Detection system and method for visually detecting slotting width of magnetic material

Abstract

The invention relates to the technical field of magnetic material slotting width detection on an industrial production line, in particular to a detection system and method for visually detecting the slotting width of a magnetic material. According to the device, the magnetic steel on the conveying belt is sensed through the sensing mechanism, the light source mechanism emits a light source to illuminate the magnetic steel on the conveying belt, a first camera and a second camera of the collecting mechanism take pictures of the two side faces of the magnetic steel at the same time so as to collect the pictures of the two side faces of the magnetic steel, and then the pictures are analyzed, processed and compared; as long as the result of any one of the two side surfaces of the magnetic steel meets the requirement, the magnetic steel is detected as a qualified product.

Description

Technical Field

[0001] The present invention relates to the technical field of detecting the slot width of magnetic materials on industrial production lines, and particularly relates to a detection system and method for visually detecting the slot width of magnetic materials. Background Art

[0002] In the production process of magnetic materials, the accurate measurement of the side slot width is an important link to ensure product quality. Traditional detection methods usually rely on manual measurement, which has problems such as low efficiency, large error, and high labor intensity.

[0003] With the development of industrial automation, vision detection technology has gradually been introduced into production lines. However, existing vision detection systems often have problems such as slow response speed, insufficient accuracy, poor adaptability, and large floor area. Specifically, the slot of the magnetic steel is on the side of the magnetic steel and there is only one side. What needs to be detected is the concave width of the magnetic steel. Currently, on the workshop production line, the slot sides of the magnetic steels are randomly distributed on both sides of the conveyor belt. The current practice is to unify the directions of the slot sides of the magnetic steels into one direction. This operation is rather troublesome and prone to mistakes, such as making the slot sides of one or two magnetic steels in the opposite direction, resulting in being misjudged as unqualified products and causing a decrease in the qualified rate. Summary of the Invention

[0004] In order to overcome the above deficiencies, the purpose of the present invention is to provide a detection system for visually detecting the slot width of magnetic materials. The induction mechanism senses the magnetic steels on the conveyor belt, the light source mechanism emits light to illuminate the magnetic steels on the conveyor belt, the first camera and the second camera of the acquisition mechanism simultaneously take pictures of the two sides of the magnetic steels to collect the pictures of the two sides of the magnetic steels, and then analyze and process them and compare. As long as the result of any one of the two sides of the magnetic steels meets the requirements, it is detected as a qualified product; a detection method for visually detecting the slot width of magnetic materials is also provided.

[0005] The technical solution for the present invention to solve its technical problems is as follows: A detection system for visually detecting the slot width of magnetic materials, including an upper computer and a controller that are electrically connected. Among them, it further includes: An induction mechanism for sensing the magnetic steels on the conveyor belt; A light source mechanism for emitting light to illuminate the magnetic steels on the conveyor belt; An acquisition mechanism for taking pictures of the magnetic steels on the conveyor belt to collect the electronic data information of the magnetic steels; A blowing mechanism for blowing unqualified magnetic steels off the conveyor belt; Among them, the light source mechanism includes a first light source and a second light source that are electrically connected to the controller and are arranged on both sides of the conveyor belt; The acquisition mechanism includes a first camera and a second camera that are electrically connected to the controller and are arranged on both sides of the conveyor belt.

[0006] As an improvement of the present invention, the first camera is below the first light source, and the second camera is below the second light source.

[0007] As a further improvement of the present invention, both the first light source and the second light source adopt strip light sources.

[0008] As a further improvement of the present invention, the induction mechanism includes a first fiber optic sensor and a second fiber optic sensor that are electrically connected to the controller and are arranged on both sides of the conveyor belt.

[0009] As a further improvement of the present invention, the blowing mechanism includes a high-frequency valve and an air pipe connected to each other, and the high-frequency valve is electrically connected to the controller.

