System and method for processing relaxed objects
Through the combination of magnets and wire holding fixtures, the problem of uncontrolled position of flexible lines during inspection is solved, precise control of flexible lines is achieved, and the accuracy of the inspection system is improved.
Patent Information
- Application Number
- CN202510109282.7
- Authority / Receiving Office
- CN · China
- Patent Type
- Applications(China)
- Current Assignee / Owner
- Priority Date
- 2025-01-17
- Filing Date
- 2025-01-23
- Publication Date
- 2025-07-25
AI Technical Summary
Existing inspection systems are difficult to accurately handle the position of flexible lines on the product, resulting in the misjudgment of image analysis as a defect.
The flexible wire is fixed with a magnet and held outside the field of view of the inspection device by a movable wire retaining fixture, and the positions of the wires are controlled using multiple actuators to ensure that they do not hinder imaging during the inspection.
It effectively avoids interference from flexible lines on imaging, ensures the accuracy and reliability of product inspection, and reduces the rate of misjudgment.
Smart Images
Figure CN120369707A_ABST
Abstract
Description
[0001] Cross - Reference to Related Applications
[0002] This application claims the benefit of U.S. Provisional Patent Application No. 63 / 623,991, filed on January 23, 2024, the entire disclosure of which is incorporated herein by reference. Technical Field
[0003] This disclosure relates to object inspection systems, and more particularly, to visual inspection systems for inspecting articles that include slack or flexible components, such as polymer products that include exposed flexible wires. Background Art
[0004] During manufacturing, it is often desirable to inspect products to ensure the required precision and / or detect defects (by way of example only). Some inspection systems rely on using cameras to image products and subjecting those images to analysis to detect defects. Thus, accurate inspection and / or product imaging requires precise handling of the product during inspection. This is particularly problematic when some or all of the product is flexible or slack in nature. For example, some mandrel - formed polymer products utilize flexible metal wires bonded thereto to affect their desired functionality. The presence of these wires, particularly at locations where they may exit the underlying product and thus be uncontrolled, can interfere with the inspection process. Improved systems and methods for accurately inspecting these and other types of products are desired. Summary of the Invention
[0005] According to an embodiment of the present disclosure, a system adapted to inspect an object that includes a flexible wire includes a feeding device that feeds the object toward an inspection device, a selectively movable magnet, and a selectively movable wire holding fixture. The magnet is adapted to secure to the flexible wire of the object when the flexible wire approaches the inspection device. The wire holding fixture engages the wire secured by the magnet and holds the wire in a predetermined position relative to the object being inspected and outside the detection field of the inspection device. Brief Description of the Drawings
[0006] The present invention will now be described, by way of example, with reference to the accompanying drawings, in which:
[0007] Figure 1 is an orthographic view of an exemplary product to be inspected that can be used to describe embodiments of the present disclosure;
[0008] Figure 2 is a partial orthographic view of an inspection system according to an embodiment of the present disclosure;
[0009] Figure 3 is Figure 2 another partial orthographic view of the inspection system of
[0010] Figure 4is a simplified front view of a product inspected by the inspection system of the present invention; and
[0011] Figure 5 is a simplified process diagram showing the flexible object handling process utilized by the inspection system of the present disclosure. Detailed Description of the Invention
[0012] Exemplary embodiments of the present disclosure will be described in detail below with reference to the accompanying drawings, in which like reference numerals represent like elements. However, the present disclosure may be embodied in many different forms and should not be construed as limited to the embodiments set forth herein; rather, these embodiments are provided so that this disclosure will be thorough and complete, and will fully convey the concept of the present disclosure to those skilled in the art.
[0013] In the following detailed description, for purposes of explanation, numerous specific details are set forth in order to provide a thorough understanding of the disclosed embodiments. However, it will be apparent that one or more embodiments may be practiced without these specific details. In other instances, well-known structures and devices are shown schematically in order to simplify the drawings.
