Full-automatic extrusion detection equipment and system and rubber ring invisible crack detection method

Abstract

The invention discloses full-automatic extrusion detection equipment, a full-automatic extrusion detection system and a rubber ring invisible crack detection method. The equipment comprises a main body frame, a vibrator automatic feeding mechanism, a multi-station servo automatic grabbing device, a plurality of detection stations, an active glass extrusion turntable, a discharge port and an image analysis processing unit. The system comprises the equipment, a control system and an image processing system, motion is accurately controlled through a servo motor and an encoder, and an image is analyzed by adopting a deep learning algorithm. The detection method comprises the following steps: firstly feeding, then grabbing to a detection station, synchronously extruding by a rotating part, shooting and detecting, processing and analyzing an image to remove unqualified products, and finally discharging. In addition, the system is further provided with a data storage and analysis module, detection results can be stored and subjected to statistical analysis, reports and suggestions are generated, and efficient and accurate detection of the rubber rings is achieved.

Description

Technical Field

[0001] The present invention relates to the technical field of rubber ring product detection, and specifically relates to a fully automatic extrusion detection device, system and a method for detecting invisible cracks in rubber rings. Background Art

[0002] Currently, for detecting invisible cracks in rubber ring products on the market, the method of feeding materials by a vibrating disk is generally adopted. The products are sent to the extrusion wheel through a glass conveyor belt. Subsequently, the extrusion wheel rotates to drive the products to rotate automatically under the extrusion state. When the products are subjected to external forces, the invisible cracked parts will deform, making the cracks appear. Then, a camera is used to photograph and detect the cracking condition of the deformed part.

[0003] However, there are many problems with the existing detection methods: When using a glass disk for product feeding, there are high requirements for the feeding spacing of the products. If the spacing is set improperly, it is easy to cause ineffective feeding.

[0004] Moreover, the operation mode of the existing equipment on the market is generally single-station detection, and this method has great limitations in terms of efficiency.

[0005] Due to the method of feeding materials by rotating the glass disk, it is difficult to accurately control the position where the products enter the extrusion wheel, resulting in large displacement deviations of the products in the extrusion detection link, which in turn affects the detection accuracy. Summary of the Invention

[0006] The purpose of the present invention is to provide a fully automatic extrusion detection device, system and a method for detecting invisible cracks in rubber rings, so as to solve the problems in the prior art such as high requirements for the feeding spacing of rubber ring product detection equipment, low detection efficiency, and affected detection accuracy.

[0007] To achieve the above purpose, the present invention provides the following technical solutions: The present invention relates to the technical field of automated detection equipment, and specifically is a fully automatic extrusion detection device and system, as well as a method for detecting invisible cracks in rubber ring products using the device and system. The device and system are mainly used for efficiently and accurately extruding and detecting rubber ring products to identify and eliminate unqualified products with invisible cracks or other appearance defects.

[0008] A fully automatic extrusion testing device of the present invention comprises a main frame 1 for supporting and installing all structural components; wherein a vibrator automatic feeding mechanism 2 is responsible for conveying the rubber ring to be tested into the device; a multi-station servo automatic grabbing device is responsible for grabbing the product from the vibrator automatic feeding mechanism 2 and placing it accurately at the testing station; the testing station 4 comprises a clamping extrusion wheel 5 and a multi-angle camera for extruding and real-time shooting of the rubber ring; an active glass extrusion turntable 6 is located below the testing station 4 and is used to drive the product to self-rotate in an extruded state; a discharge port 7 is used to discharge the rubber ring that has been tested out of the device;

[0009] In addition, the captured images are processed and analyzed through capture, detection, comparison, recognition and rejection units to achieve automatic rejection of unqualified products.

[0010] Furthermore, the active glass extrusion turntable 6 rotates clockwise, while the clamping extrusion wheels and the multi-angle camera 1 on both sides thereof rotate counterclockwise to achieve synchronous extrusion and detection of the product.

[0011] Furthermore, each of the active glass squeezing turntables 6 drives two sets of clamping squeezing wheels and the multi-angle camera 1 to work simultaneously, thereby realizing multi-station synchronous detection.

[0012] Furthermore, the multi-station servo automatic gripping mechanism 3 ensures that each rubber ring is accurately positioned at the detection station, thereby avoiding repeated detection, invalid detection and invalid rejection.

[0013] Furthermore, the capture unit is used to capture the product image synchronously during the rotation of the clamping and squeezing wheel 5 and the multi-angle camera;

[0014] The detection unit is used to detect the image captured by the capture unit;

[0015] The comparison unit is used to compare the detection result of the detection unit with the preset standard; The identification unit is used to identify whether the rubber ring is qualified according to the comparison result of the comparison unit;

[0016] The rejecting unit is used to reject the unqualified rubber rings identified by the identifying unit.

