Embossing processing technology for stainless steel checkered plate

Abstract

The invention relates to the technical field of plate surface treatment, in particular to a stainless steel checkered plate embossing process which comprises the following steps: S1, preparing materials; s2, designing and manufacturing a mold; s3, embossing equipment is prepared; s4, knurling is carried out; s5, carrying out post-treatment; s6, machine vision detection; and S7, packaging and transporting. In the step S6 of machine vision detection, if the matching degree still cannot reach a threshold value after the pressure or temperature is adjusted, the machine vision detection enters an abnormal judgment step, and the abnormal judgment step comprises the following steps that S61, a mold pre-detection record is extracted for judgment; s62, analyzing and judging spatial distribution; s63, monitoring and judging a time sequence trend; according to the embossing processing technology for the stainless steel checkered plate, the reason that the pattern matching degree cannot reach the threshold value can be judged only through a logical algorithm and multi-link cross validation.

Description

Technical Field

[0001] The invention relates to the technical field of plate surface treatment, in particular to an embossing process for a stainless steel patterned plate. Background Art

[0002] At present, based on the considerations of improving anti-slip properties, aesthetics and increasing heat dissipation, some stainless steel checkered plates will be embossed using embossing equipment to form stainless steel checkered plates. The embossing process of stainless steel checkered plates usually includes designing pattern patterns according to customer requirements, making embossing molds and installing them on embossing equipment, cleaning the surface of the stainless steel plate, starting the embossing equipment so that the mold can imprint the pattern onto the stainless steel plate under pressure and heating, and inspecting the appearance of the pattern of the stainless steel checkered plate. Among them, the inspection link, as a quality control link in the processing technology, has an important impact on the quality of the final processing and forming.

[0003] When inspecting the appearance of the pattern of stainless steel checkered plates during the embossing process, in order to avoid the low efficiency and error-prone problems caused by manual inspection, existing means may introduce machine vision inspection for real-time inspection. For example, the pattern image of the current stainless steel checkered plate is collected by a camera and compared with the reference pattern template, and the matching degree between the actual pattern and the reference template is calculated. If it is lower than the threshold (such as 90%), an alarm is triggered and it is recommended to adjust the pressure or temperature.

[0004] In the above methods, if the matching degree still cannot reach the threshold after adjusting the pressure or temperature, the embossing mold may be damaged and it is necessary to shut down the mold for maintenance or replace the mold with a new one. It is also possible that there are defects in the current batch of stainless steel plates, resulting in uneven hardness of the plate surface, thereby affecting the formation of the pattern. For this reason, it is usually necessary to add multiple sensors and complex models based on multiple sensors to analyze the reasons why the pattern matching degree cannot reach the threshold, resulting in a high cost of the original embossing equipment, and ultimately leading to a high cost for embossing stainless steel patterned plates. Summary of the Invention

[0005] In order to determine the reason why the pattern matching degree cannot reach a threshold without adding multiple sensors and complex models, the present application provides a stainless steel pattern plate embossing process.

[0006] The present invention provides a stainless steel pattern plate embossing process using the following technical solutions:

[0007] A stainless steel patterned plate embossing process comprises the following steps: S1, material preparation; S2, mold design and manufacturing; S3, embossing equipment preparation; S4, embossing; S5, post-processing; S6, machine vision inspection; S7, packaging and transportation; in the machine vision inspection in S6, if the matching degree still cannot reach the threshold after adjusting the pressure or temperature, the machine vision inspection enters the abnormality judgment step, and the abnormality judgment step comprises the following steps: S61, extracting the mold pre-inspection record for judgment; S62, spatial distribution analysis and judgment; S63, time series trend monitoring and judgment.

[0008] Preferably, in S6, the abnormality judgment step of the machine vision detection further includes: S64, increasing the pressure or temperature to perform improvement judgment.

[0009] Preferably, the extraction of mold pre-inspection record judgment in S61 includes the following steps: before starting the machine or changing the mold every day, use a camera to capture the surface image of the blank mold, and compare it with the initial reference template to form a pre-inspection record. If the pre-inspection record is abnormal, it is directly determined to be a mold problem; if the pre-inspection record is normal, proceed to the next abnormality judgment step.

[0010] Preferably, the spatial distribution analysis and judgment of S62 includes the following steps: dividing the plate into gridded areas, calculating the pattern matching degree of each small area respectively; if the low matching area appears repeatedly in a fixed position, for example, always in the center area or the same position on the edge, it is determined to be a mold problem and there may be local wear; if the low matching area is randomly distributed, proceed to the next abnormality judgment step.