[0014] According to an embodiment of the present disclosure, a system for visually inspecting an object including a flexible wire is provided. The system generally includes inspection means (e.g., a plurality of cameras) and is adapted to receive the object to be inspected in a feed direction (e.g., along the elongated longitudinal axis of the object). The system further includes a magnet configured to fix the flexible wire of the object when the flexible wire of the object approaches the inspection means and before the flexible wire of the object enters the field of view of the inspection means. A first actuator is provided for biasing the magnet and the wire captured thereby from a first position close to the object to be inspected to a second position away from the object to be inspected. Once moved away from the object, a wire holding fixture of the system captures the wire from the second position. As the object to be inspected also approaches the visual inspection means, a second actuator then translates the wire holding fixture and the wire in the feed direction towards the visual inspection means. During the translation, the wire holding fixture holds the wire in a position outside one or more fields of view of the inspection means. Since the wire holding fixture cannot be further translated due to mechanical obstruction (e.g., caused by spatial limitations of the inspection means and / or the inspection system), a third actuator raises or further biases the wire holding fixture, and thus the wire, away from the object, preventing it from sagging or arcing and ensuring that it remains outside the (multiple) fields of view of the inspection means when the inspection of the object is completed.
[0015] Generally referring to Figure 1, an exemplary product 1 that can be used to describe the system of the present disclosure may include, for example, a polymer body formed as a mandrel (e.g., an elongated cylindrical body), and one or more wires 4 are bonded to or within the polymer body along its axial direction. The product 1 includes a first end 2 and a second end 3 that are first fed into the inspection device. To ensure product quality, the product 1 must be inspected along its length by a product inspection system 100, as Figure 2 shown.
[0016] The presence of the wire 4 creates difficulties during the inspection of the product 1. Specifically, if the exposed wire 4 is captured by the imaging device of the inspection system 100, the image analysis algorithm utilized by the system, which is adapted to detect defects in the product 1, will typically mistake the wire for a defect (e.g., a crack or a rupture) in the product. Therefore, as the wire 4 at the end 3 of the product 1 approaches the inspection system 100, particularly its (multiple) imaging devices, the position of the wire 4 must be precisely controlled. For example, the wire 4 must be biased out of the field of view of the imaging device of the system during the inspection process, positioned to limit its visibility, and / or maintained in a consistent and predictable position relative to the product 1 such that it can be identified and masked or discarded during image processing.
[0017] Referring to Figure 2 , the exemplary inspection system 100 includes a plurality of inspection devices, such as imaging devices or cameras. More specifically, the exemplary inspection system 100 includes four cameras 5a, 5b, 5c, and 5d that are radially arranged around the central axis or the elongation axis of the product 1. In an exemplary embodiment, the cameras 5a, 5b, 5c, 5d are arranged around the product 1 at 90-degree increments such that images of the top, bottom, left, and right sides of the product 1 are captured. As shown, the cameras 5a, 5b, 5c, 5d are adapted to image sections of the product 1 as the product 1 passes through the funnel 16.
[0018] The product 1 is fed, for example, from a workbench 11 in an inspection or feed direction I that is parallel (or coaxial) to the axis of the product. The product 1 can be automatically fed via a pair of grippers 6a, 6b that are arranged along the product 1 in the feed direction I. The grippers 6a, 6b are adapted to grip the product 1 and incrementally move or index it in the feed direction I. Of course, other types of feed elements, such as rollers, etc., can be used.
[0019] As cameras 5a, 5b, 5c, 5d image product 1, associated image processing software analyzes the images of the product to detect defects in the product. This can include, for example, measuring the product to detect dimensions for determining whether product 1 falls outside of a predetermined acceptable range or tolerance, and inspecting the surface of the product for structural defects such as cracks, lines, etc. If inspection system 100 detects a defect, product 1 can be marked as rejected and pulled from further manufacturing, processing, or packaging.
[0020] From Figure 1 and Figure 2 It can be seen that at the start of the inspection cycle, line 4 is only exposed at the end 3 of product 1. However, when product 1 has been sufficiently indexed such that line 4 reaches position 12 adjacent to the vision inspection device (e.g., camera), the position of the exposed line 4 must be controlled by the system. This is achieved by line handling mechanism 200 according to an embodiment of the present disclosure.
