Full-automatic rotating disc type detection machine

Abstract

The invention relates to a full-automatic rotating disc type detection machine, and discloses a die cutting sheet automatic optical detection method and equipment thereof, when products are detected to be unqualified, qualified products, surface defect unqualified products and size unqualified products can be automatically sorted and classified and stacked, the efficiency is improved, the detection precision is ensured, and the production efficiency is improved. A 12 million-pixel industrial camera is adopted for detection, the dimensional tolerance can reach + / -0.02 mm, the area tolerance can reach 0.01 mm < 2 >, automatic detection of six failure modes of size, missing, overlapping, smudginess, foreign matter, reversing, waste and bubbles of products on die cutting sheets can be achieved, manpower is reduced, quality control is improved, the detection speed can reach 900 pcs / h, and the detection rate reaches 99.9% or above.

Description

Technical Field

[0001] The invention relates to a visual detection method and equipment for sheet-like planar materials, belonging to the technical field of automatic detection equipment for sheet-like planar materials. Background Art

[0002] As for sheet-like planar materials, they are one of the indispensable materials for remote controllers, printers, computers, mobile phones, etc. They are used to make circuits and circuit switching devices on remote controllers, printers, computers, mobile phones. At present, for the production of sheet-like planar materials, in the final process after the production is completed, the sheet needs to be inspected in order to detect the product conditions, product positions, foreign objects, etc. on it. At present, this kind of inspection is generally completed manually, and the efficiency of manual inspection is low, which is difficult to meet the production requirements of automated production lines.

[0003] In view of the above problems, the present invention provides an automatic optical detection method and device for sheet-like planar materials, so as to improve the automatic detection efficiency of sheet-like planar materials. Summary of the invention

[0004] To achieve the above purpose, the present invention provides the following technical solution: an automatic optical detection method for sheet-like planar materials, characterized in that the method uses a visual light source system to detect products on sheet-like planar materials, taking the product as sheet-like planar materials as an example, and the detection object at least includes the analysis and detection of the size, missing, overlapping, foreign matter, reverse, waste, dirt, and bubbles of the sheet-like planar materials. It includes the following steps:

[0005] (1) Material lifting: The material lifting system of the silo lifts the flat sheet material to the height to be taken;

[0006] (2) Material collection: The material collection and discharge system sucks the product from the silo and moves it to the turntable station platform;

[0007] (3) Image capture: After the material is collected, the PLC sends a signal to take a picture, and the industrial camera of the visual light source system takes a picture and captures the image;

[0008] (4) Image processing: The image processing module processes the image and sends it to the PLC after the image processing is completed;

[0009] (5) Conveying: The turntable rotates and is conveyed to the designated sorting and unloading station according to the PLC instructions;

[0010] (6) Sorting: If the product is qualified, the host computer sends an OK signal to the PLC, causing the turntable to rotate to the OK sorting station, and the cylinder moves to the top of the flat sheet material, and the flat sheet material is sucked by the suction nozzle, and then the cylinder moves to the top of the silo to put the flat sheet material into the OK silo; if the product is unqualified due to surface defects, the host computer sends a surface defect NG signal to the PLC, causing the turntable to rotate to the surface defect NG sorting station, and the cylinder moves to the top of the flat sheet material, and the flat sheet material is sucked by the suction nozzle, and then the cylinder moves to the top of the silo to put the flat sheet material into the surface defect NG silo; if the product is unqualified in size, the host computer sends a size NG signal to the PLC, causing the turntable to rotate to the size NG sorting station, and the cylinder moves to the top of the flat sheet material, and the flat sheet material is sucked by the suction nozzle, and then the cylinder moves to the top of the silo to put the flat sheet material into the size NG silo;

[0011] Further, as a preference, the analysis and detection of the size detection of the sheet-like planar material comprises the following steps:

[0012] (i) Manually frame the inspection area of ​​the sheet-like flat material;

[0013] (ii) Calibrate the detection area and convert the pixel size into the actual size in mm

[0014] (iii) The system searches for all products that need to be inspected in the framed area and performs image shape correction;

[0015] (iiii) fitting the objects to be measured, setting a measurement group consisting of two measurement objects, and measuring the dimensions between the two objects in each group;

[0016] The framed inspection area includes the boundary of the product to be inspected.