[0010] A detection method for visually detecting the slot width of a magnetic material, which includes the following steps: S1. The magnetic steel to be detected enters the conveyor belt. S2. The induction mechanism senses the magnetic steel to be detected on the conveyor belt and sends a signal to the controller. S3. The controller sends a light source instruction to control the light source mechanism to turn on. S4. The controller sends a photographing instruction to control the acquisition mechanism to take a photograph. After the acquisition mechanism takes a photograph, it sends the acquired electronic data information of the magnetic steel to the controller. S5. The controller sends the received electronic data information of the magnetic steel to the host computer. The host computer analyzes and processes the electronic data information of the magnetic steel to obtain an acquisition value, compares the acquisition value with a set value. For the magnetic steel that does not meet the requirements, the host computer sends an instruction to the controller to control the blowing mechanism to blow it out of the conveyor belt.

[0011] As a further improvement of the present invention, it is characterized in that in step S2, when the first fiber optic sensor and the second fiber optic sensor simultaneously sense the magnetic steel to be detected on the conveyor belt, a signal is sent to the controller.

[0012] As a further improvement of the present invention, in step S3, the controller sends a light source instruction to simultaneously control the first light source and the second light source to turn on, illuminating both sides of the magnetic steel on the conveyor belt.

[0013] As a further improvement of the present invention, in step S4, the first camera and the second camera respectively take photographs of both sides of the magnetic steel on the conveyor belt.

[0014] As a further improvement of the present invention, in step S5, the host computer binarizes the electronic data information of the permanent magnet and measures the width of the cut groove of the permanent magnet according to the electronic data information of the permanent magnet.

[0015] In the present invention, the permanent magnet on the conveyor belt is sensed by the sensing mechanism, the light source mechanism emits light to illuminate the permanent magnet on the conveyor belt, the first camera and the second camera of the acquisition mechanism take pictures of the two sides of the permanent magnet at the same time to collect the pictures of the two sides of the permanent magnet, and then analyze and process them, and then compare. As long as the result of any one of the two sides of the permanent magnet meets the requirements, it is detected as a qualified product. BRIEF DESCRIPTION OF THE DRAWINGS

[0016] For ease of explanation, the present invention will be described in detail by the following preferred embodiments and accompanying drawings.

[0017] Figure 1 It is a step block diagram of a method for visually detecting the width of a cut groove of a magnetic material according to the present invention. DETAILED DESCRIPTION OF THE EMBODIMENTS

[0019] In order to make the objectives, technical solutions and advantages of the present invention clearer, the present invention will be further described in detail below with reference to the accompanying drawings and embodiments. It should be understood that the specific embodiments described herein are only used to explain the present invention and are not used to limit the present invention.

[0020] A visual detection system for detecting the width of a cut groove of a magnetic material according to the present invention includes a host computer and a controller that are electrically connected. It uses a graphical programming automation industrial software, which provides a series of significant advantages in the fields of testing, measurement and control applications. The intuitive and easy-to-use graphical programming reduces the entry threshold, and the method of connecting and calling the encapsulated function blocks to complete the programming also saves the programming cycle. This method also makes the programming process more intuitive and easy to understand, without having to remember complex programming syntax, and is especially suitable for the fields of testing and measurement. It has strong hardware interaction capabilities, rich hardware interfaces and driver programs to support communication with various hardware devices and instruments, and has a powerful ecosystem, including a large number of third-party tools, modules and libraries. Users can expand its functions through expansion modules and toolkits, and its modules and toolkits are in a hot update state; the controller uses a well-known brand controller as a PLC control to be responsible for controlling the entire detection process.

[0021] A visual detection system for detecting the width of a cut groove of a magnetic material according to the present invention further includes: A sensing mechanism for sensing the permanent magnet on the conveyor belt; A light source mechanism for emitting light to illuminate the permanent magnet on the conveyor belt; A collecting mechanism for photographing the magnets on the conveyor belt to collect the electronic data information of the magnets; A blowing mechanism for blowing the unqualified magnets out of the conveyor belt; Among them, the light source mechanism includes a first light source and a second light source that are electrically connected to the controller and arranged on both sides of the conveyor belt. Both the first light source and the second light source adopt strip-shaped light sources to provide uniform lighting conditions. When both the first light source and the second light source adopt strip-shaped light sources, the picture of the magnet groove taken by the collecting mechanism is the clearest, and the contrast is the highest after subsequent binarization processing, and the detection accuracy is the highest; moreover, the two opposed strip-shaped light sources act as backlight plates for each other, which can enhance the ambient brightness.