[0021] Line handling mechanism 200 ensures that line 4 remains outside the field of view of at least a portion of cameras 5a, 5b, 5c, 5d. In one embodiment, mechanism 200 is operable to move line 4 such that it is not visible to any of cameras 5a, 5b, 5c, 5d, or is only visible to, for example, camera 5a for a limited time. During this time, line 4 can be masked during image processing as it is held in a consistent position by handling mechanism 200.
[0022] Now generally referring to Figure 2 and Figure 3 , the functionality of line handling mechanism 200 will now be described. In one embodiment, line handling mechanism 200 includes a movable magnet 202 and a movable line holding fixture 204. Due to the magnetism of line 4, as it approaches magnet 202 near position 12, it attaches to the magnet. With particular reference to Figure 3 , a detailed view of magnet 202 contacting and holding line 4 is shown.
[0023] Once line 4 is attached to magnet 202, actuator 208 causes the magnet to extend outwardly (i.e., horizontally) and away from product 1. The final extended position of line 4 allows the line to be engaged by line holding fixture 204. It is noted that line holding fixture 204 operates on a 2-axis system. In particular, actuator 214 operates to allow line holding fixture 204 to travel along the main axis of product 1 (i.e., in the feed direction), and actuator 220 enables line holding fixture 204 to travel in the vertical direction. As actuator 208 causes magnet 202 to extend outwardly with line 4, actuator 214 moves line holding fixture 204 toward line 4 such that notch 209 defined at the end of line holding fixture 204 captures the line.
[0024] In the case where the wire 4 is captured by the wire holding fixture 204, further indexing of the product 1 is matched by a similar indexing of the wire holding fixture 204 (and thus the wire 4 held in the notch 209) achieved via the actuator 214. This matching indexing maintains a consistent orientation of the wire 4 relative to the cameras 5a, 5b, 5c, 5d. More specifically, Figure 4 A cross-sectional representation of the wire 4 attached to the magnet 202 and disposed within the notch 209 of the wire holding fixture 204 is shown. As shown, the wire 4 is held outside the fields of view 15a, 15b, 15c, and 15d of the respective cameras 5a, 5b, 5c, 5d. In this way, the mechanism 200 is operable to hold the wire 4 in an ideal position when inspecting the product 1.
[0025] From Figure 2 and Figure 3 It should be understood that when the wire holding fixture 204 approaches the region of the funnel 16, its further indexing in the feed direction is physically prevented. At this time, the movement of the wire holding fixture 204 stops, but the product 1 needs to continue moving in the feed direction. As a result, the angle between the wire 4 and the main axis of the product 1 slowly decreases. This creates a bend, arc, or sag in the wire 4 near the end of the inspection process. To remedy this, the actuator 220 is adapted to vertically raise the wire holding fixture 204 to compensate for the bend so that the wire 4 does not fall into the field of view of at least each of the cameras 5a, 5b, 5c, 5d, although the wire 4 may initially be visible in the field of view 15a of the camera 5a at the start of the wire processing. However, this section of the wire can be considered during the inspection process. In this way, the mechanism 200 ensures that the wire 4 does not obstruct the inspection of the product for most of the entire cycle.
[0026] Figure 4 A simplified flowchart showing the above functions of the system according to an embodiment of the present disclosure is provided.
[0027] In a first step 300, a linear product including a wire extending from its end is indexed through a four-camera inspection system.
[0028] In step 302, the wire contacts and attaches to the magnet.
[0029] In step 304, the actuator biases the magnet and the attached wire away from the product to prevent the wire from entering or blocking the field of view of the camera during inspection.
[0030] In step 306, once the wire is biased by the magnet, another actuator moves the wire holding fixture towards the wire.
[0031] In step 308, a notch defined in the wire holding fixture captures the wire.
[0032] In step 310, the wire holding fixture travels with the product in the feed direction during its inspection until it can no longer travel due to physical blockage by the system.