[0017] The full-automatic extrusion detection system of the present invention, in addition to the above-mentioned equipment, further includes a control system and an image processing system. The control system is responsible for controlling the overall operation of the equipment, including the synchronous operation of the vibrator automatic feeding mechanism 2, the multi-station servo automatic grasping mechanism 3, the active glass extrusion turntable 6, the clamping extrusion wheel 5, and the multi-angle camera. The image processing system is used to receive the images taken by the multi-angle camera and perform real-time analysis through the image processing unit to identify the invisible cracks and other appearance defects of the product and reject them. In addition, the system also includes a data storage and analysis module for storing the detection results and performing statistical analysis to generate detection reports and quality control suggestions.

[0018] Furthermore, the control system precisely controls the movements of the multi-station servo automatic grasping mechanism 3 and the active glass extrusion turntable 6 through servo motors and encoders to ensure the precise positioning and synchronous extrusion detection of the product at the detection station.

[0019] Furthermore, the image processing system uses deep learning algorithms to perform real-time analysis on the images taken by the multi-angle camera to identify the invisible cracks and other appearance defects of the product.

[0020] A method for detecting invisible cracks in a rubber ring according to the present invention includes the following steps:

[0021] Step 1: Feed the rubber ring-shaped product into the equipment through the vibrator automatic feeding mechanism 2.

[0022] Step 2: Precisely place the product onto the detection station 4 through the multi-station servo automatic grasping mechanism 3.

[0023] Step 3: Start the active glass extrusion turntable 6 to rotate clockwise, and at the same time, the clamping extrusion wheel 5 and the multi-angle camera rotate counterclockwise to perform synchronous extrusion and real-time shooting detection on the product.

[0024] Step 4: Process and analyze the taken images through the capture unit, detection unit, comparison unit, recognition unit, and rejection unit to identify and reject unqualified products.

[0025] Step 5: Discharge the product after detection from the equipment through the discharge port 7.

[0026] The technical effects and advantages of the present invention:

[0027] 1. Through the vibrator automatic feeding mechanism, multi-station servo grasping mechanism, synchronous extrusion detection, and automatic rejection unit, the entire process from feeding, detection to sorting is realized without human operation, significantly reducing labor costs. Each active glass extrusion turntable drives two sets of clamping extrusion wheels and multi-angle cameras, supporting multi-station parallel detection, greatly improving the detection efficiency. The speed increases geometrically. For each additional station, the efficiency doubles. The efficiency of 4 stations is increased by 3 times, and the efficiency of 6 stations is increased by 5 times.

[0028] 2. The clamping and squeezing wheel that rotates counterclockwise and the multi-angle camera are adopted. Combining with the synchronous clockwise rotation of the active glass turntable, it ensures that the product is photographed in all directions under the squeezing state, covering 360-degree surface details and avoiding missed inspections. Deep learning algorithm analysis: The image processing system is based on deep learning algorithms and can real-time identify defects that are difficult to detect by the naked eye, such as invisible cracks and micro-scratches, with a detection accuracy of over 99%. The movement of the grasping mechanism and the turntable are precisely controlled by a servo motor and an encoder, with a positioning accuracy of ±0.1 mm, avoiding repeated detections or invalid rejections.

[0029] 3. The system integrates a data storage module to record the detection results of each batch of products and generate statistical analysis reports (such as defect type distribution, yield trend), providing a basis for process optimization. Combining the rapid response of the comparison unit and the recognition unit, unqualified products can be rejected within 0.3 seconds, ensuring the continuity and quality consistency of the production line.

[0030] 4. The turntable made of high-strength glass material has both transparency and pressure resistance, facilitating unobstructed shooting by the multi-angle camera and ensuring the stability of the squeezing process at the same time. The clamping pressure can be automatically adjusted according to different specifications of rubber rings, avoiding product deformation caused by excessive squeezing and adapting to diverse production requirements.

[0031] 5. It solves the problems of low efficiency, strong subjectivity, and easy fatigue in traditional manual inspections, especially suitable for the detection scenario of invisible cracks with high-precision requirements. Through multi-angle synchronous shooting and squeezing rotation mechanism, it overcomes the defect that traditional mechanical inspections can only cover a single angle, improving the detection rate of complex defects. BRIEF DESCRIPTION OF THE DRAWINGS

[0032] Figure 1 is a schematic structural diagram of the present invention;

[0033] Figure 2 is a partial detail diagram of the present invention;

[0034] Figure 3 is a step flow chart of the present invention.

