the calibration sample hole plate; Step 3: The sample well plate driving device moves the calibration sample well plate to the position where the material pinhole detection is located; Step 4: The calibration sample well plate rotates to simulate the linear transmission state of the material, and the camera collects images at the same time; Step 5: Image processing and analysis: The processing computer receives the image signal from the camera, performs image processing and analysis, calculates the pore size of the micropores through an algorithm, and compares it with the actual size; Step 6: parameter adjustment and calibration; If the aperture measurement deviation is found to be out of range, the aperture measurement parameters are adjusted automatically or manually; the steps of image acquisition, processing and analysis are repeated until the aperture measurement deviation is within the allowable range; Step 7, lateral movement and multi-point detection: The lateral movement linear module is started to drive the calibration sample well plate to move at a uniform speed along the axis direction of the material conveying roller. During the movement, steps 4 to 6 are repeated evenly at different positions according to the set spacing; Step 8: System reset and state switching; After all the position points are automatically inspected and calibrated, the calibration sample well plate is withdrawn to the initial position; Switch the state of the pinhole detection device to the online production detection state.

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