Cylindrical material appearance inspection machine

Abstract

This invention discloses a cylindrical material appearance inspection machine, comprising an inspection and handling assembly and a unloading assembly. The inspection and handling assembly uses a dual-track linear vibration feeder, coupled with a multi-chamber adaptive suction cup gripper. Multi-angle imaging is achieved through a V-shaped arrangement of line and planar cameras, and a conductive rubber roller rotation mechanism ensures stable inspection. The unloading assembly is automatically classified using a ring sorting mechanism. The equipment innovatively employs a deep learning algorithm for defect identification, supports online model updates, and is adaptable to cylindrical materials with diameters ranging from 5 to 50 mm. This invention features high inspection efficiency (dual-channel design improves efficiency by over 100%), high accuracy (minimum defect identification 0.05 mm), and strong compatibility. It is particularly suitable for the appearance quality inspection of cylindrical industrial products such as lithium batteries, bearing rings, and bottle caps, solving the problems of low efficiency and high false negative rate of traditional inspection methods.

Description

Technical Field

[0001] This invention relates to the field of automated inspection equipment technology, and in particular to an automated device for detecting and sorting appearance defects in cylindrical materials (such as batteries, bearings, bottle caps, etc.). Background Technology

[0002] In the manufacturing process of cylindrical industrial parts (such as battery cells, bearing rings, and metal bottle caps), appearance quality inspection is a crucial step in ensuring product pass rates. Traditional inspection methods mainly rely on manual visual inspection, where inspectors visually examine the product surface for defects such as scratches, dents, and stains. This method is not only labor-intensive but also prone to missed inspections and misjudgments due to visual fatigue.

[0003] With the development of industrial automation, various automated inspection equipment has emerged on the market. These devices typically use a vibratory feeder for material feeding, a robotic arm for gripping, and an industrial camera for imaging to achieve their inspection functions. However, existing equipment still has many shortcomings in practical applications: materials are prone to collision damage during the feeding process; they have poor adaptability to products of different sizes, requiring adjustments to the mechanical structure when changing specifications; products are prone to slippage during rotational inspection, leading to blurred images; and the image processing algorithms used have limited ability to identify minute defects.

[0004] Especially against the backdrop of the current transformation of the manufacturing industry towards intelligence and flexibility, traditional testing equipment can no longer meet the higher requirements of enterprises for testing accuracy, efficiency, and flexibility. How to achieve efficient, accurate, and multi-specification automated appearance inspection has become a technical challenge that urgently needs to be solved in the industry. Summary of the Invention

[0005] The technical problem to be solved by the present invention is to provide a cylindrical material appearance inspection machine with high inspection efficiency and high accuracy.

[0006] This invention is achieved through the following solution: a cylindrical material appearance inspection machine, comprising an inspection and handling assembly and a unloading assembly, wherein the inspection and handling assembly is connected to the unloading assembly;

[0007] The detection and handling assembly includes a first machine base, which has a feeding component, a material gripping PPU component, a line scan camera component, a planar component, a handling component, and a rotating component.

[0008] The feeding assembly includes a non-destructive disc, which contains dual linear vibration tracks, the ends of which are connected to a guide and sorting mechanism.

[0009] The material gripping PPU assembly includes a first lead screw, two first lead screws connected to a first linear rail at their middle, the first linear rail connected to a PPU mechanism, a suction cup connected to the bottom of the PPU mechanism, and the first lead screws fixedly connected to the first machine base.

[0010] The line scan camera assembly includes a second lead screw, with a second linear rail connected to the middle of the two second lead screws. A first servo motor and two sets of line scan cameras are connected to the second linear rail. The first servo motor drives the line scan cameras, and the second lead screw is fixedly connected to the first machine base.

[0011] The planar camera assembly includes a third lead screw, with a third linear rail connected at the middle of the two third lead screws. Two planar detection cameras are connected to the third linear rail, and the third lead screw is fixedly connected to the first machine tool.

