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

Abstract

The application discloses a kind of full-automatic extrusion detection equipment, system and rubber ring invisible cracking detection method, equipment includes main frame, vibrator automatic feeding mechanism, multi-station servo automatic material grabbing device, multiple detection stations, active glass extrusion carousel, discharge port and image analysis processing unit.System contains the equipment, control system and image processing system, motion is accurately controlled by servo motor and encoder, and image is analyzed using deep learning algorithm.Detection method is: first feeding, then grab to detection station, rotate component synchronous extrusion and shoot detection, process and analyze image to eliminate unqualified products, and finally discharge.In addition, the system is also provided with data storage and analysis module, can store detection results and statistical analysis, generate report and suggestion, realize the efficient, accurate detection of rubber ring.

Description

Technical Field

[0001] This invention relates to the field of rubber ring product testing technology, specifically to a fully automatic extrusion testing equipment, system, and method for detecting hidden cracks in rubber rings. Background Technology

[0002] Currently, the common method for detecting hidden cracks in rubber ring products is to use a vibratory feeder, where the product is fed into an extrusion roller via a glass conveyor belt. The extrusion roller then rotates, causing the product to spin under pressure. When the product is subjected to external force, the hidden cracks deform, revealing the cracks. The deformed areas are then photographed for inspection.

[0003] However, existing testing methods have several problems: when using glass trays for product loading, the spacing between the products is critical. Improper spacing can easily lead to invalid loading.

[0004] Furthermore, the current equipment on the market generally operates in a single-station testing mode, which has significant limitations in terms of efficiency.

[0005] Because of the rotating glass disc feeding method, it is difficult to precisely control the position of the product entering the extrusion roller, which may lead to a large displacement deviation of the product during the extrusion inspection process, thus affecting the inspection accuracy. Summary of the Invention

[0006] The purpose of this invention is to provide a fully automatic extrusion testing equipment, system, and method for detecting hidden cracks in rubber rings, so as to solve the problems of high requirements for feeding spacing, low testing efficiency, and affected testing accuracy in the existing rubber ring product testing equipment.

[0007] To achieve the above objectives, the present invention provides the following technical solution: The present invention relates to the field of automated testing equipment technology, specifically a fully automated extrusion testing equipment and system, and a method for detecting hidden cracks in rubber ring products using the equipment and system. This equipment and system is mainly used for efficient and accurate extrusion and testing of rubber ring products to identify and reject unqualified products with hidden cracks or other appearance defects.

[0008] This invention discloses a fully automatic extrusion testing device, comprising a main frame 1 for supporting and mounting 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 gripping device is responsible for gripping the product from the vibrator automatic feeding mechanism 2 and accurately placing it into the testing station; the testing station 4 includes a clamping extrusion wheel 5 and a multi-angle camera for extruding the rubber ring and capturing real-time images for testing; an active glass extrusion turntable 6 is located below the testing station 4 for driving the product to rotate under extrusion; and a discharge port 7 is used to discharge the tested rubber ring from the device.

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

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

[0011] Furthermore, each of the active glass extrusion turntables 6 simultaneously drives two sets of clamping extrusion wheels and multi-angle cameras 1 to work, 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, avoiding duplicate detection, invalid detection, and invalid rejection.

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

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

[0015] 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 based on the comparison result of the comparison unit.

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

[0017] The fully automatic extrusion inspection system of this invention, in addition to the aforementioned equipment, also 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 vibratory automatic feeding mechanism 2, the multi-station servo automatic gripping mechanism 3, the active glass extrusion turntable 6, the clamping extrusion rollers 5, and the multi-angle camera. The image processing system receives images captured by the multi-angle camera and performs real-time analysis through the image processing unit to identify hidden cracks and other appearance defects in the product, and rejects them. Furthermore, the system includes a data storage and analysis module for storing inspection results, performing statistical analysis, and generating inspection reports and quality control recommendations.

[0018] Furthermore, the control system precisely controls the movement of the multi-station servo automatic gripping mechanism 3 and the active glass extrusion turntable 6 through servo motors and encoders, ensuring the precise positioning and synchronous extrusion detection of the product at the inspection station;

[0019] Furthermore, the image processing system employs deep learning algorithms to perform real-time analysis of images captured by multi-angle cameras, identifying hidden cracks and other appearance defects in the product.

