Welding shaft anti-reverse device and method

Abstract

The invention provides a welding shaft anti-reversing device and method, and relates to the technical field of welding processes in injection molding production. The device comprises a welding jig, wherein a penetrating light hole is formed in the part, where a shaft to be welded is placed, of the welding jig; the image acquisition system comprises a light source and an image receiver which are arranged on the two sides of the welding jig, and the light source projects the end shape of the shaft to the image receiver through the light hole; and the image processing system is used for comparing the acquired image with a pre-stored standard image. The method comprises the steps that a shaft is placed on a welding jig; projecting the shaft end shape onto an image receiver by a light source; acquiring a projection image and comparing the projection image with a standard image; sending a matching signal to a welding control system when a comparison result meets a matching condition; the welding control system determines whether to allow the welding operation according to whether the matching signal is received. By means of the device, mistaken machining caused by reverse installation of the shaft can be effectively prevented, manual secondary inspection is reduced, and production efficiency and product quality are improved.

Description

Technical Field

[0001] The invention relates to the technical field of injection molding production, and in particular to a welding shaft anti-reverse device and method. Background Art

[0002] In the injection molding industry, welding is an important part of the product manufacturing process. During the welding process, due to the diversification of product requirements, the shapes of the shafts are often different, which brings certain challenges to the welding operation.

[0003] At present, welding jigs are widely used in the industry to position and fix workpieces to ensure welding quality. However, existing welding jigs have obvious shortcomings in preventing operating errors, especially in preventing the common problem of reverse installation of shafts. Due to the diversity of shaft shapes, the anti-reverse design principle of existing welding jigs is difficult to adapt to all types of shafts, and cannot effectively prevent operators from negligently placing the shafts backwards, resulting in misprocessing.

[0004] When the shaft is incorrectly placed in the welding fixture for processing, defective welds will be produced. More seriously, these defective welds may flow into the downstream workstation and become unqualified finished products after injection molding, resulting in material waste and reduced production efficiency. To avoid this, the existing technology mainly relies on manual secondary selection inspection after welding to screen out the welded workpieces and prevent them from flowing into the downstream workstation.

[0005] This method that relies on manual inspection has many flaws: first, manual inspection is easily affected by subjective factors, and the inspection effect is difficult to guarantee; second, it requires specialized inspectors, which consumes a lot of manpower; third, manual inspection speed is limited, which affects production efficiency; finally, long-term repetitive inspection work can easily lead to fatigue of inspectors, further reducing the accuracy of inspections. Summary of the invention

[0006] The purpose of the present invention is to provide a welding shaft anti-reverse device and method, which can effectively prevent incorrect processing caused by reverse installation of shaft parts during the welding process, reduce reliance on manual secondary inspection, and improve production efficiency and product quality.

[0007] To achieve the above object, the present invention is implemented through the following technical solutions:

[0008] A welding shaft anti-reverse device, comprising:

[0009] A welding jig is used to place the shaft to be welded, and a through light-transmitting hole is opened at the position of the welding jig where the shaft to be welded is placed;

[0010] An image acquisition system, comprising a light source and an image receiver, wherein the light source is arranged on one side of the welding jig, and the image receiver is arranged on the other side of the welding jig, and the light source projects the shape of the end of the shaft onto the image receiver through a light-transmitting hole on the welding jig;

[0011] An image processing system, electrically connected to the image receiver, for receiving an image captured by the image receiver and comparing the image with a pre-stored standard image;

[0012] The welding control system is electrically connected to the image processing system. The welding control system allows welding operation when receiving a matching signal sent by the image processing system, and prohibits welding operation when not receiving the matching signal.

[0013] Further: the image processing system comprises:

[0014] An image storage module, used for storing a standard image when the shaft is correctly placed;

[0015] An image comparison module, used for comparing the image captured by the image receiver with the standard image;

[0016] The signal generating module is used to generate the matching signal when the comparison result meets the preset matching condition.

[0017] Furthermore: the image processing system also includes a display module, which is used to display an "OK" mark when the comparison result meets the preset matching condition, and display an "NG" mark when the comparison result does not meet the preset matching condition.

[0018] Further: the welding control system comprises:

[0019] A signal receiving module, used for receiving a signal sent by the image processing system;

[0020] A control start module, used to control the start or stop of the welding machine according to the received signal;

[0021] The welding execution module is used to execute the welding operation when the control start module allows it.

[0022] Furthermore: the light source is a point light source, and the shape of the light-transmitting hole is adapted to the shape of the end of the shaft.

[0023] Furthermore: the image receiver is a CCD or CMOS image sensor.