[0012] The conveying assembly includes a base, on which two lifting slide cylinders are connected. Each lifting slide cylinder is connected to three electric cylinder grippers, and the three electric cylinder grippers on the same side are arranged side by side.

[0013] The rotating assembly is located below the planar camera assembly. The rotating assembly includes a fixing mechanism connected to the first machine base. Two sets of roller mechanisms and a second servo motor are connected to the fixing mechanism, and the second servo motor drives the roller mechanisms.

[0014] The unloading assembly includes a second machine base, on which unloading assembly components are mounted.

[0015] The dual linear vibration tracks of the feeding assembly adopt frequency coupling control technology, with a vibration phase difference of 90°±5° between the two tracks. The guide and sorting mechanism includes a laser sensor and a pneumatic baffle to achieve active correction of the material orientation.

[0016] The suction cup of the material gripping PPU assembly has a multi-chamber silicone structure, with each chamber independently controlled by negative pressure. The surface of the suction cup is provided with annular grooves to accommodate materials of different diameters.

[0017] The two sets of line scan cameras in the line scan camera assembly are arranged in a V-shape with an included angle of 60°-120°, and are equipped with a coaxial light source and a diffuse reflector to form a composite lighting system.

[0018] The roller mechanism of the rotating component is covered with conductive rubber, and the center distance between the two sets of rollers can be adjusted online via an electric push rod with an adjustment accuracy of ±0.05mm.

[0019] The electric cylinder gripper of the conveying assembly integrates a pressure sensor, and the dynamic range of the gripping force is adjustable from 5 to 50 N. The spacing between the three grippers is adaptively adjusted through a servo module.

[0020] It also includes a machine vision processing system that uses deep learning algorithms to classify defects in images captured by line scan cameras and planar cameras, and the classification model supports online updates.

[0021] The material feeding assembly includes a material feeding turntable connected to a material feeding push rod. A receiving box is provided at the lower part of the material feeding push rod, and the receiving box is connected to the second machine base. Both the material feeding push rod and the receiving box are arranged in a ring.

[0022] The receiving box has 6-8 units.

[0023] The inner wall of the non-destructive disk and the upper part of the dual linear vibration track are provided with wool felt.

[0024] The beneficial effects of this invention are as follows:

[0025] 1. Non-destructive feeding and multi-size compatible design: The non-destructive tray covered with wool felt and the multi-chamber suction cup structure significantly reduce material loss and are suitable for cylindrical materials with a diameter of 5-50mm.

[0026] 2. Dual-channel inspection and efficient sorting: Enables rapid product handling. After being handled from one track, the product is inspected from two tracks. After the product is picked up as a PPU component, it passes through the line scan inspection station, the plane inspection station, and the unloading turntable station. The two rows of products are quickly handled through these four stations one by one, improving the inspection efficiency by more than 100%.

[0027] 3. High-precision imaging system: V-shaped camera layout (60°-120° adjustable) and coaxial light source-diffuse reflector composite illumination, with a defect detection rate of 99.5%;

[0028] 4. Dynamic adjustment mechanism: The electric push rod precisely controls the center distance of the rollers (±0.05mm), and with the help of conductive rubber coating, it eliminates rotational slippage;

[0029] 5. Intelligent classification system: Deep learning algorithms support online model updates, with a classification accuracy of >98%, reducing the cost of manual review. Attached Figure Description

[0030] Figure 1 This is a three-dimensional structural diagram of the cylindrical material appearance inspection machine of the present invention.

[0031] Figure 2 This is a three-dimensional structural diagram of the upper part of the inspection and handling assembly of the cylindrical material appearance inspection machine of the present invention.

[0032] Figure 3 This is a three-dimensional structural diagram of the PPU gripping component of the cylindrical material appearance inspection machine of the present invention.

[0033] Figure 4This is a three-dimensional structural schematic diagram of the line scan camera assembly of the cylindrical material appearance inspection machine of the present invention.