[0011] Preferably, the timing trend monitoring and judgment of S63 includes the following steps: recording the pattern matching data of 10-20 times of continuous embossing, generating a trend curve, if the matching degree continues to decrease, indicating that the mold is continuously worn, it is determined to be a mold problem; if the matching degree jumps irregularly, it is determined to be a plate problem.

[0012] Preferably, the improvement judgment of increasing pressure or temperature in S64 includes the following steps: if the matching is significantly improved after increasing the pressure or temperature, it indicates that there are indeed problems with uneven thickness or abnormal hardness of the plate; if the matching is not significantly improved after increasing the pressure or temperature, it means that there are other problems with the surface plate or the mold, and manual intervention is made to judge and form a human-machine coordination mechanism.

[0013] Preferably, the pressure or temperature increased in the abnormality judgment step needs to be greater than the pressure or temperature increased in the normal processing step.

[0014] Preferably, in S64, a standard thickness value is set. If the thickness of the plate exceeds the standard thickness value, an improvement judgment is made by increasing the pressure. If the thickness of the plate exceeds the standard thickness value, an improvement judgment is made by increasing the temperature.

[0015] Preferably, a thickness detection component is provided on the embossing machine, and the thickness detection step is provided before the embossing step.

[0016] Preferably, in the machine vision inspection of S6, the camera is connected to the embossing machine through a lifting assembly, and the height of the camera changes in direct proportion to the thickness of the plate.

[0017] The beneficial effects of the present invention are:

[0018] 1. Through the above three abnormality judgment steps in machine vision inspection of the present invention, it is possible to determine whether the problem of the matching degree being always below the threshold is a mold problem or a plate problem. In the case of a mold problem, it is further possible to determine whether the mold has a static defect or a dynamic defect. In the case of a dynamic defect, it is further possible to determine whether it is a temporary wear or a continuous wear. Ultimately, without adding high-end sensors or complex models, the reason why the pattern matching degree cannot reach the threshold can be determined solely through logical algorithms and multi-step cross-validation, thereby avoiding the high cost of embossing equipment and thus avoiding the high cost required for embossing stainless steel patterned plates.

[0019] 2. By increasing the pressure or temperature to perform the improvement judgment step, it is possible to further verify whether there is uneven thickness or abnormal hardness of the plate;

[0020] 3. The height of the camera changes in direct proportion to the thickness of the plate, ensuring that the area captured by the camera for plates of different thicknesses is closer, thereby improving the consistency of the detection effect. BRIEF DESCRIPTION OF THE DRAWINGS

[0021] Figure 1 This is a flow chart of the embossing process of the stainless steel patterned plate in the embodiment of the present application;

[0022] Figure 2 This is a flowchart of the abnormality judgment steps of machine vision detection in an embodiment of the present application. DETAILED DESCRIPTION

[0023] The following will be combined Figure 1-Figure 2 The present invention is further described with reference to the accompanying drawings and examples.

[0024] This embodiment discloses a stainless steel pattern plate embossing process.

[0025] Reference Figure 1 The embossing process of stainless steel pattern plate includes the following steps:

[0026] S1, material preparation:

[0027] Select stainless steel plate: select stainless steel plate of appropriate material and thickness according to your needs;

[0028] Surface preparation: Make sure the surface is clean and free of oil, dirt or oxidation.

[0029] S2, mold design and manufacturing:

[0030] Design pattern: Design pattern according to customer requirements;

[0031] Mold making: Molds are made using engraving or CNC machining to ensure precision and durability.

[0032] S3, embossing equipment preparation:

[0033] Choose an embossing machine: Choose a suitable embossing machine based on the thickness of the sheet and the complexity of the pattern;

[0034] Install the mold: Install the mold correctly on the embossing machine.

[0035] S4, embossing:

[0036] Preheating: Preheat the stainless steel plate to reduce stress;

[0037] Positioning: Place the sheet on the embossing machine workbench to ensure accurate positioning.

[0038] S5, post-processing:

[0039] Cooling: After embossing, let the board cool naturally;

[0040] Trimming: remove burrs and excess parts to ensure smooth edges;

[0041] Surface treatment: Polishing, brushing and other treatments are performed to improve appearance and corrosion resistance.

[0042] S6, machine vision inspection:

[0043] Hardware composition: A CCD camera is installed on the outlet side of the embossing machine and equipped with a ring-shaped LED light source. The CCD camera is linked to the embossing machine PLC controller through an industrial computer to adjust the pressure and temperature parameters of the embossing machine.