[0017] Further, preferably, the analysis and detection of missing sheet-like planar material comprises the following steps:

[0018] (a) Setting the detection area of ​​sheet-like planar materials;

[0019] (aa) Select about 15 qualified sheet-shaped planar materials for feature training to generate a standard image of qualified products;

[0020] (aaa) Set the judgment threshold to perform difference analysis and detection. If the difference characteristics between the area to be detected and the same area of ​​the standard image exceed the range set by the threshold, it is judged as unqualified.

[0021] The framed detection area includes the product boundary and the detection boundary of each sheet-like flat material; the detection area difference threshold can be set according to the product situation.

[0022] Further, preferably, the analysis and detection of overlapping of sheet-like planar materials comprises the following steps:

[0023] (b) setting a detection area for sheet-like planar materials;

[0024] (bb) selecting about 15 qualified sheet-shaped planar materials for feature training to generate a standard image of qualified products;

[0025] (bbb) Set a judgment threshold to perform difference analysis and detection. If the difference characteristics between the area to be detected and the same area of ​​the standard image exceed the range set by the threshold, it is judged as unqualified.

[0026] The framed detection area includes the product boundary and the detection boundary of each sheet-like flat material; the detection area difference threshold can be set according to the product situation.

[0027] Further, as a preference, the analysis and detection of foreign matter comprises the following steps:

[0028] (c) setting a detection area for sheet-like planar materials;

[0029] (cc) Select about 15 qualified sheet-shaped planar materials for feature training to generate a standard image of qualified products;

[0030] (ccc) Set the judgment threshold to perform difference analysis and detection. If the difference characteristics between the area to be detected and the same area of ​​the standard image exceed the range set by the threshold, it is judged as unqualified.

[0031] The framed detection area includes the product boundary and the detection boundary of each sheet-like flat material; the detection area difference threshold can be set according to the product situation.

[0032] Further, preferably, the reverse analysis and detection of the sheet-like planar material comprises the following steps:

[0033] (d) setting a detection area for sheet-like planar materials;

[0034] (dd) Select about 15 qualified sheet-shaped planar materials for feature training and generate a standard image of qualified products;

[0035] (ddd) Set the judgment threshold for difference analysis and detection. If the difference characteristics between the area to be detected and the same area of ​​the standard image exceed the range set by the threshold, it is judged as unqualified.

[0036] The framed detection area includes the product boundary and the detection boundary of each sheet-like flat material; the detection area difference threshold can be set according to the product situation.

[0037] Further, as a preference, the analysis and detection of waste materials comprises the following steps:

[0038] (e) setting a detection area for sheet-like planar materials;

[0039] (ee) selecting about 15 qualified sheet-shaped planar materials for feature training and generating a standard image of qualified products;

[0040] (eee) Set a judgment threshold to perform difference analysis and detection. If the difference characteristics between the area to be detected and the same area of ​​the standard image exceed the range set by the threshold, it is judged as unqualified.

[0041] The framed detection area includes the product boundary and the detection boundary of each sheet-like flat material; the detection area difference threshold can be set according to the product situation.

[0042] Further, preferably, the analysis and detection of dirt includes the following steps:

[0043] (f) setting a detection area for sheet-like planar materials;

[0044] (ff) selecting about 15 qualified sheet-shaped planar materials for feature training to generate a standard image of qualified products;

[0045] (fff) Set a judgment threshold to perform difference analysis and detection. If the difference characteristics between the area to be detected and the same area of ​​the standard image exceed the range set by the threshold, it is judged as unqualified.

[0046] The framed detection area includes the product boundary and the detection boundary of each sheet-like flat material; the detection area difference threshold can be set according to the product situation.

[0047] Further, preferably, the analysis and detection of bubbles comprises the following steps:

[0048] (g) setting a detection area for sheet-like planar materials;

[0049] (gg) Select about 15 qualified sheet-shaped planar materials for feature training and generate a standard image of qualified products;

[0050] (ggg) Set the judgment threshold for difference analysis and detection. If the difference characteristics between the area to be detected and the same area of ​​the standard image exceed the range set by the threshold, it is judged as unqualified.