[0034] Figure 5 This is a three-dimensional structural diagram of the handling component of the cylindrical material appearance inspection machine of the present invention.

[0035] Figure 6 This is a side view of the conveying assembly of the cylindrical material appearance inspection machine of the present invention.

[0036] Figure 7 This is a side view of the rotating assembly of the cylindrical material appearance inspection machine of the present invention.

[0037] In the diagram: 1 is the inspection and handling assembly; 11 is the first machine tool; 12 is the feeding assembly; 121 is the non-destructive disc; 122 is the dual linear vibration track; 123 is the guide and sorting mechanism; 124 is wool felt; 13 is the material gripping PPU assembly; 131 is the first lead screw; 132 is the first linear guide; 133 is the PPU mechanism; 14 is the line scan camera assembly; 141 is the second lead screw; 142 is the second linear guide; 143 is the first servo motor; 144 is the line scan camera; 144a is the coaxial light source; 144b is the diffuse reflector; 15 is the planar assembly; 151 is the first... Three lead screws, 152 is the third linear guide, 153 is the planar detection camera, 16 is the conveying assembly, 161 is the base, 162 is the lifting slide cylinder, 163 is the electric cylinder gripper, 163a is the pressure sensor, 163b is the servo module, 17 is the rotating assembly, 171 is the fixing mechanism, 172 is the roller mechanism, 172a is the conductive rubber, 172b is the electric push rod, 173 is the servo motor, 2 is the unloading assembly, 21 is the second machine base, 22 is the unloading assembly assembly, 221 is the unloading turntable, 222 is the unloading push rod, and 223 is the receiving box. Detailed Implementation

[0038] The following is combined with Figure 1-7 The present invention will be further described, but the scope of protection of the present invention is not limited to the contents described herein.

[0039] Example 1: Application of Lithium Battery Cell Appearance Inspection

[0040] This embodiment details the application of a cylindrical material appearance inspection machine in an 18650 lithium battery cell production line. For example... Figure 1 As shown, the entire system consists of two main parts: the detection and handling assembly (1) and the unloading assembly (2). The components work together to achieve efficient and accurate detection.

[0041] Material feeding system workflow:

[0042] The feeding assembly (12) uses a specially designed non-destructive disc (121), the inner wall of which and the surface of the dual linear vibration track (122) are covered with a 3mm thick wool felt (124) buffer layer. The dual linear vibration track (122) adopts frequency coupling control technology, and the vibration phase difference between the two tracks is precisely controlled at 90°±2°, the vibration frequency is 50Hz, and the amplitude is 0.5mm. This design ensures that the battery cells maintain a stable spacing during transportation, and the measured collision energy is reduced by more than 90%. When the battery cell reaches the end of the track, the high-precision laser sensor (resolution 0.01mm) of the guide sorting mechanism (123) detects the orientation of the battery cell in real time, and the air pressure baffle completes the position correction within 50ms, ensuring that all battery cells enter the inspection station in the same direction.

[0043] Grasping and positioning system:

[0044] The first lead screw (131) of the PPU gripping assembly (13) is driven by a servo motor, which drives the PPU mechanism (133) to move linearly along the first linear guide (132), achieving a repeatability positioning accuracy of ±0.02mm. The suction cup (134) adopts an innovative six-chamber silicone structure, with each chamber independently connected to a vacuum generator, and the vacuum level can be adjusted within the range of -20kPa to -80kPa. The annular groove (134a) design on the surface of the suction cup (134) allows it to perfectly fit battery cells with a diameter of 18mm ±0.2mm, with a measured gripping success rate of over 99.9%.

[0045] Visual inspection system:

[0046] The two 20-megapixel line scan cameras (144) of the line scan camera assembly (14) are arranged at a 75° angle. This V-shaped structure, combined with the ring-shaped LED coaxial light source (144a), can completely cover the cylindrical surface of the battery cell. The camera acquires images at a speed of 3,000 lines per second, and with the help of a specially designed diffuse reflector (144b), uniform illumination is ensured under different surface characteristics. The two 5-megapixel planar inspection cameras (153) of the planar camera assembly (15) are adjusted in position via a third lead screw (151) to perform high-precision imaging of both ends of the battery cell, which can detect key features such as the quality of the electrode welding.

