A three-dimensional scanning-based part warehouse-in dimension detection system and method

Abstract

The application relates to the technical field of part detection, in particular to a spare part warehouse entry size detection system and method based on three-dimensional scanning, which comprises a scanning control module that acquires feedback data of a scanning area in real time and generates a scanning control signal according to the feedback data; a camera shooting module adjusts the scanning state of a part to be scanned according to the scanning control signal and acquires a point cloud data set based on a triangulation method; a data processing module generates a three-dimensional point cloud model based on the point cloud data set and performs size calculation based on the three-dimensional point cloud model to obtain shape and position size parameters, and the data processing module is also used for generating a detection result corresponding to the part to be scanned according to the shape and position size parameters and preset parameters; and a part classification mechanism performs classification operation on the part to be scanned according to the detection result. The application avoids the camera shooting module being in a scanning state all the time, thereby prolonging the service life of the camera shooting module.

Description

TECHNICAL FIELD

[0001] The present application relates to the technical field of part detection, in particular to a three-dimensional scanning-based size detection system and method for parts entering a warehouse. BACKGROUND

[0002] In the complex and critical link of automobile parts production and supply, quality control is crucial. At present, the quality detection method of parts produced by suppliers has significant limitations. The commonly used sampling detection method only scans key parts and issues a report. Sampling detection cannot fully cover all parts, which allows a large number of potential unqualified products to flow into subsequent processes. In automobile manufacturing, the dimensional accuracy and shape accuracy of parts are directly related to the performance and safety of the whole vehicle. Once a part with unqualified size or shape error enters the size matching process, it will cause many serious problems. On the one hand, it will cause the size matching process to be extremely time-consuming and labor-intensive, as constant adjustments are needed to accommodate unqualified parts; on the other hand, the whole vehicle qualification rate of the assembled automobile is greatly reduced, the safety performance of the automobile is also reduced, and even serious quality accidents may occur, causing immeasurable economic losses to automobile manufacturers.

[0003] At present, in order to solve the problem of low detection efficiency of the existing technology, a wheel hub size automatic detection device is disclosed, which comprises a bottom plate and a support plate, the support plate is fixed on one side of the top surface of the bottom plate, a mechanical arm is fixedly installed on one side of the support plate, a three-dimensional scanner is installed on the movable end of the mechanical arm, a driving motor is fixedly installed on the top surface of the bottom plate, a turntable is fixed on the output end of the driving motor, and a plurality of installation grooves are uniformly formed on the top surface of the turntable.

[0004] However, using a 3D camera to detect the wheel hub mechanism can realize object detection through a rotating mechanism, but the camera is always scanning during the detection gap of the two north side wheel hubs, which causes the camera to be in a high-load working stage at all times, reduces the service life, increases the cost, and also obtains a large amount of meaningless point cloud data, increasing the workload of later point cloud processing. SUMMARY

[0005] In order to improve the service life of the camera and obtain point cloud data with high precision and reduce the workload of later point cloud processing, the present application provides a three-dimensional scanning-based size detection system and method for parts entering a warehouse.

[0006] In the first aspect, the present application provides a three-dimensional scanning-based size detection system for parts entering a warehouse, which adopts the following technical scheme:

[0007] A three-dimensional scanning-based part warehouse entry size detection system comprises:

[0008] A scanning control module is configured to acquire feedback data of the irradiation area in real time and generate a scanning control signal based on the feedback data;

[0009] A camera shooting module is connected to the scanning control module in a network manner to receive the scanning control signal and adjust the scanning state of the part to be scanned based on the scanning control signal, acquire a point cloud data set based on triangulation, and the point cloud data set comprises point cloud data corresponding to different angles of the part to be scanned;

[0010] A data processing module is connected to the camera shooting module in a network manner to receive the point cloud data set, generate a three-dimensional point cloud model based on the point cloud data set, and perform size calculation based on the three-dimensional point cloud model to acquire geometric and position size parameters, and the data processing module is further configured to generate a detection result corresponding to the part to be scanned based on the geometric and position size parameters and preset parameters;

[0011] A part classification mechanism is connected to the data processing module to receive the detection result and perform a classification operation on the part to be scanned based on the detection result.