[0022] In the present invention, the collecting mechanism includes a first camera and a second camera that are electrically connected to the controller and arranged on both sides of the conveyor belt. The first camera is located below the first light source, and the second camera is located below the second light source. The first camera and the second camera are respectively used to take pictures of the two sides of the magnet. That is to say, two-sided shooting is adopted to collect pictures of the two sides at the same time, and the width measurement of the grooved surface of the magnet is detected. Since the two sides of the magnet are detected simultaneously, there are two results. After analysis and processing, as long as the grooved width of one side is qualified, it is considered a qualified product and does not need to be screened out; moreover, the photographing detection method is two-station counter-shooting, so a magnet only needs to be photographed once and does not need to be photographed separately twice. After the magnet is photographed, it is immediately screened and blown according to the result. The detection time of the magnet is short, the path is short, and the occupied volume is also very small.

[0023] In the present invention, the induction mechanism includes a first fiber optic sensor and a second fiber optic sensor that are electrically connected to the controller and arranged on both sides of the conveyor belt.

[0024] In the present invention, the blowing mechanism includes a high-frequency valve and an air pipe connected to each other, and the high-frequency valve is electrically connected to the controller.

[0025] A visual inspection system for detecting the grooved width of magnetic materials according to the present invention has the following advantages: 1. It is difficult to measure the magnet groove manually, and it is also difficult to measure accurately with a caliper. The present invention can replace manual inspection of the groove width, and one piece can be detected in 250 ms, and the efficiency is far higher than manual measurement with a caliper.

[0026] 2. Low energy consumption, the rated power of the overall equipment of the present invention is about 500w.

[0027] 3. The overall equipment of the present invention is small and has wide applicability, is easy to install and deploy, and is not easy to interfere with the original equipment.

[0028] Such as Figure 1As shown in the figure, a method for detecting the slot width of a magnetic material in visual inspection according to the present invention includes the following steps: S1. The magnet to be detected enters the conveyor belt. S2. The induction mechanism senses the magnet to be detected on the conveyor belt and sends a signal to the controller. S3. The controller sends a light source instruction to control the light source mechanism to turn on. S4. The controller sends a photographing instruction to control the acquisition mechanism to take a photograph. After the acquisition mechanism takes a photograph, it sends the acquired electronic data information of the magnet to the controller. S5. The controller sends the received electronic data information of the magnet to the host computer. The host computer analyzes and processes the electronic data information of the magnet to obtain an acquisition value, compares the acquisition value with a set value. For the magnet that does not meet the requirements, the host computer sends an instruction to the controller to control the blowing mechanism to blow it out of the conveyor belt.

[0029] Specifically, it includes the following steps: 1. Start the host computer to run the detection. The scanning cycle values for left and right image detection are initially 0, the left and right measurement pixel results are 0, the left and right actual size results are 0, and the clearing operation value is 1. The host computer does not report a communication error with the controller PLC, the light source and the image are normal, the running speed of the conveyor belt is stable, and the parameters are set reasonably. 2. The induction mechanism senses the magnet to be detected on the conveyor belt. The controller internally detects this rising edge signal and internally triggers to record the current real time, for example: T#106751d_23h_47m_16s_854.775807ms. 3. When the difference between the recorded time and the real time is equal to the currently set photographing delay time, output a photographing command, and the two cameras complete photographing simultaneously. 4. After photographing, the host computer performs image processing and analysis to obtain the result values of the two-side image measurement this time, and increments the scanning cycle by 1. 5. The controller continuously collects the scanning values on both sides of the host computer. When the scanning values on both sides are simultaneously greater than the previous scanning values, then perform bit setting calculation and after a 100 ms delay, compare the collected measurement values on both sides with the set values on the left and right sides respectively. If both are less than the set value of 0.5 mm, then record this time as a non-conforming product, otherwise no processing will be done.