[0051] The framed detection area includes the product boundary and the detection boundary of each sheet-like flat material; the detection area difference threshold can be set according to the product situation.

[0052] Furthermore, the present invention provides a device used in the automatic optical detection method of sheet-like planar materials, characterized in that the device includes a frame, a silo, a material ejection system, a material retrieving system, a conveying system, a work station platform, a sorting system, a visual camera light source system, a PLC control system and a touch screen display, wherein:

[0053] The rack is equipped with the material bin, material ejection system, material retrieving system, conveying system, work station platform, sorting system, visual camera light source system, PLC control system and touch screen display;

[0054] There are 4 silos in total, which are placed on the same side as the feeding system and the sorting system;

[0055] The material ejection system is located directly in front of the frame;

[0056] The material taking system is on the same side as the material pushing system. After the material pushing system pushes the sheet-like planar material to a specified position, the material taking system performs a material taking action.

[0057] The conveying system is located at the center of the frame;

[0058] There are 4 workstation platforms in total, which are located in the conveying system;

[0059] The sorting system is located on the remaining three surfaces inside the rack;

[0060] The visual camera light source system is connected to the PLC control system and is on the same side as the material taking system, so as to facilitate imaging detection immediately after material taking is completed;

[0061] The touch screen display is connected to the PLC control system, and can monitor the operation of the equipment in real time. In the equipment debugging state, the feeding system, conveying system, visual camera light source system and sorting system can be manually controlled.

[0062] Further, as a preferred embodiment, the ejection system pushes the support plate through a stepping electric cylinder to complete the ejection action;

[0063] The material taking system drives the suction cups through the y-axis and z-axis cylinders to grab the sheet-like planar material and place it on the workstation platform, and then the visual camera light source starts to take pictures and take images, and after the pictures are taken, they are transmitted to the designated sorting system;

[0064] The conveying system conveys the sheet-like planar materials to the designated sorting system by rotating the circular turntable;

[0065] The working platform is located in the conveying system and has a hole size of 210mm*110mm. High-transmittance tempered glass is inlaid in the hole. There are 4 holes in total, one evenly distributed every 90°.

[0066] The sorting system has three in total, and the suction cups are driven by the y-axis and z-axis cylinders to grab the sheet-like planar materials and place them in the silo;

[0067] The visual light source system at least includes a high-definition camera and a light source. The high-definition camera includes but is not limited to a 12-megapixel industrial camera with a resolution of 4096*3000. The light source includes but is not limited to a blue backlight.

[0068] Compared with the prior art, the present invention has the following beneficial effects:

[0069] When the present invention detects that the product is unqualified, it can automatically identify the unqualified surface defects and unqualified size products, improve efficiency and ensure detection accuracy. The present invention uses a 12 million pixel industrial camera for detection, and the size tolerance can reach ±0.02mm and the area tolerance is 0.01mm. 2 , reducing manual work and improving quality control. The present invention can realize automatic detection of eight failure modes of product size, missing, overlapping, foreign matter, reverse, waste, dirt and bubbles on sheet-like flat materials. The detection speed of the present invention can reach 900pcs / h, and the detection rate can reach more than 99.9%. BRIEF DESCRIPTION OF THE DRAWINGS

[0070] Figure 1 It is a schematic diagram of the appearance structure of the fully automatic turntable type detection machine of the present invention;

[0071] Figure 2 It is a schematic diagram of the structure of the material taking device and the optical imaging device of the fully automatic turntable type detection machine of the present invention;

[0072] Figure 3 It is a structural schematic diagram of the sorting device and the conveying device of the fully automatic turntable type detection machine of the present invention;

[0073] Figure 4 It is a structural schematic diagram of the material ejection device of the fully automatic turntable type inspection machine of the present invention;

[0074] Figure 5 It is a schematic diagram of the work flow structure of the fully automatic turntable type detection machine of the present invention;

[0075] Figure 6 It is a schematic diagram of the main parameters and indicators of the fully automatic turntable type testing machine of the present invention; DETAILED DESCRIPTION

[0076] 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.