[0024] The present invention also provides a welding shaft anti-reverse method using the welding shaft anti-reverse device, comprising the following steps:

[0025] S1: Place the shaft to be welded on the welding jig;

[0026] S2: projecting the end shape of the shaft onto an image receiver through a light source;

[0027] S3: The image receiver collects the projected image and transmits it to the image processing system;

[0028] S4: The image processing system compares the acquired projection image with the pre-stored standard image;

[0029] S5: If the comparison result meets the preset matching condition, the image processing system sends a matching signal to the welding control system;

[0030] S6: The welding control system decides whether to allow welding operation based on whether a matching signal is received

[0031] Further: the step S5 also includes:

[0032] S51: If the comparison result meets the preset matching condition, an “OK” mark is displayed;

[0033] S52: If the comparison result does not meet the preset matching condition, an “NG” mark is displayed.

[0034] Further: the step S6 comprises:

[0035] S61: If a matching signal is received, the welding operation is allowed;

[0036] S62: If no matching signal is received, the welding operation is prohibited.

[0037] Further: in step S4, the comparison includes:

[0038] S41: extracting features of the collected projection image and the pre-stored standard image;

[0039] S42: Calculate the similarity between the features;

[0040] S43: Compare the similarity with a preset threshold, and if the similarity is greater than or equal to the preset threshold, determine that the comparison result meets the preset matching condition.

[0041] Compared with the prior art, the present invention has the following beneficial effects:

[0042] 1. The present invention realizes the automatic recognition and control of the shaft placement status in the welding process by applying visual projection control technology to the field of welding reverse prevention. The technical solution adopts a combination of light source, light-transmitting hole and image receiver, which can accurately capture the characteristic shape of the shaft end and perform real-time image comparison and analysis through the control system, thereby effectively preventing the operator from placing the shaft reversely and causing misprocessing problems.

[0043] Second, the present invention can achieve the goal of 100% preventing the shaft from being reversed, effectively avoiding the situation where defective welding products flow into downstream workstations and are subsequently processed into unqualified finished products by injection molding, greatly improving product quality and production efficiency. Compared with the traditional manual secondary selection and inspection method, the present invention realizes automated detection and error-proofing control, significantly reduces the need for manual inspection, and saves a lot of manpower and material costs.

[0044] 3. The design structure of the present invention is simple, easy to implement on the existing welding fixture, convenient to operate, and highly adaptable. The device has stable and reliable performance, can meet the anti-reverse requirements of shafts of different shapes, realizes the intelligent upgrade of the welding process, and has high practical value and promotion and application prospects. BRIEF DESCRIPTION OF THE DRAWINGS

[0045] Figure 1 It is a schematic diagram of the layout structure of an image acquisition system for a welding shaft anti-reverse device;

[0046] Figure 2 It is an enlarged schematic diagram of the structure at the light transmission hole;

[0047] Figure 3 It is a schematic diagram of a system framework diagram of a welding shaft anti-reverse device;

[0048] Figure 4 A schematic diagram of a flow chart of steps of a method for preventing a welding shaft from backlashing;

[0049] In the figure:

[0050] 1. Welding jig; 2. Image receiver; 3. Light source; 4. Axis; 5. Light hole. DETAILED DESCRIPTION

[0051] The technical solution of the present invention will be described clearly and completely below in conjunction with the accompanying drawings. 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.

[0052] In the description of the present invention, it should be noted that the terms "center", "upper", "lower", "left", "right", "vertical", "horizontal", "inner", "outer", etc., indicating the orientation or positional relationship, are based on the orientation or positional relationship shown in the drawings, and are only for the convenience of describing the present invention and simplifying the description, rather than indicating or implying that the device or element referred to must have a specific orientation, be constructed and operated in a specific orientation, and therefore cannot be understood as limiting the present invention. In addition, the terms "first", "second", and "third" are used for descriptive purposes only, and cannot be understood as indicating or implying relative importance.

[0053] The present invention provides a welding shaft anti-reverse device and method, which will be further described in detail below in conjunction with specific embodiments.

[0054] The welding shaft anti-reverse device of the present invention comprises a welding fixture 1, an image acquisition system, an image processing system and a welding control system. The welding fixture 1 is used to place the shaft 4 to be welded, and a through light-transmitting hole 5 is opened at the position where the shaft 4 is placed. The design of the light-transmitting hole 5 is one of the keys of the present invention, and its shape is adapted to the end shape of the shaft 4 to be welded, so that the contour characteristics of the end of the shaft 4 can be accurately reflected when light passes through.