[0020] The present invention provides a method for detecting hidden cracks in rubber rings, comprising the following steps:

[0021] Step 1: The rubber ring product is fed into the equipment by the vibrator automatic feeding mechanism 2;

[0022] Step 2: The product is precisely placed into the inspection station 4 by the multi-station servo automatic gripping mechanism 3;

[0023] Step 3: Start the active glass extrusion turntable 6 to rotate clockwise, while simultaneously clamping the extrusion wheel 5 and the multi-angle camera to rotate counterclockwise, to simultaneously extrude the product and perform real-time shooting and detection;

[0024] Step 4: The captured images are processed and analyzed through the capture unit, detection unit, comparison unit, recognition unit, and rejection unit to identify and reject unqualified products;

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

[0026] The technical effects and advantages of this invention are as follows:

[0027] 1. Through an automatic feeding mechanism with a vibrator, a multi-station servo gripping mechanism, and a synchronous extrusion detection and automatic rejection unit, the entire process from feeding and detection to sorting is automated, significantly reducing labor costs. Each active glass extrusion turntable drives two sets of clamping extrusion wheels and a multi-angle camera, supporting parallel detection at multiple stations, greatly improving detection efficiency and increasing speed exponentially. Efficiency doubles with each additional station, triples with 4 stations, and increases fivefold with 6 stations.

[0028] 2. Employing counter-clockwise rotating clamping and squeezing wheels and multi-angle cameras, combined with the synchronous clockwise rotation of the active glass turntable, ensures that the product is captured from all angles while under pressure, covering 360-degree surface details and avoiding missed detections; Deep learning algorithm analysis: The image processing system, based on deep learning algorithms, can identify defects that are difficult to detect with the naked eye, such as invisible cracks and tiny scratches, in real time, with a detection accuracy of over 99%; Precise control of the gripping mechanism and turntable movement through servo motors and encoders achieves a positioning accuracy of ±0.1mm, avoiding duplicate detection or invalid rejections.

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

[0030] 4. The turntable is made of high-strength glass material, which combines transparency and pressure resistance, making it easy for multi-angle cameras to shoot without obstruction, while ensuring the stability of the extrusion process; the clamping pressure can be automatically adjusted according to the rubber rings of different specifications to avoid excessive extrusion that could cause product deformation, thus adapting to diverse production needs.

[0031] 5. It solves the problems of low efficiency, strong subjectivity and easy fatigue of traditional manual inspection, and is especially suitable for high-precision hidden crack detection scenarios; through multi-angle synchronous shooting and extrusion rotation mechanism, it overcomes the shortcomings of traditional mechanical inspection that can only cover a single angle and improves the detection rate of complex defects. Attached Figure Description

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

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

[0034] Figure 3 This is a flowchart of the steps of the present invention.

[0035] In the diagram: 1-Main frame, 2-Automatic vibrator feeding mechanism, 3-Multi-station servo automatic gripping mechanism, 4-Detection station, 5-Clamping extrusion wheel, 6-Active glass extrusion turntable, 7-Discharge port. Detailed Implementation

[0036] The technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.

[0037] The specific embodiments of the present invention will be described in detail below with reference to the accompanying drawings and examples.

[0038] Example 1: Fully Automated Extrusion Testing Equipment

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

[0040] Automatic feeding mechanism with vibrator: It feeds the rubber ring product to be tested into the equipment through vibration, ensuring that the product can enter the testing process in an orderly and continuous manner.

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

[0042] Inspection Station: Each inspection station includes clamping and extrusion rollers and multi-angle cameras. The clamping and extrusion rollers are used to compress the rubber ring, causing it to deform; the multi-angle cameras are used to capture real-time images of the rubber ring during the extrusion process, capturing image information of its deformation. Multi-angle cameras and light sources are evenly distributed in the up, down, left, and right directions of each set of clamping and extrusion rollers to inspect the appearance of the product from various angles. To prevent the camera space from being unable to directly take pictures, a prism can be introduced to reflect light at 90 degrees to detect the corresponding position.

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

[0044] Discharge port: The tested products are discharged from the equipment by mechanical or pneumatic devices to facilitate subsequent processing.

[0045] The image processing unit includes an image capture unit, a detection unit, a comparison unit, a recognition unit, and a rejection unit. The image capture unit is responsible for simultaneously capturing product images during the rotation of the clamping and squeezing rollers and the multi-angle camera; the detection unit detects the images captured by the image capture unit; the comparison unit compares the detection results with preset standards; the recognition unit identifies whether the product is qualified based on the comparison results; and the rejection unit rejects unqualified products identified by the recognition unit.

[0046] Example 2: Fully Automated Extrusion Detection System

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

[0048] Control system: The system precisely controls the movement of the multi-station servo automatic gripping mechanism and the active glass extrusion turntable through servo motors and encoders, ensuring the accurate positioning and synchronous extrusion testing of the product at the inspection station; the control system is also responsible for coordinating the working rhythm of each component to ensure the smooth operation of the entire inspection process.

[0049] Image Processing System: Employs deep learning algorithms to analyze images captured by multi-angle cameras in real time, identifying hidden cracks and other appearance defects in products. The system processes and analyzes images through modules such as capture, detection, comparison, recognition, and rejection units to automatically eliminate defective products.