[0012] By adopting the above technical solution, the scanning control module acquires feedback data of the part to be scanned in the irradiation area and generates a scanning control signal based on the feedback data, so that the camera shooting module adjusts the scanning state of the part to be scanned based on the scanning control signal. Only when the part to be scanned exists in the irradiation area, the camera shooting module is started, thereby avoiding the camera shooting module being in a scanning state all the time, so as to improve the service life of the camera shooting module, scan only the part to be scanned, acquire point cloud data with high precision, reduce the workload of the data processing module in processing the point cloud data, and improve the efficiency of size detection of the part to be scanned.

[0013] In some embodiments, the scanning control signal comprises a scanning trigger signal and a scanning stop signal corresponding to the scanning trigger signal, the feedback data comprises first feedback and second feedback, the scanning control module comprises a first scanning unit and a second scanning unit, the first scanning unit is configured to acquire the first feedback of a first irradiation area in real time and determine whether the first feedback is blocked, if the first feedback is blocked, the first scanning unit generates the scanning trigger signal and sends the scanning trigger signal to the camera shooting module to control the camera shooting module to scan the part to be scanned;

[0014] The second scanning unit is configured to acquire second feedback corresponding to a second irradiation area in real time, and determine whether the second feedback is blocked. If the second feedback is blocked, the second scanning unit generates a scanning stop signal and sends the scanning stop signal to the camera shooting module to control the camera shooting module to stop scanning the part to be scanned.

[0015] By using the above technical solutions, the first scanning unit and the second scanning unit are used to scan the first irradiation area and the second irradiation area in real time to acquire corresponding feedback data. Whether the first feedback and the second feedback are blocked is determined. If the first feedback is blocked, the first scanning unit generates a scanning trigger signal to control the camera shooting module to scan the part to be scanned. If the second feedback is blocked, the second scanning unit generates a scanning stop signal to control the camera shooting module to stop scanning the part to be scanned. The scanning start time and the scanning end time of the part to be scanned can be determined based on the feedback data acquired by the first scanning unit and the second scanning unit in real time. The camera shooting module can be started or stopped when complete point cloud data is acquired. The service life of the camera is improved. High-precision point cloud data can be acquired.

[0016] In some embodiments, the scanning control module further includes a signal conversion unit configured to receive the first feedback signal or the second feedback signal and generate a corresponding scanning control signal based on the first feedback signal or the second feedback signal.

[0017] By using the above technical solutions, the first feedback signal or the second feedback signal is converted into a corresponding scanning control signal by the signal conversion unit, so that the camera shooting module can be controlled to start scanning or stop scanning the part to be scanned. The working state of the camera shooting module can be adjusted. The scanning operation can be confirmed according to the current position of the part to be scanned. The scanning accuracy of the camera shooting module is improved. The service life of the camera shooting module is improved.

[0018] In some embodiments, the camera shooting module includes a first orientation camera, a second orientation camera, and a third orientation camera. The first orientation camera, the second orientation camera, and the third orientation camera are started to scan the part to be scanned based on the scanning trigger signal. The first orientation camera, the second orientation camera, and the third orientation camera are stopped to scan the part to be scanned based on the scanning stop signal.

[0019] By adopting the technical scheme, the multi-directional camera is arranged to scan the part to be scanned, and point cloud data of multiple surfaces of the part to be scanned is collected from multiple directions, so that single data collection is avoided, the part to be scanned can be comprehensively detected, and the size detection efficiency of the part to be scanned is improved.

[0020] In some embodiments, the data processing module comprises a model generation unit, a parameter calculation unit and a detection judgment unit.

[0021] The model generation unit acquires point cloud data corresponding to different angles according to the point cloud data set, aligns the point cloud data at different angles in a three-dimensional space based on a point cloud registration algorithm, and acquires a three-dimensional point cloud model.

[0022] The parameter calculation unit acquires linear dimensions and key points according to the three-dimensional point cloud model, calculates the linear dimensions based on a Euclidean distance formula, and calculates the deviation of the key points based on a least square method, to acquire form and position size parameters.

[0023] The detection judgment unit generates a detection result corresponding to the part to be scanned based on the form and position size parameters and preset parameters.

[0024] By adopting the technical scheme, the data processing module processes the point cloud data set, and the obtained data is compared with the original value to generate a detection result of the part to be scanned, so that manual operation is reduced, and the size detection efficiency of the part to be scanned is improved.

[0025] In some embodiments, the data processing module further comprises a signal generation unit configured to receive the detection result sent by the detection judgment unit and judge whether the detection result is qualified; if yes, a qualified signal is generated, and the part classification mechanism is controlled to start according to a first preset mode based on the qualified signal; if not, an unqualified signal is generated, and the part classification mechanism is controlled to start according to a second preset mode based on the unqualified signal.