[0030] Within the present invention, in step S2, when the first fiber optic sensor and the second fiber optic sensor simultaneously sense the magnet to be detected on the conveyor belt, a signal is sent to the controller. Specifically, after the first fiber optic sensor and the second fiber optic sensor sense the magnet to be detected on the conveyor belt, the controller PLC obtains the photographing delay time (the photographing time is set by the host computer) through communication with the host computer, and uses the stack program in the controller PLC to push and pop the stack to achieve that after the set photographing time from the sensor, the controller PLC outputs a command to trigger the simultaneous photographing of the cameras on both the left and right sides. It can also be said that by detecting the rising delay of the incoming material, the stack program is triggered, and the current real-time time is pushed onto the stack. Program example: StackPush(In:=Real-time time stack, InOut:=Photographing stack array[0], Size:=Photographing stack size, Num:=Photographing stack Num); When the stack array is not zero, the stored time value is popped from the stack, and the real-time time is continuously subtracted from the popped time. When the obtained result is greater than or equal to the photographing delay time, the controller PLC outputs a command to trigger the simultaneous photographing of the cameras on both the left and right sides.

[0031] Within the present invention, in step S3, the controller sends a light source instruction and simultaneously controls the first light source and the second light source to turn on, illuminating both sides of the magnet on the conveyor belt. When both the first light source and the second light source adopt strip light sources, the picture of the magnet groove captured by the acquisition mechanism is the clearest, and after subsequent binarization processing, the contrast is the highest and the detection accuracy is the highest. Moreover, the two opposed strip light sources act as backlight plates for each other, which can enhance the ambient brightness.

[0032] Within the present invention, in step S4, the first camera and the second camera respectively take pictures of both sides of the magnet on the conveyor belt. By taking pictures from two sides, the pictures of both sides are collected simultaneously. After taking pictures, wait for 100 ms to ensure that the image processing on both the left and right sides is completed and the data is the latest.

[0033] Within the present invention, in step S5, the host computer performs binarization processing on the electronic data information of the permanent magnet, and measures the grooving width of the permanent magnet according to the electronic data information of the permanent magnet; specifically, the host computer vision program performs binarization processing on the captured image, and measures the width of the dark area (i.e., the grooving width) of the specified area through ROL (region of interest). The parameters of binarization and width measurement are adjusted through the front panel of the vision software to achieve the optimal effect; the measurement result is transmitted to the controller PLC through the host computer vision software. Inside the controller PLC, the set value is compared with the measured value. If the measured values of both sides of the permanent magnet are less than the set value, it is determined as a non-conforming product, the NG count is incremented by 1, and the result of NG is pushed onto and popped from the stack using the stack program. The pop time is also set by the host computer and obtained through communication with the host computer. After reaching the set blowing time (340 ms), the controller PLC controls the high-frequency valve to blow the non-conforming product off the belt; if the measured value of any one side of the two sides of the permanent magnet is greater than the set value, it is determined as a conforming product and no processing is performed. The permanent magnet then reaches the stacking machine along with the conveyor belt.

[0034] Within the invention, a control method is programmed in the controller PLC. Global variables are established inside the controller and publicly communicated through the host computer EIP to achieve communication with the vision, trigger the camera to take pictures using the IO hard trigger method for taking pictures, use the high-frequency valve to blow air, use the opposed fiber optic and amplifier to detect the incoming material. After obtaining the image, it undergoes binarization processing, and the width of the grooved part is obtained using the measurement function and compared with the set width of 0.5 mm. If it is less than 0.5 mm, it is determined as non-conforming. After the PLC receives the non-conforming signal, it will blow air after a delay of 350 ms. At this time, the permanent magnet is just located at the blowing port of the high-frequency valve, and the non-conforming material is blown out of the conveyor belt.

[0035] Within the present invention, through the front panel of the vision software, the binarization threshold gray value below 170 is segmented into pure black, and the image gray value part of 170 - 255 is segmented into pure white. Parameters such as the ROL area position are manually box-selected, and then the ROI parameters are output to the measurement function. Since the image has undergone binarization, the edge strength is 1, the smoothing parameter is 4, the steepness parameter is 2, the measurement interval is 5 pixels, and the number of measurement points is ROI, which is the total number of X-axis pixels divided by 5. The final measurement value is calculated as the average of each measurement point to ensure the measurement accuracy. A binarization function based on the gray value is used.