[0035] In the figure: 1 - main body frame, 2 - vibrator automatic feeding mechanism, 3 - multi-station servo automatic grasping mechanism, 4 - detection station, 5 - clamping and squeezing wheel, 6 - active glass squeezing turntable, 7 - discharge port. DETAILED DESCRIPTION OF THE INVENTION

[0036] Next, the technical solutions in the embodiments of the present invention will be clearly and completely described in conjunction with the accompanying drawings in the embodiments of the present invention. Obviously, the described embodiments are only a part of the embodiments of the present invention, rather than all the embodiments. All other embodiments obtained by those of ordinary skill in the art based on the embodiments of the present invention without creative efforts shall fall within the protection scope of the present invention.

[0037] The following will describe in detail the specific implementation manners of the present invention in conjunction with the accompanying drawings and embodiments.

[0038] Embodiment 1: Fully automatic extrusion detection equipment

[0039] Main body frame: As the support structure of the entire equipment, the main body frame is made of high-strength materials to ensure the stability and durability of the equipment.

[0040] Vibrator automatic feeding mechanism: The rubber ring-shaped products to be detected are fed into the equipment through vibration to ensure that the products can enter the detection process orderly and continuously.

[0041] Multi-station servo automatic grasping device: Driven by a servo motor, by precisely controlling the position and speed of the grasping mechanism, it ensures the accurate position of each rubber ring at the detection station, avoiding repeated detection, invalid detection and invalid rejection.

[0042] Detection station: Each detection station includes a clamping and extrusion wheel and a multi-angle camera. The clamping and extrusion wheel is used to extrude the rubber ring to make it deform; the multi-angle camera is used to take real-time pictures of the rubber ring during the extrusion process to capture the image information during its deformation process. Multi-angle cameras and light sources are evenly distributed in the up, down, left and right directions of each group of clamping and extrusion wheels to detect the appearance of the product at each angle. To prevent the camera from being unable to take pictures directly in the space, a prism method can be introduced to reflect the light image by 90 degrees to detect the corresponding position.

[0043] Active glass extrusion turntable: Located below the detection station, made of glass material, with good transparency and wear resistance. The active glass extrusion turntable rotates clockwise by a servo motor plus a reducer, combined with the counterclockwise rotation of the clamping and extrusion wheel and the multi-angle camera (using a servo motor plus a reducer to rotate counterclockwise, with the speed synchronized with the motor of the active wheel), to achieve synchronous extrusion and detection of the product.

[0044] Discharge port: The detected products are discharged from the equipment through mechanical or pneumatic devices for subsequent processing.

[0045] Image processing unit: It includes a capture unit, a detection unit, a comparison unit, an identification unit, and a rejection unit. The capture unit is responsible for synchronously capturing product images during the rotation of the clamping extrusion wheel and the multi-angle camera; the detection unit detects the images captured by the capture unit; the comparison unit compares the results detected by the detection unit with the preset standards; the identification unit identifies whether the product is qualified according to the comparison results of the comparison unit; and the rejection unit rejects the unqualified products identified by the identification unit.

[0046] Embodiment 2: Fully automatic extrusion detection system

[0047] Based on Embodiment 1, a control system and an image processing system are added;

[0048] Control system: It precisely controls the movement of the multi-station servo automatic grasping mechanism and the active glass extrusion turntable through a servo motor and an encoder to ensure the precise positioning and synchronous extrusion detection of the product at the detection station; the control system is also responsible for coordinating the working rhythm of each component to ensure the smooth progress of the entire detection process.

[0049] Image processing system: It uses deep learning algorithms to perform real-time analysis on the images captured by the multi-angle camera to identify invisible cracks and other appearance defects of the product. The image processing system processes and analyzes the images through modules such as the capture unit, the detection unit, the comparison unit, the identification unit, and the rejection unit to achieve the automatic rejection of unqualified products.

[0050] Data storage and analysis module: It is used to store the detection results and perform statistical analysis to generate detection reports and quality control suggestions. This module can help users understand the product quality status and optimize the production process and quality control process.

[0051] Embodiment 3: Method for detecting invisible cracks in rubber ring products

[0052] Use the equipment and system in Embodiment 1 or Embodiment 2 to perform the detection of invisible cracks in rubber ring products according to the following steps:

[0053] Step 1: Feed the rubber ring product into the equipment through the vibrator automatic feeding mechanism.

[0054] Step 2: Precisely place the product on the detection station through the multi-station servo automatic grasping mechanism.

[0055] Step 3: Start the active glass extrusion turntable to rotate clockwise, and at the same time, the clamping extrusion wheel and the multi-angle camera rotate counterclockwise to perform synchronous extrusion and real-time shooting detection on the product.

[0056] Step 4: Process and analyze the captured images through the capture unit, the detection unit, the comparison unit, the identification unit, and the rejection unit to identify and reject unqualified products.

[0057] Step Five: Discharge the products that have completed the detection from the discharging port of the equipment for subsequent processing or packaging.