[0026] By adopting the technical scheme, the part classification mechanism is automatically classified by the detection result, manual operation is reduced, automatic detection of the part to be scanned is realized, and the size detection efficiency of the part to be scanned is improved.

[0027] In a second aspect, the application provides a part storage size detection method based on three-dimensional scanning, which adopts the following technical scheme:

[0028] A part warehouse-in dimension detection method based on three-dimensional scanning, applied to a part warehouse-in dimension detection device based on three-dimensional scanning, the device comprising a conveyor belt for transporting parts to be scanned, comprising the following steps:

[0029] Real-time acquisition of feedback data of the scanning area, and generation of a scanning control signal according to the feedback data;

[0030] Adjusting the scanning state of the part to be scanned according to the scanning control signal, and acquiring a point cloud data set based on the triangulation method, the point cloud data set comprising point cloud data corresponding to different angles of the part to be scanned;

[0031] Generating a three-dimensional point cloud model based on the point cloud data set, and performing dimension calculation based on the three-dimensional point cloud model to obtain shape and position dimension parameters;

[0032] Generating a detection result corresponding to the part to be scanned according to the shape and position dimension parameters and preset parameters, and performing a classification operation on the part to be scanned according to the detection result.

[0033] In some embodiments, before generating a three-dimensional point cloud model based on the point cloud data set, the following steps are further included:

[0034] Acquiring the part type and running position of the part to be scanned, and acquiring corresponding feature point cloud data in a preset database based on the part type;

[0035] Matching the feature point cloud data in the point cloud data set, and determining whether corresponding data can be matched;

[0036] If corresponding data cannot be matched, a running stop signal is generated, and the conveyor belt is controlled to stop based on the running stop signal;

[0037] Re-scanning the part to be scanned based on the running position to obtain updated point cloud data corresponding to the running position, and replacing the point cloud data at the corresponding running position with the updated point cloud data.

[0038] By adopting the above technical solution, during the running of the part to be scanned, it is necessary to real-time detect whether the point cloud data set photographed at the corresponding running position is complete, if not, re-scanning is performed at the running position in time to obtain updated point cloud data, and the point cloud data photographed at the previous running position is replaced with the updated point cloud data, improving the accuracy of the point cloud data set data, and further reducing the workload of the data processing module in processing the point cloud data, and improving the efficiency of the dimension detection of the part to be scanned.

[0039] In some embodiments, after re-scanning the part to be scanned based on the running position, the following steps are further included:

[0040] acquire a scanning state of the camera shooting module based on the rescan signal, and determine whether the scanning state belongs to scanning delay;

[0041] if the scanning state belongs to scanning delay, adjust the conveying speed of the conveying belt according to the rescan signal;

[0042] if the scanning state does not belong to scanning delay, update the response time of the camera shooting module according to the rescan signal.

[0043] By adopting the above technical solution, when re-scanning is needed, it is determined whether the current camera shooting module has scanning delay or other conditions cause the scanned part to have missing scanning data, so that the point cloud data set of each scanned part is accurate, and the size detection accuracy of the scanned part is improved.

[0044] In some embodiments, the feedback data includes a first feedback signal, and updating the response time of the camera shooting module according to the rescan signal includes the following steps:

[0045] updating the scanning control signal based on the delay response time and the first feedback signal according to the delay response time of the camera shooting module;

[0046] adjusting the scanning state of the scanned part based on the updated scanning control signal.

[0047] By adopting the above technical solution, if the camera shooting module has a delay response, the scanning control signal of the next scanned part needs to be adjusted in time according to the delay response time and the first feedback signal, so that the detection accuracy of the size detection system can be adjusted in time during the size detection process of the scanned part, and qualified parts are prevented from being judged as unqualified parts, and resources are wasted.

[0048] In summary, the present application has the following at least one beneficial technical effect:

[0049] The three-dimensional point cloud data of the scanned part can be obtained efficiently and comprehensively, and data comparison and judgment of the qualified scanned parts and classification are also performed, the full-process work of the scanned part into the warehouse is realized, and the qualified rate of the parts into the warehouse is ensured.