[0050] Data storage and analysis module: This module stores test results, performs statistical analysis, and generates test reports and quality control recommendations. It helps users understand product quality status and optimize production processes and quality control procedures.

[0051] Example 3: Method for detecting hidden cracks in rubber ring products

[0052] Using the equipment and system described in Example 1 or Example 2, perform the following steps to detect hidden cracks in rubber ring products:

[0053] Step 1: The rubber ring product is fed into the equipment by the automatic feeding mechanism of the vibrator.

[0054] Step 2: The product is precisely placed onto the inspection station using a multi-station servo automatic gripping mechanism.

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

[0056] 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.

[0057] Step 5: Discharge the tested products from the equipment through the discharge port for further processing or packaging.

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

[0059] The applicant further declares that while the above embodiments illustrate the implementation method and apparatus structure of the present invention, the present invention is not limited to the above-described embodiments, meaning that the present invention must rely on the above methods and structures to be implemented. Those skilled in the art should understand that any improvements to the present invention, equivalent substitutions for the selected implementation methods, additions to steps, and selections of specific methods all fall within the protection and disclosure scope of the present invention.

[0060] This invention is not limited to the above-described embodiments. All methods that employ similar structures and approaches to achieve the objectives of this invention are within the scope of protection of this invention.

Claims

1. A fully automatic extrusion testing device, characterized in that: include The main frame (1) is used to support and install all structural components; The vibrator automatic feeding mechanism (2) is used to transport the rubber ring to be tested into the equipment; A multi-station servo automatic gripping mechanism (3) is used to grip the rubber ring from the vibrator automatic feeding mechanism (2) and accurately place it at the detection station; Multiple inspection stations (4), each inspection station (4) includes a clamping extrusion wheel (5) and a multi-angle camera for extruding and real-time shooting inspection of the rubber ring; An active glass extrusion turntable (6) is located below the inspection station (4) and is used to drive the rubber ring to rotate under the extrusion state; there is a rubber ring between the active glass extrusion turntable (6) and each clamping extrusion wheel (5); The discharge port (7) is used to discharge the tested rubber rings from the equipment; The system includes a capture unit, a detection unit, a comparison unit, an identification unit, and a rejection unit, which are used to process and analyze the captured images, identify and reject unqualified rubber rings. The active glass extrusion turntable (6) rotates clockwise, while the clamping extrusion wheels and multi-angle cameras on both sides rotate counterclockwise to achieve synchronous extrusion and detection of the rubber ring.

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

3. The fully automatic extrusion testing equipment according to claim 1, characterized in that: The image capture unit is used to capture images of the rubber ring simultaneously during the rotation of the clamping extrusion wheel (5) and the multi-angle camera; The detection unit is used to detect the images 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 based on the comparison result of the comparison unit; The rejection unit is used to reject the unqualified rubber rings identified by the identification unit.

4. A fully automatic extrusion detection system, characterized in that, include: The fully automatic extrusion testing equipment as described in any one of claims 1-3; Control system: Used to control the operation of the equipment, including the automatic feeding mechanism of the vibrator (2), the multi-station servo automatic gripping mechanism (3), the active glass extrusion turntable (6), the clamping extrusion wheel (5) and the synchronous operation of the multi-angle camera; Image processing system: used to receive images captured by multi-angle cameras, and to perform image analysis and processing through a capture unit, detection unit, comparison unit, recognition unit and rejection unit to identify and reject unqualified rubber rings; The control system precisely controls the movement of the multi-station servo automatic gripping mechanism (3) and the active glass extrusion turntable (6) through servo motors and encoders, ensuring the precise positioning and synchronous extrusion detection of the rubber ring at the detection station; The image processing system uses deep learning algorithms to analyze images captured by multi-angle cameras in real time, identifying hidden cracks and other appearance defects in the rubber ring.

5. The fully automatic extrusion detection system according to claim 4, characterized in that: The system also includes a data storage and analysis module for storing test results, performing statistical analysis, and generating test reports and quality control recommendations.

6. A method for detecting hidden cracks in a rubber ring, characterized in that, include: The fully automatic extrusion testing equipment as described in any one of claims 1-3 includes the following steps: Step 1: The rubber ring is fed into the equipment by the automatic feeding mechanism (2) of the vibrator; Step 2: The rubber ring is precisely placed into the inspection station (4) by the multi-station servo automatic gripping mechanism (3); Step 3: Start the active glass extrusion turntable (6) to rotate clockwise, while clamping the extrusion wheel (5) and the multi-angle camera to rotate counterclockwise, to simultaneously extrude the rubber ring and perform real-time shooting detection; 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 rubber rings; Step 5: Discharge the tested rubber rings from the equipment through the discharge port (7).

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