[0055] The image acquisition system includes a light source 3 and an image receiver 2. The light source 3 is arranged on one side of the welding jig 1 and is designed as a point light source 3, which can generate relatively concentrated light. The image receiver 2 is arranged on the other side of the welding jig 1 and can be a CCD or CMOS image sensor, which is used to receive the image of the end shape of the shaft 4 projected by the light source 3 through the light-transmitting hole 5. When the shaft 4 is placed correctly, its end shape will project a specific image through the light-transmitting hole 5; when the shaft 4 is placed incorrectly or reversely, the projected image will be different from the image when it is placed correctly.

[0056] The image processing system is electrically connected to the image receiver 2 and is responsible for processing the collected image information. The system includes an image storage module, an image comparison module and a signal generation module. The image storage module pre-stores a standard image when the shaft 4 is correctly placed as a reference for comparison. The image comparison module compares the projection image collected in real time by the image receiver 2 with the standard image. The comparison process includes extracting the features of the two images, calculating the similarity between the features, and comparing the similarity with a preset threshold. When the similarity reaches or exceeds the preset threshold, it is determined that the comparison result meets the preset matching condition, indicating that the placement of the shaft 4 is correct; otherwise, it indicates that there may be a problem with the placement of the shaft 4. When the comparison result meets the preset matching condition, the signal generation module generates a matching signal and sends it to the welding control system.

[0057] The image processing system may also include a display module for intuitively displaying the comparison result. When the comparison result meets the preset matching condition, the display module displays an "OK" mark; when the comparison result does not meet the preset matching condition, the display module displays an "NG" mark. This design enables the operator to intuitively understand the placement status of the shaft 4, which is convenient for timely adjustment.

[0058] The welding control system is electrically connected to the image processing system and is responsible for controlling the execution of the welding operation according to the judgment result of the image processing system. The system includes a signal receiving module, a control start module and a welding execution module. The signal receiving module receives the matching signal from the image processing system; the control start module determines whether to allow the welding machine to start according to whether the matching signal is received; the welding execution module executes the specific welding operation when the control start module allows it.

[0059] When the operator correctly places the axis 4 on the welding fixture 1 and presses the start button, if the image processing system confirms that the axis 4 is placed correctly and sends a matching signal, the welding control system will allow the welding operation to be performed; conversely, if the image processing system does not send a matching signal (because the axis 4 is not placed correctly), the welding control system will prohibit the welding operation, and the welding machine cannot be started even if the operator presses the start button, thereby effectively preventing the occurrence of misprocessing.

[0060] In another embodiment, the present invention further provides a welding shaft anti-reverse method using the welding shaft anti-reverse device. The specific implementation steps of the method are as follows:

[0061] S1: placing the shaft 4 to be welded on the welding jig 1. The operator places the shaft 4 at a designated position of the welding jig 1 according to the normal operation process.

[0062] S2: The end shape of the shaft 4 is projected onto the image receiver 2 through the light source 3. The light generated by the light source 3 passes through the light-transmitting hole 5 on the welding jig 1, and the end shape of the shaft 4 forms a projected image on the image receiver 2.

[0063] S3: The image receiver 2 collects the projection image and transmits it to the image processing system. This step is completed automatically without operator intervention.

[0064] S4: The image processing system compares the captured projection image with the pre-stored standard image.

[0065] Specifically, the comparison process first extracts the features of the two images, then calculates the similarity between the features, and finally compares the similarity with a preset threshold. If the similarity reaches or exceeds the preset threshold, it is determined that the comparison result meets the preset matching condition.

[0066] S5: The comparison result meets the preset matching condition. If the comparison result meets the preset matching condition, the image processing system sends a matching signal to the welding control system.

[0067] Specifically, the image processing system will display an "OK" sign and send a matching signal to the welding control system; if the comparison result does not meet the preset matching conditions, the "NG" sign will be displayed and no matching signal will be sent.

[0068] S6: The welding control system determines whether to allow the welding operation according to whether a matching signal is received.

[0069] Specifically, if a matching signal is received, indicating that the placement of shaft 4 is correct, the welding control system allows the welding operation to be performed; if no matching signal is received, indicating that there may be a problem with the placement of shaft 4, the welding control system prohibits the welding operation, thereby preventing misprocessing.

[0070] In practical applications, the welding shaft anti-reverse device of the present invention can be integrated into an existing welding workstation and linked with the welding equipment. Practice has proved that the device can achieve the goal of 100% preventing the shaft 4 from being reversed, effectively preventing defective welding products from flowing into downstream workstations, greatly reducing the need for manual secondary inspection, improving production efficiency, and saving manpower and material costs.