[0047] Rotation and sorting system:

[0048] The roller mechanism (172) of the rotating component (17) is coated with a specially formulated conductive rubber (172a), achieving a friction coefficient of over 0.8. Driven by the second servo motor (173), the battery cell rotates at a uniform speed of 60 rpm, with a measured slippage rate of less than 0.1%. The three electric cylinder grippers (163) of the conveying component (16) are driven by the lifting slide cylinder (162), and the gripper spacing is automatically adjusted by the servo module (163b) to ensure a stable and reliable sorting process.

[0049] Data processing system:

[0050] The machine vision processing system (4) adopts an improved ResNet-18 deep learning model, and the training set contains 500,000 defect samples of various types. The system supports online model updates and can accurately identify defects such as scratches and dents ≥0.05mm, and classify special defects such as electrolyte leakage.

[0051] The machine vision processing system adopts a distributed computing architecture, consisting of an image acquisition module, an intelligent analysis module, and a decision output module. After the line scan camera (144) and the planar camera (153) acquire product images, the data is transmitted to the processing system via a 10Gbps fiber optic network. The system first performs pixel-level calibration, using a feature-point-based image registration algorithm to ensure that the spatial consistency of the images from multiple camera perspectives reaches sub-pixel accuracy (±0.1 pixel).

[0052] Example 2: Implementation of a full inspection system for bearing rings

[0053] This embodiment demonstrates the in-depth application of the equipment in a scenario involving 100% inspection of precision bearing races. For example... Figure 2 As shown, the system has undergone several customized improvements to meet the special requirements of the bearing rings.

[0054] Feeding system optimization:

[0055] The dual linear vibration track (122) of the feeding assembly (12) adopts independent vibration control. By adjusting the phase difference between the two tracks to 85°, the problem of material jamming caused by weight difference of the bearing rings is effectively solved. The guide sorting mechanism (123) is equipped with a high-sensitivity eddy current sensor, which can accurately identify bearing rings of different materials such as GCr15 and 9Cr18, and automatically group them for processing. The feed inlet of the non-destructive disc (121) is equipped with a buffer air curtain device, which can control the bearing ring collision damage rate to below 0.01% in actual tests.

[0056] Detection system upgrade:

[0057] The line scan camera assembly (14) is equipped with a 50-megapixel high-speed line scan camera (144), which, together with a specially designed diffuse illumination system, can clearly capture the micro-machining marks on the raceway surface of the raceway. The camera resolution reaches 0.005mm / pixel, and it can identify machining defects as small as 0.02mm. The planar inspection camera (153) of the planar camera assembly (15) is upgraded to a symmetrical arrangement on both sides, which can simultaneously detect the parallelism and surface quality of the two end faces of the raceway.

[0058] Rotary system reinforcement:

[0059] The second servo motor (173) of the rotating assembly (17) has been upgraded to a high-torque model of 5 N·m to ensure stable rotation of heavy-duty bearing rings (maximum single weight 1.2 kg). The center distance of the roller mechanism (172) is infinitely adjustable from 20-80 mm via an electric push rod (172b), with an adjustment accuracy of ±0.05 mm, adaptable to various bearing specifications. The thickness of the conductive rubber (172a) coating layer has been increased to 5 mm to further reduce the risk of slippage.

[0060] Improvements to the handling system:

[0061] The electric cylinder grippers (163) of the handling assembly (16) integrate a high-precision pressure sensor (163a), and the clamping force can be dynamically adjusted within the range of 5-50N. The spacing between the three grippers is adaptively adjusted through a servo module (163b), which can accommodate rings with an outer diameter of up to 80mm. The lifting slide cylinder (162) adopts a double guide rail structure to ensure smooth and vibration-free handling.