[0077] The present invention provides a technical solution: Figure 1 -Attached Figure 6 The optical inspection device used in the automatic optical inspection method for sheet-like planar materials of the present invention comprises a frame 1; a display screen 2; a material taking device 3; a silo 4; an optical imaging device 5; a conveying device 6; an operation station platform 7; a qualified product sorting device 8; a surface defect unqualified product sorting device 9; a size unqualified product 10; a material ejecting device 11; wherein a display screen 2 is provided at one corner of the frame 1; a material taking device 3 is provided inside the frame 1; a silo 4; an optical imaging device 5; a conveying device 6; an operation station platform 7; a qualified product sorting device 8; a surface defect unqualified product sorting device 9; a size unqualified product sorting device 10; a material ejecting device 11 1; the material taking device 3 is arranged at one side inside the frame 1; the optical imaging device 5 is arranged above the material taking device 3; the conveying device 6 is arranged in the middle position inside the frame 1; the work station platform 7 is arranged on the platform of the conveying device 6, separated by 90°, a total of four; the qualified product sorting device 8 is arranged at 90° on the left side of the material taking device 3; the surface defect unqualified product sorting device 9 is arranged directly opposite to the material taking device 3; the size unqualified product sorting device 10 is arranged at 90° on the right side of the material taking device 3; the lifting device 11 is arranged below the material taking device 3;

[0078] In this embodiment: the display screen 2 can freely adjust the angle and position of the display screen through the rocker; it is fixed to the frame 1 by screws; the silo plays the role of limiting the material taking and discharging; the material taking device 3 plays the role of sucking the flat sheet material from the silo 4 to the work station platform 7; the surface defect unqualified product sorting device 9 and the size unqualified product sorting device 10 play the role of sucking the flat sheet material from the work station platform 7 to the silo 4 after reaching the corresponding work sorting device according to the program judgment result; the lifting device 11 plays the role of pushing the product to be tested to a specified height to facilitate the material taking device 3 to suck;

[0079] The optical imaging device 5 at least includes a high-definition camera and a light source. The high-definition camera is a 12-megapixel industrial camera with a resolution of 4096*3000. The light source is a blue backlight. In this embodiment, the parameter indicators of the fully automatic turntable inspection machine are as follows: Figure 6 .

[0080] When the present invention detects that a product is unqualified, it can automatically sort qualified products, unqualified products with surface defects, and unqualified products with dimensions for classification and stacking, thereby improving efficiency while ensuring detection accuracy. The present invention uses a 12-megapixel industrial camera for detection, with a size tolerance of ±0.02mm and an area tolerance of 0.01mm. 2 , reducing manual work and improving quality control. The present invention can realize automatic detection of eight failure modes of product size, missing, overlapping, foreign matter, reverse, waste, dirt and bubbles on die-cut materials. The detection speed of the present invention can reach 10m / min, and the detection rate can reach more than 99.9%.

[0081] Although embodiments of the present invention have been shown and described, it will be appreciated by those skilled in the art that various changes, modifications, substitutions and variations may be made to the embodiments without departing from the principles and spirit of the present invention, and that the scope of the present invention is defined by the appended claims and their equivalents.

Claims

1. The present invention discloses a visual inspection device for sheet-like planar materials, which can automatically load, inspect, and sort sheet-like products, improves inspection efficiency and saves labor costs, avoids mis-inspection caused by human factors, and is mainly used for efficiently inspecting the appearance anomalies and sizes of sheet-like materials, and includes the following devices: 1) Automatic adsorption device: For film-like sheet materials, the Y-axis and Z-axis front and back and up and down cylinders are used for operation, and multiple specifications of suction nozzles are used for vacuum adsorption; 2) Conveying device: It adopts turntable uniform speed transmission, and adopts reduction motor and cam divider to ensure the consistency of the turntable rotation angle each time; 3) Material limiting device: limit the position of each loading to prevent the product to be tested from deviating from the detection range; 4) Workstation platform: This equipment is equipped with 4 workstations on the turntable conveyor, namely, loading station, unloading station for OK products, unloading station for defective products in appearance, and unloading station for defective products in size. There is one station every 90 degrees, evenly arranged. Each station is a rectangular opening of 210mm*110mm. High-transmittance tempered glass is inlaid in the opening. Sheet materials are placed above the tempered glass for inspection and unloading sorting. 5) Optical imaging device: using industrial high-speed cameras and lenses, equipped with backlight sources, to perform imaging detection on sheet materials that reach the bottom of the optical imaging device; 6) Automatic sorting device: It uses the Y-axis and Z-axis front and back and upper and lower cylinders to operate, and uses multiple specifications of suction nozzles to use vacuum adsorption to sort the sheet materials that arrive at the designated station according to computer instructions; 7) Computer identification device: Identify the captured image according to the pre-entered inspection requirements and display the defective area on the display.