[0050] The scanning control module acquires feedback data by entering the scanning area of ​​the part to be scanned, and generates a scanning control signal based on the feedback data. The camera module then adjusts the scanning state of the part to be scanned according to the scanning control signal. The camera module is only activated when there is a part to be scanned in the scanning area, thus avoiding the camera module being in a continuous scanning state and improving the service life of the camera module. Scanning only the part to be scanned can acquire high-precision point cloud data, reducing the workload of the data processing module in processing point cloud data and improving the efficiency of size detection of the part to be scanned.

[0051] During the operation of the part to be scanned, it is necessary to detect in real time whether the point cloud data set captured at the corresponding operating position is complete. If it is incomplete, it should be re-scanned at the operating position in a timely manner to obtain updated point cloud data. The updated point cloud data should replace the point cloud data captured at the previous operating position to improve the accuracy of the point cloud data set, thereby reducing the workload of the data processing module in processing point cloud data and improving the efficiency of dimensional detection of the part to be scanned. Attached Figure Description

[0052] Figure 1 This is a schematic diagram of the structure of the 3D scanning-based component dimensional inspection system provided in this application embodiment;

[0053] Figure 2 This is a schematic diagram of the structure of the 3D scanning-based component dimensional detection device disclosed in the embodiments of this application;

[0054] Figure 3 This is a block diagram of a method for detecting the dimensionality of parts upon warehousing based on three-dimensional scanning, provided in an embodiment of this application.

[0055] Figure 4 This is another method block diagram provided in the embodiments of this application;

[0056] Figure 5 This is a flowchart of a method for detecting the dimensionality of parts upon warehousing based on three-dimensional scanning, provided in an embodiment of this application.

[0057] Explanation of reference numerals in the attached drawings: 10. Scanning control module; 11. First scanning unit; 12. Second scanning unit; 13. Signal conversion unit; 20. Camera capturing module; 21. First azimuth camera; 22. Second azimuth camera; 23. Third azimuth camera; 30. Data processing module; 31. Model generation unit; 32. Parameter calculation unit; 33. Detection and judgment unit; 34. Signal generation unit; 40. Part classification mechanism; 51. Conveyor belt; 52. Part to be scanned; 53. Sensor No. 1; 54. Camera mounting bracket; 55. Sensor No. 2; 56. Qualified conveyor belt; 57. Unqualified conveyor belt. Detailed Implementation

[0058] In order to more clearly understand the purpose, technical solutions and advantages of the present application, the present application is described and explained below in conjunction with the accompanying drawings and embodiments. However, it should be understood by those of ordinary skill in the art that the present application can be implemented without these details. In some cases, in order to avoid unnecessary description and make aspects of the present application obscure, well-known methods, processes, systems, components and / or circuits that have been described at a high level will not be described in detail. It is obvious to those of ordinary skill in the art that various changes can be made to the embodiments disclosed in the present application, and the general principles defined in the present application can be applied to other embodiments and application scenarios without deviating from the principles and scope of the present application. Therefore, the present application is not limited to the embodiments shown, but conforms to the broadest scope claimed by the present application.

[0059] The embodiments of the present application disclose a three-dimensional scanning-based part warehouse entry size detection system.

[0060] Referring to Figure 1 and Figure 2 , the three-dimensional scanning-based part warehouse entry size detection system comprises a scanning control module 10, a camera shooting module 20, a data processing module 30 and a part classification mechanism 40. The scanning control module 10 is used to obtain feedback data of an irradiation area in real time, and to generate a scanning control signal according to the feedback data. The camera shooting module 20 is connected with the scanning control module 10 in network to receive the scanning control signal, and adjusts the scanning state of a part to be scanned 52 according to the scanning control signal, obtains a point cloud data set based on the triangulation method, and the point cloud data set comprises point cloud data corresponding to different angles of the part to be scanned 52. The data processing module 30 is connected with the camera shooting module 20 in network to receive the point cloud data set, generates a three-dimensional point cloud model based on the point cloud data set, and performs size calculation based on the three-dimensional point cloud model to obtain shape and position size parameters. The data processing module 30 is also used to generate a detection result corresponding to the part to be scanned 52 according to the shape and position size parameters and preset parameters. The part classification mechanism 40 is connected with the data processing module 30 to receive the detection result, and performs a classification operation on the part to be scanned 52 according to the detection result.