[0062] Intelligent Analysis System:

[0063] The machine vision processing system (4) employs a multi-scale feature fusion algorithm to focus on detecting abnormal grinding patterns on the raceway of the grinding ring. By establishing a Gabor filter bank, the uniformity of the grinding pattern can be quantitatively analyzed, and periodic defects caused by grinding wheel wear can be detected in a timely manner. The system has a built-in SPC statistical analysis module, which can monitor process fluctuations in real time.

[0064] Example 3: Quality Inspection Plan for Aluminum Beverage Bottle Caps

[0065] This embodiment details an innovative application of the equipment in the quality inspection of food-grade aluminum bottle caps. For example... Figure 3 As shown, the system has been comprehensively optimized to meet the special requirements of bottle caps.

[0066] Improvements to the feeding system:

[0067] The vibration frequency of the dual linear vibrating track (122) of the feeding assembly (12) is optimized to 30Hz, the amplitude is adjusted to 0.3mm, and a buffer air curtain device is added. This configuration effectively prevents bottle caps with a thickness of only 0.15mm from stacking during the conveying process. The guide and sorting mechanism (123) of the non-destructive tray (121) adopts a non-contact photoelectric sensor array to avoid bottle cap deformation that may be caused by traditional mechanical baffles.

[0068] Innovation in crawling systems:

[0069] The suction cup (134) of the PPU gripping assembly (13) has been upgraded to a flexible adaptive structure with a built-in high-sensitivity pressure feedback system. When a risk of cap deformation is detected, the system can automatically adjust the vacuum level within 10ms to ensure that the 0.15mm thick cap is not deformed during gripping. The movement speed of the PPU mechanism (133) has been optimized to 0.5m / s, improving cycle time while maintaining positioning accuracy (±0.03mm).

[0070] Detection system configuration:

[0071] The line scan camera assembly (14) is equipped with a 365nm ultraviolet light source, which, together with the high-resolution color line scan camera (144), can simultaneously detect the printing quality of bottle caps and substrate defects. Through HSV color space analysis, it can accurately identify defects as small as 0.1mm. 2 The printing color difference; ultraviolet imaging can detect micro-cracks that are invisible to the naked eye. The planar inspection camera (153) of the planar camera assembly (15) is upgraded to a 20-megapixel model, which can detect the integrity of the inner liner of the bottle cap.

[0072] Rotation system optimization:

[0073] The rotating component (17) innovatively adopts non-contact magnetic drive technology, which uses a precisely controlled alternating magnetic field to levitate and rotate the bottle cap, completely avoiding the wear of the bottle cap coating by traditional rollers. The system is equipped with a high-precision angle encoder to ensure that the rotation positioning accuracy reaches ±0.1°.

[0074] Sorting and Traceability System:

[0075] The unloading assembly (2) has an unloading turntable (221) connected to six annularly arranged unloading push rods (222) that sort bottle caps to their corresponding receiving boxes (223). The quality judgment system integrates OCR functionality, which can simultaneously read and verify information such as production batch number and shelf life. All test data is automatically uploaded to the MES system to generate a complete quality traceability report.

[0076] Although the technical solutions of the present invention have been described and enumerated in detail, it should be understood that modifications to the above embodiments or the adoption of equivalent alternatives are obvious to those skilled in the art. Such modifications or improvements made without departing from the spirit of the present invention are all within the scope of protection claimed by the present invention.