2. A method for automatic optical detection of sheet-like planar materials, characterized in that: The method uses a visual light source system to detect sheet-like planar materials, taking product die-cut sheet materials as an example, and the detection object at least includes the analysis and detection of the size, missing, overlapping, foreign matter, reverse, waste, dirt, and bubbles of the sheet-like planar materials, which includes the following steps: 1) Material lifting: The material lifting system of the silo lifts the flat sheet material to the height to be taken; 2) Material collection: The material collection and discharge system sucks the product from the silo and moves it to the turntable station platform; 3) Image capture: After the material is taken, the PLC sends a photo signal, and the industrial camera of the visual light source system takes photos and captures images; 4) Image processing: The image processing module processes the image and sends it to the PLC after the image processing is completed; 5) Conveying: The turntable rotates and is conveyed to the designated sorting and unloading station according to the PLC instructions; 6) Sorting: After the sheet material arrives at the unloading station specified by the PLC, the cylinder moves to the top of the flat sheet material, sucks the flat sheet material with a suction nozzle, and then moves to the top of the silo to put the flat sheet material into the silo; The image processing step at least includes the analysis and detection of the size, missing, overlapping, foreign matter, reversal, waste, dirt and bubbles of the sheet-like planar material.

3. The automatic optical detection method for sheet-like planar materials according to claim 2, characterized in that: The analysis and detection of the size detection of sheet flat materials includes the following steps: 1) Manually frame the inspection area of ​​flaky flat materials; 2) Calibrate the detection area and convert the pixel size into the actual size in mm 3) The system searches for all products that need to be inspected in the area according to the framed area and performs image shape correction; 4) Fit the objects to be measured, set a measurement group consisting of two measurement objects, and measure the size between the two objects in each group; The framed inspection area includes the boundary of the product to be inspected.

4. The automatic optical detection method for sheet-like planar materials according to claim 2, characterized in that: The analysis and detection of missing sheet material includes the following steps: 1) Set the detection area of ​​flaky flat materials; 2) Select about 15 qualified sheet-shaped flat materials for feature training to generate a standard image of qualified products; 3) Set a judgment threshold to perform difference analysis and detection. If the difference between the area to be detected and the same area of ​​the standard image exceeds the range set by the threshold, it is judged as unqualified; The framed detection area includes the product boundary and the detection boundary of each sheet-like flat material; the detection area difference threshold can be set according to the product situation.

5. The automatic optical detection method for sheet-like planar materials according to claim 2, characterized in that: The analysis and detection of overlap of sheet-like planar materials includes the following steps: 1) Set the detection area of ​​flaky flat materials; 2) Select about 15 qualified sheet-shaped flat materials for feature training to generate a standard image of qualified products; 3) Set a judgment threshold to perform difference analysis and detection. If the difference characteristics between the area to be detected and the same area of ​​the standard image exceed the range set by the threshold, it is judged as unqualified.

6. The automatic optical detection method for sheet-like planar materials according to claim 2, characterized in that: The analysis and detection of foreign matter includes the following steps: 1) Set the detection area of ​​flaky flat materials; 2) Select about 15 qualified sheet-shaped flat materials for feature training to generate a standard image of qualified products; 3) Set a judgment threshold to perform difference analysis and detection. If the difference characteristics between the area to be detected and the same area of ​​the standard image exceed the range set by the threshold, it is judged as unqualified.