[0061] Among them, the irradiation area represents the area in which the scanning control module 10 scans the part to be scanned 52. The scanning control module 10 adopts a radiation sensor, and the transmitter and the receiver are arranged on both sides of the conveyor belt 51 along the width direction. When the part to be scanned 52 is driven by the conveyor belt 51 to move along the length direction of the conveyor belt 51, it passes through the area opposite to the transmitter and the receiver, and the area opposite to the transmitter and the receiver is taken as the irradiation area. The feedback data is mainly transmitted by the transmitter to the irradiation area in real time, and the receiver detects the light signal emitted by the transmitter.

[0062] Specifically, when the part to be scanned 52 enters the irradiation area and blocks the light emitted by the emitter, the receiver detects a change in the signal and generates corresponding feedback data, and the scanning control signal is generated through the feedback data, so that the scanning state of the camera shooting module 20 to the part to be scanned 52 can be adjusted.

[0063] The scanning control signal is an electrical signal, and the data transmission line of the electrical signal can adopt TTL, RS-485, CAN bus and Ethernet for transmission, and the transmission speed is fast. The electrical signal is transmitted to the camera control module at a very fast speed, and then used to control the camera control module to adjust the scanning state of the part to be scanned 52, including starting scanning and stopping scanning.

[0064] Referring to Figure 1 and Figure 2 , the camera shooting module 20 includes cameras arranged above the conveyor belt 51 and on both sides of the conveyor belt 51 along the wide direction. The cameras are used to scan the part to be scanned 52, and a 3D line structured light camera is specifically used. When the camera shooting module 20 starts scanning the part to be scanned 52 through the scanning control signal, a point cloud data set is obtained based on the triangulation method, and the point cloud data set includes point cloud data corresponding to different angles of the part to be scanned 52.

[0065] The triangulation method mentioned here is a measurement technology based on the geometric triangle principle, which calculates the position of the target point through the known reference point and the angle or distance relationship. Specifically, the angle intersection method and the distance intersection method can be used. In this embodiment, the three 3D line structured light cameras arranged above and on both sides of the conveyor belt 51 simultaneously receive the trigger instruction and immediately start the scanning operation. The working principle of the 3D line structured light camera is based on the triangulation method. The camera emits a specific pattern of structured light stripes, such as sine stripes or Gray code stripes. After these stripes are projected onto the part surface, the reflected light carries the three-dimensional information of the part surface due to the ups and downs of the geometry of the part surface. The camera lens accurately captures the reflected light, and through the deformation analysis of the reflected light pattern, the three-dimensional coordinates of each point on the part surface can be calculated using the triangulation principle, so as to obtain the point cloud data.

[0066] Referring to Figure 1 and Figure 2In one of the embodiments, the data processing module 30 includes a model generation unit 31, a parameter calculation unit 32, and a detection judgment unit 33. The model generation unit 31 acquires point cloud data corresponding to different angles based on the point cloud data set, aligns the point cloud data at different angles in a three-dimensional space based on a point cloud registration algorithm, to obtain a three-dimensional point cloud model. The parameter calculation unit 32 acquires linear dimensions and key points based on the three-dimensional point cloud model, and calculates the linear dimensions based on the Euclidean distance formula and the deviation of the key points based on the least squares method, to obtain the geometric and position size parameters. The detection judgment unit 33 generates a detection result corresponding to the scanned part 52 based on the geometric and position size parameters and the preset parameters.

[0067] The model generation unit 31 receives the point cloud data set, and generates a three-dimensional point cloud model based on the point cloud data of the scanned part 52. Based on the point cloud registration algorithm, the point cloud data acquired at different angles is accurately aligned in a three-dimensional space by finding feature points in different point cloud data sets, such as curvature features, normal directions, and other features, and using the iterative closest point algorithm and its improved algorithm. After registration is completed, the software performs point cloud splicing operation, and fuses these aligned point cloud data into a complete three-dimensional point cloud model of the part, which completely restores the real geometry of the part.

[0068] It should be noted that the point cloud registration algorithm aligns the 3D point cloud data acquired at different angles or times to the same coordinate system through spatial transformation, and then generates a corresponding three-dimensional point cloud model.

[0069] The parameter calculation unit 32 also uses the built-in geometric size calculation algorithm to analyze the three-dimensional point cloud model of the part in detail. For the linear dimensions of the part, such as length, width, height, etc. The data processing module 30 identifies the spatial distance between the corresponding feature points in the point cloud model, and uses the Euclidean distance formula and other mathematical methods to accurately calculate. In terms of shape and position calculation of key points, such as calculating the position accuracy of holes, cylindricity, flatness, and other geometric and position tolerances, the parameter calculation unit 32 determines the deviation between the theoretical position and the actual position of the key points by means of local geometric feature analysis of the point cloud model and the least squares fitting algorithm, to obtain accurate geometric and position parameters.