[0058] Through the above embodiments, the present invention provides an efficient and accurate fully automatic extrusion detection device and system, as well as a method for detecting invisible cracks in rubber ring products using the device and system, providing strong technical support for the quality detection of rubber ring products.

[0059] The applicant further declares that the present invention uses the above embodiments to illustrate the implementation method and device structure of the present invention, but the present invention is not limited to the above embodiments, that is, it does not mean that the present invention must rely on the above methods and structures to be implemented. Those skilled in the art should understand that any improvement to the present invention, equivalent replacement of the implementation method selected by the present invention, addition of steps, selection of specific methods, etc., all fall within the protection scope and the disclosed scope of the present invention.

[0060] The present invention is not limited to the above embodiments. All ways that adopt a structure and method similar to the present invention to achieve the purpose of the present invention are within the protection scope of the present invention.

Claims

1. A fully automatic extrusion detection device, characterized in that: include The main frame (1) is used to support and mount all structural components; A vibrator automatic feeding mechanism (2) is used to feed the rubber ring to be tested into the device; A multi-station servo automatic material grabbing device (3) is used to grab products from the vibrator automatic feeding mechanism (2) and accurately place them at the inspection station; A plurality of inspection stations (4), each inspection station (4) comprising a clamping extrusion wheel (5) and a multi-angle camera, for extruding and real-time photographing the rubber ring for inspection; An active glass extrusion turntable (6), located below the inspection station (4), is used to drive the product to self-rotate in an extruded state; A discharge port (7) is used to discharge the rubber ring after testing out of the equipment; The capture unit, the detection unit, the comparison unit, the recognition unit and the rejection unit are used to process and analyze the captured images, and to recognize and reject unqualified products.

2. The fully automatic extrusion detection equipment according to claim 1 is characterized in that: The active glass extrusion turntable (6) rotates clockwise, while the clamping extrusion wheels and the multi-angle camera (1) on both sides thereof rotate counterclockwise, so as to achieve synchronous extrusion and detection of the product.

3. The fully automatic extrusion detection equipment according to claim 1 is characterized in that: Each of the active glass squeezing turntables (6) drives two sets of clamping squeezing wheels and the multi-angle camera (1) to work simultaneously, thereby realizing multi-station synchronous detection.

4. The fully automatic extrusion detection equipment according to claim 1 is characterized in that: The multi-station servo automatic grasping mechanism (3) ensures that each rubber ring is accurately positioned at the detection station, thereby avoiding repeated detection, invalid detection and invalid rejection.

5. The fully automatic extrusion detection equipment according to claim 1 is characterized in that: The capture unit is used to capture the product image synchronously during the rotation of the clamping and squeezing wheel (5) and the multi-angle camera; The detection unit is used to detect the image captured by the capture unit; The comparison unit is used to compare the detection result of the detection unit with a preset standard; The identification unit is used to identify whether the rubber ring is qualified according to the comparison result of the comparison unit; The rejecting unit is used to reject the unqualified rubber rings identified by the identifying unit.

6. A fully automatic extrusion detection system, characterized in that: include: The fully automatic extrusion detection device as described in any one of claims 1 to 5; Control system: used to control the operation of the equipment, including the synchronous operation of the vibrator automatic feeding mechanism (2), the multi-station servo automatic gripping mechanism (3), the active glass extrusion turntable (6), the clamping extrusion wheel (5) and the multi-angle camera; Image processing system: used to receive images taken by multi-angle cameras, and perform image analysis and processing through the capture unit, detection unit, comparison unit, recognition unit and rejection unit to identify and reject unqualified products; The control system accurately controls the movement of the multi-station servo automatic gripping mechanism (3) and the active glass extrusion turntable (6) through a servo motor and an encoder, thereby ensuring accurate positioning and synchronous extrusion testing of the product at the testing station; The image processing system uses a deep learning algorithm to perform real-time analysis on images taken by multi-angle cameras to identify invisible cracks and other appearance defects of the product.

7. The fully automatic extrusion detection system according to claim 6, characterized in that: The system also includes a data storage and analysis module for storing the test results and performing statistical analysis to generate test reports and quality control recommendations.

8. A method for detecting invisible cracks of a rubber ring, characterized in that: The following steps are involved: Step 1: Feed the rubber ring product into the equipment through the vibrator automatic feeding mechanism (2); Step 2: The product is accurately placed at the inspection station (4) through the multi-station servo automatic gripping mechanism (3); Step 3: Start the active glass extrusion turntable (6) to rotate clockwise, and at the same time, the clamping extrusion wheel (5) and the multi-angle camera rotate counterclockwise to perform synchronous extrusion and real-time shooting inspection of the product; Step 4: The captured images are processed and analyzed by the capture unit, detection unit, comparison unit, recognition unit and rejection unit to identify and reject unqualified products; Step 5: The inspected product is discharged from the equipment through the discharge port (7).

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