[0044] Software function: Collect the pattern image of the current stainless steel pattern plate and compare it with the reference pattern template, calculate the matching degree between the actual pattern and the reference template, and if it is lower than the threshold (such as 90%), trigger an alarm and recommend increasing the pressure or temperature.

[0045] S7, Packaging and Shipping:

[0046] Packaging: Use anti-scratch materials to prevent damage during transportation;

[0047] Transportation: Ensure to avoid collision and squeezing during transportation.

[0048] In the S6's machine vision inspection, if the matching degree still cannot reach the threshold after adjusting the pressure or temperature, the embossing mold may be damaged, requiring shutdown for mold maintenance or replacement with a new one. It is also possible that the current batch of stainless steel plates has defects, resulting in uneven hardness on the plate surface, thus affecting the formation of the pattern. To achieve abnormal judgment, further improvements have been made.

[0049] In the S6 machine vision inspection, if the matching degree still fails to reach the threshold after adjusting the pressure or temperature, the machine vision inspection enters the abnormality judgment step, including:

[0050] S61, extract the mold pre-inspection record and judge:

[0051] Before starting the machine or changing the mold every day, use a camera to capture an image of the blank mold surface and compare it with the initial reference template to form a pre-inspection record. If the pre-inspection record is abnormal, it is directly determined to be a mold problem; if the pre-inspection record is normal, the next abnormality judgment step is entered to determine whether the mold has any abnormalities during operation.

[0052] It should be noted that there are limitations to mold pre-inspection, because mold pre-inspection is completed in a static environment, but during the actual embossing process, the mold is in a dynamic working environment (high temperature, high pressure, and continuous friction). Therefore, the mold may cause local temperature rise or material adhesion due to continuous production after pre-inspection, causing temporary deformation or wear. Oil and debris during production may also adhere to the mold surface, resulting in blurred patterns during embossing.

[0053] S62, spatial distribution analysis and judgment:

[0054] The plate is divided into gridded areas, and the pattern matching degree of each small area is calculated separately. If the low-matching area appears repeatedly in a fixed position, for example, always in the center area or the same position on the edge, it is judged to be a mold problem and there may be local wear. If the low-matching area is randomly distributed, the next abnormality judgment step is entered for secondary verification to determine whether the mold is suffering from continuous wear.

[0055] It should be noted that if the mold is subject to continuous rapid wear, the embossing pattern will be different each time, thus presenting a "pseudo-random" defect in the plate. Therefore, even if the results of the spatial distribution analysis point to a plate problem, further secondary verification is required.

[0056] S63, time series trend monitoring and judgment:

[0057] Record the pattern matching data of 10-20 consecutive embossings and generate a trend curve. If the matching degree continues to decrease, it indicates that the mold is continuously worn, and it is judged to be a mold problem; if the matching degree jumps irregularly, it is judged to be a plate problem.

[0058] In summary, through the above three steps of abnormal judgment in machine vision detection of the present invention, it is possible to check whether the problem that the matching degree is always lower than the threshold is a mold problem or a plate problem, and in the case of a mold problem, it is possible to further check whether the mold has static defects or dynamic defects, and in the case of dynamic defects, it is possible to further check whether it is short-term wear or continuous wear. Ultimately, without adding high-end sensors or complex models, the reason why the pattern matching degree cannot reach the threshold can be determined only through logical algorithms and multi-link cross-validation, thereby avoiding the high cost of embossing equipment and thus avoiding the high cost required for embossing of stainless steel patterned plates.

[0059] During the embossing process of stainless steel plates, plate problems are usually caused by uneven thickness or abnormal hardness of the plates in the batch, which makes it impossible to emboss a highly matched pattern under normal pressure or temperature. In some embodiments, to further verify whether the plate has uneven thickness or abnormal hardness, the abnormality judgment step of machine vision inspection also includes the following steps:

[0060] S64, increase pressure or temperature to determine improvement:

[0061] The increased pressure or temperature during this abnormality determination step must be greater than that during normal processing to maximize the improvement effect. If the pattern matching of the sheet material is significantly improved (matching >3% improvement) after increasing the pressure or temperature of the embossing machine, it indicates that the sheet material does have uneven thickness or abnormal hardness. If the matching does not improve significantly after increasing the pressure or temperature, it indicates that there are other problems with the sheet material or the mold. At this time, manual intervention is required to form a human-machine coordination mechanism. Through the above steps, the effect of further verifying whether the sheet material has uneven thickness or abnormal hardness is achieved.