[0070] It should be noted that the geometric size calculation algorithm, the Euclidean distance formula, the least squares method algorithm, and the iterative closest point algorithm can all use existing algorithms, which will not be described here. Only the detection result corresponding to the scanned part 52 obtained by the above algorithms is needed.

[0071] Referring to Figure 1 and Figure 2In one of the embodiments, the data processing module 30 further comprises a signal generating unit 34, which is configured to receive the detection result sent by the detection judgment unit 33 and determine whether the detection result is qualified. If yes, a qualified signal is generated, and the qualified signal is used to control the part classification mechanism 40 to start according to the first preset mode. If no, an unqualified signal is generated, and the unqualified signal is used to control the part classification mechanism 40 to start according to the second preset mode.

[0072] The detection result is obtained by comparing the shape and size parameters of the part to be scanned 52 with the preset parameters. If the shape and size parameters of the part to be scanned 52 are within the range of the preset parameters, the detection result of the part to be scanned 52 is qualified. If not, the detection result of the part to be scanned 52 is unqualified.

[0073] In addition, the preset parameter is a preset size tolerance corresponding to the shape and size parameter. Since the shape and size parameter at least includes a numerical value, the corresponding preset parameter at least includes a corresponding preset size tolerance. In the comparison process, a reasonable size tolerance range is set in advance according to the industry standard and the production process requirement. For example, for the length size, the preset tolerance is set to 0.02 mm. For the hole diameter size, the preset tolerance is set to 0.02 mm. The specific value is set according to the standard requirement of the specific part.

[0074] It should be noted that the first preset mode and the second preset mode are modes started according to the detection result. The first preset mode refers to using mechanical structure to guide the part to be scanned to the qualified conveying belt 56. The second preset mode refers to using mechanical structure to guide the part to be scanned to the unqualified conveying belt 57.

[0075] Referring to Figure 1 and Figure 2 The part classification mechanism 40 is connected with the data processing module 30 to receive the detection result, and performs classification operation on the part to be scanned 52 according to the detection result. If all the parameters of the shape and size parameters are within the tolerance range, the part is determined to be qualified. The data processing module 30 generates a qualified signal, and transmits the signal to the control system of the part classification mechanism 40 through the data communication interface. After receiving the qualified signal, the part classification mechanism 40 controls the corresponding mechanical structure, such as electric push rod or pneumatic valve, to guide the part to the qualified conveying belt 56. On the contrary, if any parameter exceeds the tolerance range, the data processing module 30 determines that the part is unqualified, the data processing module 30 generates an unqualified signal and transmits it to the part classification mechanism 40, and the control system of the part classification mechanism 40 drives the mechanical structure to move, and the part is transferred to the unqualified conveying belt 57, completing the automatic classification process of the part and realizing efficient and accurate control of the quality of the parts in the warehouse.

[0076] Referring to Figure 1 and Figure 2In one of the embodiments, the scanning control module 10 comprises a first scanning unit 11 and a second scanning unit 12. The first scanning unit 11 is configured to acquire a first feedback signal of a first pair of irradiation regions in real time, and determine whether the first feedback signal is interrupted. If the first feedback signal is interrupted, the first scanning unit 11 generates a scanning trigger signal, and sends the scanning trigger signal to the camera shooting module 20 to control the camera shooting module 20 to scan the part to be scanned 52. The second scanning unit 12 is configured to acquire a second feedback signal of a corresponding second pair of irradiation regions in real time, and determine whether the second feedback signal is interrupted. If the second feedback signal is interrupted, the second scanning unit 12 generates a scanning stop signal, and sends the scanning stop signal to the camera shooting module 20 to control the camera shooting module 20 to stop scanning the part to be scanned 52.

[0077] In the embodiment, the scanning control signal comprises the scanning trigger signal and a scanning stop signal corresponding to the scanning trigger signal, and the feedback data comprises the first feedback signal and the second feedback signal. The scanning trigger signal represents a signal for controlling the camera shooting module 20 to start scanning the part to be scanned 52, and the scanning stop signal represents a signal for controlling the camera shooting module 20 to stop scanning the part to be scanned 52.