Claims

1. A cylindrical material appearance inspection machine, characterized in that, It includes a detection and handling assembly (1) and a material unloading assembly (2), wherein the detection and handling assembly (1) is connected to the material unloading assembly (2); The detection and handling assembly (1) includes a first machine base (11), on which there is a feeding assembly (12), a material gripping PPU assembly (13), a line scanning camera assembly (14), a planar camera assembly (15), a handling assembly (16), and a rotating assembly (17). The feeding assembly (12) includes a non-destructive disc (121), which contains a double linear vibration track (122), the end of which is connected to a guide and sorting mechanism (123). The material gripping PPU assembly (13) includes a first lead screw (131), the middle of the two first lead screws (131) is connected to a first linear guide (132), the first linear guide (132) is connected to a PPU mechanism (133), the bottom of the PPU mechanism (133) is connected to a suction cup (134), and the first lead screw (131) is fixedly connected to the first machine base (11). The line scan camera assembly (14) includes a second lead screw (141), and the middle of the two second lead screws (141) is connected to a second linear rail (142). A first servo motor (143) and two sets of line scan cameras (144) are connected on the second linear rail (142). The first servo motor (143) drives the line scan camera (144), and the second lead screw (141) is fixedly connected to the first machine base (11). The planar camera assembly (15) includes a third lead screw (151), the middle of the two third lead screws (151) is connected to a third linear guide (152), two planar detection cameras (153) are connected on the third linear guide (152), and the third lead screw (151) is fixedly connected to the first machine base (11). The conveying assembly (16) includes a base (161), on which two lifting slide cylinders (162) are connected. Each lifting slide cylinder (162) is connected to three electric cylinder grippers (163), and the three electric cylinder grippers (163) on the same side are arranged side by side. The rotating assembly (17) includes a fixing mechanism (171) connected to the first machine base (11). Two sets of roller mechanisms (172) and a second servo motor (173) are connected to the fixing mechanism (171). The second servo motor (173) drives the roller mechanisms (172). The unloading assembly (2) includes a second machine base (21), on which an unloading assembly component (22) is mounted; The feeding assembly (12) uses frequency coupling control technology for its dual linear vibration track (122), with a vibration phase difference of 90°±5° between the two tracks. The guide and sorting mechanism (123) includes a laser sensor and a pneumatic baffle to achieve active correction of the material orientation.

2. The cylindrical material appearance inspection machine according to claim 1, characterized in that, The suction cup (134) of the material gripping PPU assembly (13) is a multi-chamber silicone structure, with each chamber independently controlled by negative pressure. The surface of the suction cup is provided with an annular groove to accommodate materials of different diameters.

3. The cylindrical material appearance inspection machine according to claim 1, characterized in that, The two sets of line scan cameras (144) of the line scan camera assembly (14) are arranged in a V-shape with an included angle of 60°-120°, and are equipped with a coaxial light source (144a) and a diffuse reflector (144b) to form a composite lighting system.

4. The cylindrical material appearance inspection machine according to claim 1, characterized in that, The roller mechanism (172) of the rotating component (17) is covered with conductive rubber (172a), and the center distance between the two sets of rollers is adjusted online by an electric push rod (172b) with an adjustment accuracy of ±0.05mm.

5. The cylindrical material appearance inspection machine according to claim 1, characterized in that, The electric cylinder gripper (163) of the conveying assembly (16) integrates a pressure sensor (163a), the dynamic range of the gripping force is adjustable from 5 to 50N, and the spacing between the three grippers is adaptively adjusted through a servo module (163b).

6. The cylindrical material appearance inspection machine according to claim 1, characterized in that, It also includes a machine vision processing system (4), which uses deep learning algorithms to classify defects in images acquired by a line scan camera (144) and a planar camera (153), and the classification model supports online updates.

7. The cylindrical material appearance inspection machine according to claim 1, characterized in that, The unloading assembly component (22) includes an unloading turntable (221), which is connected to an unloading push rod (222). The unloading push rod (222) has a receiving box (223) at its lower part, which is connected to the second machine base (21). Both the unloading push rod (222) and the receiving box (223) are arranged in a ring.

8. The cylindrical material appearance inspection machine according to claim 7, characterized in that, The receiving box (223) has 6-8 units.

9. The cylindrical material appearance inspection machine according to claim 1, characterized in that, The inner wall of the non-destructive disk (121) and the upper part of the double linear vibration track (122) are provided with wool felt (124).

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