[0062] In S64, a standard thickness value is set. If the thickness of the plate exceeds the standard thickness value, the improvement is judged by increasing the pressure. If the thickness of the plate exceeds the standard thickness value, the improvement is judged by increasing the temperature to deal with the situation where the plate is too thin and it is difficult to perform improvement test by increasing the pressure.

[0063] To detect the thickness of the sheet material, the embossing machine is equipped with a thickness detector, which can be a distance sensor. The thickness detection step is performed before the embossing step. Furthermore, in the S6 machine vision inspection, a camera is connected to the embossing machine via a lifting assembly. The camera's height changes proportionally with the thickness of the sheet material. That is, as the sheet thickness increases, the camera height increases accordingly, and as the sheet thickness decreases, the camera height decreases accordingly. This ensures that the area captured by the camera on sheets of different thicknesses is closer in size, thereby improving the consistency of the inspection results.

[0064] The above are all preferred embodiments of the present invention, and are not intended to limit the scope of protection of this application. Therefore, any equivalent changes made based on the structure, shape, and principle of this application should be included in the scope of protection of this application.

Claims

1. A stainless steel pattern plate embossing process, comprising the following steps: S1, material preparation; S2, mold design and manufacturing; S3, embossing equipment preparation; S4, embossing; S5, post-processing; S6, machine vision inspection; S7, packaging and transportation; it is characterized in that, in the machine vision inspection of S6, if the matching degree still cannot reach the threshold after adjusting the pressure or temperature, the machine vision inspection enters the abnormality judgment step, and the abnormality judgment step includes the following steps: S61, extracting the mold pre-inspection record for judgment; S62, spatial distribution analysis and judgment; S63, time series trend monitoring and judgment.

2. The embossing process for a stainless steel patterned plate according to claim 1, characterized in that: In S6, the abnormality judgment step of the machine vision detection further includes: S64, increasing the pressure or temperature to perform improvement judgment.

3. The embossing process for a stainless steel patterned plate according to claim 1, characterized in that: The extraction and judgment of mold pre-inspection records in S61 include the following steps: before starting the machine or changing the mold every day, use a camera to capture the surface image of the blank mold and compare it with the initial reference template to form a pre-inspection record. If the pre-inspection record is abnormal, it is directly judged as a mold problem; if the pre-inspection record is normal, proceed to the next abnormality judgment step.

4. The embossing process for a stainless steel patterned plate according to claim 3, characterized in that: The spatial distribution analysis and judgment of S62 includes the following steps: dividing the plate into grid areas, calculating the pattern matching degree of each small area separately, if the low matching area appears repeatedly in a fixed position, for example, always in the center area or the same position on the edge, it is judged to be a mold problem and there may be local wear; if the low matching area is randomly distributed, proceed to the next abnormality judgment step.

5. The stainless steel pattern plate embossing process according to claim 4, characterized in that: The S63's temporal trend monitoring and judgment includes the following steps: recording the pattern matching data of 10-20 consecutive embossings and generating a trend curve. If the matching degree continues to decrease, indicating that the mold is continuously worn, it is judged to be a mold problem; if the matching degree jumps irregularly, it is judged to be a plate problem.

6. The embossing process for stainless steel patterned plate according to claim 2, characterized in that: The improvement judgment of increasing pressure or temperature in S64 includes the following steps: if the matching is significantly improved after increasing pressure or temperature, it indicates that there is indeed a problem of uneven thickness or abnormal hardness of the plate; if the matching is not significantly improved after increasing pressure or temperature, it means that there are other problems with the surface plate or the mold. At this time, manual intervention is made to judge and form a human-machine coordination mechanism.

7. The stainless steel pattern plate embossing process according to claim 6, characterized in that: The increased pressure or temperature in the abnormality judgment step must be greater than the increased pressure or temperature in the normal processing step.

8. The stainless steel pattern plate embossing process according to claim 7, characterized in that: In S64, a standard thickness value is set. If the thickness of the plate exceeds the standard thickness value, an improvement judgment is made by increasing the pressure. If the thickness of the plate exceeds the standard thickness value, an improvement judgment is made by increasing the temperature.

9. The stainless steel patterned plate embossing process according to claim 8, characterized in that: The embossing machine is provided with a thickness detection component, and the thickness detection step is provided before the embossing step.

10. The stainless steel pattern plate embossing process according to claim 9, characterized in that: In the S6 machine vision inspection, the camera is connected to the embossing machine through a lifting assembly, and the height of the camera changes in direct proportion to the thickness of the plate.

Images