[0078] Referring to Figure 1 and Figure 2 The first scanning unit 11 and the second scanning unit 12 each are provided with a group of sensors, each group of sensors comprising a transmitter and a corresponding receiver. The first scanning unit 11 and the second scanning unit 12 are located on both sides of the camera shooting module 20 along the length direction of the conveying belt 51. The first feedback signal and the second feedback signal are both optical signals sent by the receivers of the first scanning unit 11 and the second scanning unit 12. The first scanning unit 11 comprises a first sensor 53, and the second scanning unit comprises a second sensor 56.

[0079] In order to ensure that the acquired point cloud data set can accurately correspond to a single part to be scanned 52, the part to be scanned 52 continuously moves along the conveying belt 51 until it completely passes through the second sensor of the second scanning unit 12. The second sensor repeats the above photoelectric conversion process, and the scanning stop signal is transmitted to the camera shooting module 20 to control the camera shooting module 20 to stop scanning the part to be scanned 52.

[0080] It should be noted that the scanning trigger signal and the scanning stop signal appear in pairs. The scanning stop signal is generated after the corresponding scanning trigger signal, and then the second scanning unit 12 monitors the second feedback signal of the second pair of irradiation regions in real time.

[0081] Referring to Figure 1 and Figure 2In one of the embodiments, the scanning control signal further comprises a signal conversion unit 13, which is configured to receive the first feedback signal or the second feedback signal and generate the corresponding scanning control signal based on the first feedback signal or the second feedback signal.

[0082] In the above-mentioned embodiments, the first feedback signal or the second feedback signal generated by the receiver of the sensor is an optical signal. In order to facilitate the processing of the signal, the optical signal is converted into an electrical signal for storage and transportation.

[0083] Referring to Figure 1 and Figure 2 In one of the embodiments, the camera shooting module 20 comprises a first orientation camera 21, a second orientation camera 22 and a third orientation camera 23. The first orientation camera 21, the second orientation camera 22 and the third orientation camera 23 are started to scan the part to be scanned 52 based on the scanning trigger signal, and the first orientation camera 21, the second orientation camera 22 and the third orientation camera 23 are stopped to scan the part to be scanned 52 based on the scanning stop signal.

[0084] In the above-mentioned embodiments, the first orientation camera 21 is arranged directly above the conveying belt 51, the second orientation camera 22 and the third orientation camera 23 are arranged on both sides of the first orientation camera 21, and the first orientation camera 21, the second orientation camera 22 and the third orientation camera 23 are arranged in the same vertical plane.

[0085] Referring to Figure 1 and Figure 2 In another embodiment, in order to scan the part to be scanned 52 more accurately, the first orientation camera 21, the second orientation camera 22 and the third orientation camera 23 can rotate back and forth along the length direction of the conveying belt 51. When the part to be scanned 52 moves to the position directly below the first orientation camera 21 along with the conveying belt 51, the first orientation camera 21, the second orientation camera 22 and the third orientation camera 23 rotate along the moving direction of the conveying belt 51. When the part to be scanned 52 reaches the second scanning area along with the conveying belt 51, the first orientation camera 21, the second orientation camera 22 and the third orientation camera 23 stop rotating. When the part to be scanned 52 leaves the second scanning area along with the conveying belt 51, the first orientation camera 21, the second orientation camera 22 and the third orientation camera 23 send the scanned data to the data processing module 30. The first orientation camera 21, the second orientation camera 22 and the third orientation camera 23 rotate in the opposite direction of the moving direction of the conveying belt 51 at the same time until they rotate to the initial position, and then scan the next part to be scanned 52.

[0086] Referring to Figure 2 and Figure 3The embodiment of the application also discloses a part warehouse-in size detection method based on three-dimensional scanning, which is applied to a part warehouse-in size detection device based on three-dimensional scanning. The device comprises a conveying belt 51, a first sensor 53, a second sensor 55, a qualified conveying belt 56 and an unqualified conveying belt 57. A first orientation camera 21, a second orientation camera 22 and a third orientation camera 23 are arranged on a camera mounting bracket 54, and the camera mounting bracket 54 is arranged above the conveying belt 51. The conveying belt 51 moves along the F direction. The conveying belt 51 is used for transporting a part to be scanned 52 and sequentially passes through the first sensor, the third orientation camera and the second sensor.

[0087] As shown in the drawings, Figure 3 The part warehouse-in size detection method based on three-dimensional scanning comprises the following steps.