[0071] The present invention has been applied in actual production and has achieved good results. The device is installed on the welding station. When the operator correctly places the shaft 4 on the welding fixture 1, the display will display "OK" and the welding can be performed normally by pressing the start button. When the operator puts the shaft 4 in reverse, the display will display "NG". At this time, pressing the start button will not trigger the welding operation, and the operator needs to readjust the placement direction of the shaft 4. This mechanism eliminates defective welding products caused by incorrect placement of the shaft 4 from the source, avoiding greater losses caused by defective products flowing into downstream processes.

[0072] To sum up, the welding shaft anti-reverse device and method provided by the present invention, through the organic combination of visual inspection and welding control, realizes the automatic identification and control of the placement status of the shaft, fundamentally solves the problem of welding shaft anti-reverse, ensures product quality, improves production efficiency, and reduces production costs. It has high practical value and promotion and application prospects.

[0073] The above embodiments are only for illustrating the technical concept and features of the present invention, and their purpose is to enable people familiar with the technology to understand the content of the present invention and implement it accordingly, and they cannot be used to limit the protection scope of the present invention. Any equivalent transformation or modification made according to the spirit of the present invention should be included in the protection scope of the present invention.

Claims

1. A welding shaft anti-reverse device, characterized in that: include: A welding jig is used to place the shaft to be welded, and a through light-transmitting hole is opened at the position of the welding jig where the shaft to be welded is placed; An image acquisition system, comprising a light source and an image receiver, wherein the light source is arranged on one side of the welding jig, and the image receiver is arranged on the other side of the welding jig, and the light source projects the shape of the end of the shaft onto the image receiver through a light-transmitting hole on the welding jig; An image processing system, electrically connected to the image receiver, for receiving an image captured by the image receiver and comparing the image with a pre-stored standard image; The welding control system is electrically connected to the image processing system. The welding control system allows welding operation when receiving a matching signal sent by the image processing system, and prohibits welding operation when not receiving the matching signal.

2. A welding shaft anti-reverse device according to claim 1, characterized in that: The image processing system comprises: An image storage module, used for storing a standard image when the shaft is correctly placed; An image comparison module, used for comparing the image captured by the image receiver with the standard image; The signal generating module is used to generate the matching signal when the comparison result meets the preset matching condition.

3. A welding shaft anti-reverse device according to claim 2, characterized in that: The image processing system also includes a display module, which is used to display an "OK" mark when the comparison result meets the preset matching condition, and display an "NG" mark when the comparison result does not meet the preset matching condition.

4. The welding shaft anti-reverse device according to claim 1, characterized in that: The welding control system comprises: A signal receiving module, used for receiving a signal sent by the image processing system; A control start module, used to control the start or stop of the welding machine according to the received signal; The welding execution module is used to execute the welding operation when the control start module allows it.

5. The welding shaft anti-reverse device according to claim 1, characterized in that: The light source is a point light source, and the shape of the light-transmitting hole matches the shape of the end of the shaft.

6. The welding shaft anti-reverse device according to claim 1, characterized in that: The image receiver is a CCD or CMOS image sensor.

7. A welding shaft anti-reverse method using the welding shaft anti-reverse device according to any one of claims 1 to 6, characterized in that: The following steps are involved: S1: Place the shaft to be welded on the welding jig; S2: projecting the end shape of the shaft onto an image receiver through a light source; S3: The image receiver collects the projected image and transmits it to the image processing system; S4: The image processing system compares the acquired projection image with the pre-stored standard image; S5: If the comparison result meets the preset matching condition, the image processing system sends a matching signal to the welding control system; S6: The welding control system determines whether to allow the welding operation according to whether the matching signal is received.

8. A welding shaft anti-reverse method according to claim 7, characterized in that: The step S5 further comprises: S51: If the comparison result meets the preset matching condition, an "OK" mark is displayed; S52: If the comparison result does not meet the preset matching condition, an "NG" mark is displayed.

9. A welding shaft anti-reverse method according to claim 7, characterized in that: The step S6 comprises: S61: If a matching signal is received, the welding operation is allowed; S62: If no matching signal is received, the welding operation is prohibited.

10. A welding shaft anti-reverse method according to claim 7, characterized in that: In step S4, the comparison includes: S41: extracting features of the collected projection image and the pre-stored standard image; S42: Calculate the similarity between the features; S43: Compare the similarity with a preset threshold, and if the similarity is greater than or equal to the preset threshold, determine that the comparison result meets the preset matching condition.

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