[0036] Within the present invention, parameters such as the camera shooting delay time of 100 ms and the blowing time of 350 ms are set in the PLC program, and the operation waiting time for the image processing result is 100 ms to ensure the system response speed and accuracy.

[0037] Through the combination of the host computer and the PLC controller, the present invention realizes the automatic detection and sorting of the side grooving width of the magnetic steel, and has the advantages of high detection accuracy, fast response speed, high degree of automation, etc., which can effectively improve production efficiency and product quality.

[0038] Most of the existing vision detection devices need a large space for installation, while the present invention only needs to complete the detection and screening process on the conveyor belt. Its small size makes it easier to deploy and will not cause too much interference to the original equipment.

[0039] The above are only the preferred embodiments of the present invention and are not intended to limit the present invention. Any modifications, equivalent replacements, and improvements made within the spirit and principle of the present invention shall be included in the protection scope of the present invention.

Claims

1. A detection system for visually detecting the slot width of a magnetic material, comprising an electrically connected host computer and a controller, characterized in that: Also includes: The induction mechanism is used to sense the magnetic steel on the conveyor belt; A light source mechanism, used for emitting light source to illuminate the magnetic steel on the conveyor belt; A collection mechanism, used to take pictures of the magnetic steel on the conveyor belt to collect electronic data information of the magnetic steel; The air blowing mechanism is used to blow the unqualified magnetic steel out of the conveyor belt; Wherein, the light source mechanism comprises a first light source and a second light source which are electrically connected to the controller and are arranged on both sides of the conveyor belt; The acquisition mechanism includes a first camera and a second camera which are electrically connected to the controller and are arranged on both sides of the conveyor belt.

2. A detection system for visually detecting the slot width of magnetic materials according to claim 1, characterized in that: The first camera is located below the first light source, and the second camera is located below the second light source.

3. A detection system for visually detecting the slot width of magnetic materials according to claim 2, characterized in that: The first light source and the second light source are both bar-shaped light sources.

4. A detection system for visually detecting the slot width of magnetic materials according to claim 1, characterized in that: The sensing mechanism includes a first optical fiber sensor and a second optical fiber sensor which are electrically connected to the controller and are arranged on both sides of the conveyor belt.

5. A detection system for visually detecting the slot width of magnetic materials according to claim 1, characterized in that: The blowing mechanism comprises a high-frequency valve and an air pipe connected to each other, and the high-frequency valve is electrically connected to the controller.

6. A method for visually detecting the slot width of a magnetic material, characterized in that: The steps include: S1. The magnetic steel to be tested enters the conveyor belt; S2, the sensing mechanism senses the magnetic steel to be detected on the conveyor belt and sends a signal to the controller; S3, the controller sends a light source instruction to control the light source mechanism to turn on; S4, the controller sends a photo command to control the collection mechanism to take photos, and the collection mechanism sends the collected electronic data information of the magnetic steel to the controller after taking photos; S5. The controller sends the received electronic data information of the magnetic steel to the host computer. The host computer analyzes and processes the electronic data information of the magnetic steel to obtain the collected value, and compares the collected value with the set value. For the magnetic steel that does not meet the requirements, the host computer sends instructions to the controller to control the blowing mechanism to blow it out of the conveyor belt.

7. A method for visually detecting the slot width of magnetic materials according to claim 1, characterized in that: In step S2, the first optical fiber sensor and the second optical fiber sensor simultaneously sense the magnetic steel to be detected on the conveyor belt, and then send a signal to the controller.

8. The method for visually detecting the slot width of magnetic materials according to claim 1, characterized in that: In step S3, the controller sends a light source instruction to control the first light source and the second light source to turn on simultaneously, illuminating the two sides of the magnetic steel on the conveyor belt.

9. A method for visually detecting the slot width of magnetic materials according to claim 8, characterized in that: In step S4, the first camera and the second camera respectively take pictures of the two side surfaces of the magnetic steel on the conveyor belt.

10. The method for visually detecting the slot width of magnetic materials according to claim 1, characterized in that: In step S5, the host computer performs binarization processing on the electronic data information of the magnetic steel, and measures the width of the slot of the magnetic steel according to the electronic data information of the magnetic steel.

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