[0033] In step 312, the movement of the wire holding fixture stops and the product continues to move through the inspection.
[0034] In step 314, as the angle of the wire relative to the product decreases (e.g., due to sagging or bending caused by the stationary holding fixture), another actuator raises the wire holding fixture to mitigate this decrease in the relative angle or bending of the wire.
[0035] In step 316, during further inspection, the wire remains out of the field of view of each camera.
[0036] In step 318, the product inspection is completed and the wire holding fixture and magnet return to their respective initial or original positions.
Claims
1. A system (100) adapted to inspect an object (1) including a flexible line (4), comprising: Feeding devices (6a, 6b) adapted to feed the object (1) towards inspection devices (5a, 5b, 5c, 5d) in a feeding direction; A movable magnet (202) adapted to fix the line (4) to the magnet (202) when the line (4) of the object (1) approaches the inspection devices (5a, 5b, 5c, 5d); And A movable line holding clamp (204) adapted to engage with the line (4) fixed by the magnet (202) and hold the line in a predetermined position relative to the object (1) to be inspected.
2. The system (100) according to claim 1, further comprising a first actuator (208) operably connected to the magnet (202) and adapted to position the magnet and the line (4) fixed to the magnet relative to the object (1) to be inspected.
3. The system (100) according to claim 2, wherein, The first actuator (208) is capable of moving between a first position close to the object (1) and a second position away from the object (1).
4. The system (100) according to claim 3, further comprising a second actuator (214) operably connected to the line holding clamp (204) and adapted to position and hold the line (4) relative to the object (1) in a predetermined position.
5. The system (100) according to claim 4, wherein, The second actuator (214) is adapted to bias the line holding clamp (204) in the feeding direction when the object (1) moves along the feeding direction.
6. The system (100) according to claim 5, further comprising a third actuator (220) operably connected to the line holding clamp (204).
7. The system (100) according to claim 6, wherein, The third actuator (220) is adapted to bias the line holding clamp (204) in a direction perpendicular to the feeding direction.
8. The system (100) according to claim 7, wherein, In response to the second actuator (214) stopping the movement of the line holding clamp in the feeding direction, the third actuator (220) vertically biases the line holding clamp (204).
9. The system (100) according to claim 8, wherein, The vertical movement of the line holding clamp (204) is operable to remove the bend in the line (4) caused by the stop of the line holding clamp in the feeding direction.
10. The system (100) according to claim 9, wherein, The line holding clamp (204) defines a notch (209) adapted to capture the line fixed by the magnet (202).
11. The system (100) according to claim 10, wherein, The notch (209) is open in the feeding direction and is adapted to capture the line (1) fixed by the magnet (202) when the line holding clamp (204) is translated in the feeding direction by the second actuator (214).
12. The system (100) according to claim 1, wherein, The inspection devices (5a, 5b, 5c, 5d) include a plurality of cameras radially arranged around a central axis of the object to be inspected.
13. The system (100) according to claim 12, wherein, The line holding clamp (202) is adapted to keep the line (1) out of the field of view of each of the plurality of cameras (5a, 5b, 5c, 5d) when the line holding clamp is translated in the feeding direction.
14. A method for inspecting an object (1) including an exposed flexible wire (4) using a system (100), comprising: Feeding (300) a portion of the object that does not include the exposed flexible wire in a feed direction past a visual inspection device (5a, 5b, 5c, 5d); Fixing (302) the wire to a magnet as the exposed wire approaches the visual inspection device (5a, 5b, 5c, 5d); Translating (304) the magnet and the wire away from the object; Capturing the wire with a wire holding fixture in a position where the wire is outside the field of view of the visual inspection device (5a, 5b, 5c, 5d); Translating (310) the wire holding fixture together with the wire in the feed direction as the object is continuously fed past the visual inspection device; Stopping (312) the wire holding fixture as the wire holding fixture approaches the end of a travel range in the feed direction; And Translating (314) the wire holding fixture in a direction perpendicular to the feed direction as the object continues towards the visual inspection device (5a, 5b, 5c, 5d).