7. The automatic optical detection method for sheet-like planar materials according to claim 2, characterized in that: Reverse analysis and detection includes the following steps: 1) Set the detection area of ​​flaky flat materials; 2) Select about 15 qualified sheet-shaped flat materials for feature training to generate a standard image of qualified products; 3) Set a judgment threshold to perform difference analysis and detection. If the difference characteristics between the area to be detected and the same area of ​​the standard image exceed the range set by the threshold, it is judged as unqualified.

8. The automatic optical detection method for sheet-like planar materials according to claim 2, characterized in that: The analysis and testing of waste materials includes the following steps: 1) Set the detection area of ​​flaky flat materials; 2) Select about 15 qualified sheet-shaped flat materials for feature training to generate a standard image of qualified products; 3) Set a judgment threshold to perform difference analysis and detection. If the difference characteristics between the area to be detected and the same area of ​​the standard image exceed the range set by the threshold, it is judged as unqualified.

9. The automatic optical detection method for sheet-like planar materials according to claim 2, characterized in that: The analysis and detection of dirt includes the following steps: 1) Set the detection area of ​​flaky flat materials; 2) Select about 15 qualified sheet-shaped flat materials for feature training to generate a standard image of qualified products; 3) Set a judgment threshold to perform difference analysis and detection. If the difference characteristics between the area to be detected and the same area of ​​the standard image exceed the range set by the threshold, it is judged as unqualified.

10. The automatic optical detection method for sheet-like planar materials according to claim 2, characterized in that: The analysis and detection of bubbles includes the following steps: 1) Set the detection area of ​​flaky flat materials; 2) Select about 15 qualified sheet-shaped flat materials for feature training to generate a standard image of qualified products; 3) Set a judgment threshold to perform difference analysis and detection. If the difference characteristics between the area to be detected and the same area of ​​the standard image exceed the range set by the threshold, it is judged as unqualified.

11. The device used in the automatic optical detection method of sheet-like planar materials according to any one of claims 1 to 10, characterized in that: The equipment includes a rack, a silo, a material ejection system, a material retrieving system, a conveying system, a workstation platform, a sorting system, a visual camera light source system, a PLC control system and a touch screen display, among which: 1) The rack is equipped with the silo, material ejection system, material retrieving system, conveying system, work station platform, sorting system, visual camera light source system, PLC control system and touch screen display; 2) There are 4 silos in total, which are placed on the same side as the feeding system and the sorting system; 3) The material ejection system is located directly in front of the frame; 4) The material taking system and the material pushing system are on the same side, and after the material pushing system pushes the sheet-like flat material to a designated position, the material taking system performs a material taking action; 5) The conveying system is located at the center of the frame; 6) There are 4 workstation platforms in total, which are located in the conveying system; 7) The sorting system is located on the remaining three surfaces inside the rack; 8) The visual camera light source system is connected to the PLC control system and is on the same side as the material taking system, so as to facilitate imaging detection immediately after the material taking is completed; 9) The touch screen display is connected to the PLC control system to monitor the operation of the equipment in real time, and in the equipment debugging state, it can manually control the feeding system, conveying system, visual camera light source system and sorting system.

12. The automatic optical inspection device for sheet-like planar materials according to claim 11, characterized in that: 1) The ejection system pushes the support plate through the stepping electric cylinder to complete the ejection action; 2) The material taking system drives the suction cups through the y-axis and z-axis cylinders to grab the sheet-like planar material and place it on the workstation platform, and then the visual camera light source starts to take pictures and take pictures, and after the pictures are taken, they are transmitted to the designated sorting system; 3) The conveying system conveys the sheet-like planar material to the designated sorting system by rotating the circular turntable; 4) The working platform is located in the conveying system and the opening size is 210mm*110mm. High-transmittance tempered glass is inlaid in the hole. There are 4 openings in total, one evenly distributed every 90°; 5) There are three sorting systems in total, which use the y-axis and z-axis cylinders to drive the suction cups to grab the sheet-like flat materials and place them in the silo; 6) The visual light source system includes at least a high-definition camera and a light source. The high-definition camera includes but is not limited to a 12-megapixel industrial camera with a resolution of 4096*3000, and the light source includes but is not limited to a blue backlight.

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