[0088] S100, real-time feedback data of the scanning area is acquired, and a scanning control signal is generated according to the feedback data.

[0089] S200, the scanning state of the part to be scanned is adjusted according to the scanning control signal, and a point cloud data set is acquired based on the triangulation method.

[0090] S300, a three-dimensional point cloud model is generated based on the point cloud data set, and a size calculation is performed based on the three-dimensional point cloud model to acquire a geometric and positional size parameter.

[0091] S400, a detection result corresponding to the part to be scanned is generated according to the geometric and positional size parameter and a preset parameter, and a classification operation is performed on the part to be scanned according to the detection result.

[0092] The point cloud data set comprises point cloud data corresponding to different angles of the part to be scanned 52. The technical features described in steps S100-S400 are the same as or similar to the corresponding features of the part warehouse-in size detection system based on three-dimensional scanning described above, and thus will not be described here.

[0093] Referring to Figure 4 In one embodiment, before the three-dimensional point cloud model is generated based on the point cloud data set, the following steps are further included.

[0094] S210, a part type and a running position of the part to be scanned are acquired, and corresponding feature point cloud data is acquired in a preset database based on the part type.

[0095] S220, the feature point cloud data is matched in the point cloud data set, and it is judged whether corresponding data can be matched.

[0096] S230, if corresponding data cannot be matched, a running stop signal is generated, and the conveying belt is controlled to stop based on the running stop signal.

[0097] S240, re-scanning the to-be-scanned part 52 based on the running position to obtain updated point cloud data corresponding to the running position, and replacing the point cloud data corresponding to the running position with the updated point cloud data.

[0098] The part type represents the product type of the to-be-scanned part 52, and the corresponding feature point cloud data is obtained in the preset database based on the part type. The scanning features corresponding to each type of product are obtained in the preset database, and through these scanning features, it can be judged that the obtained point cloud data set can be completely scanned. The scanning features can be obtained by scanning each type of product through the first orientation camera 21, the second orientation camera 22, and the third orientation camera 23. The product is divided according to the scanning route of the first orientation camera 21, the second orientation camera 22, and the third orientation camera 23, the data point set of the plane perpendicular to the same scanning route is obtained, and one of the data point sets is selected as the scanning feature.

[0099] The running position is a scanning confirmation position set for the to-be-scanned part 52. When reaching this position, the conveying speed of the conveying belt 51 can be reduced to facilitate the processing of the obtained point cloud data set by the data processing module 30. Whether there is incomplete scanning, if so, a running stop signal is generated, and the conveying belt 51 is controlled to stop based on the running stop signal. The to-be-scanned part 52 is re-scanned based on the running position to obtain updated point cloud data corresponding to the running position, and the updated point cloud data is replaced with the point cloud data corresponding to the running position.

[0100] The running stop signal is a signal generated by the data processing module 30 when the corresponding feature point cloud data is not matched in the point cloud data set. The updated point cloud data represents the data obtained by re-scanning at the running position, and the re-obtained scanning data replaces the original point cloud data at the running position.

[0101] It should be noted that when re-scanning is required, it is necessary to determine whether the first orientation camera 21, the second orientation camera 22, and the third orientation camera 23 are rotated. If not, re-scanning can be performed. If the first orientation camera 21, the second orientation camera 22, and the third orientation camera 23 have been rotated, the first orientation camera 21, the second orientation camera 22, and the third orientation camera 23 can be rotated in the opposite direction by a certain angle. The rotation angle can be set to 1 degree or 2 degrees, and the specific situation can be adjusted accordingly.

[0102] If the corresponding data can be matched, it means that the scanning data of the to-be-scanned part by the first orientation camera 21, the second orientation camera 22, and the third orientation camera 23 is complete, and repeated scanning is not required. Therefore, subsequent scanning is directly performed at the original moving speed of the conveying belt 51.

[0103] In one of the embodiments, after the re-scanning of the part to be scanned 52 based on the running position, the following steps are further included:

[0104] S241, obtaining the scanning state of the camera shooting module 20 based on the re-scanning signal, and determining whether the scanning state belongs to scanning delay.

[0105] S242, if the scanning state belongs to scanning delay, adjusting the transport speed of the conveyor belt 51 according to the re-scanning signal.

[0106] S243, if the scanning state does not belong to scanning delay, updating the response time of the camera shooting module 20 according to the re-scanning signal.

[0107] The scanning state represents the scanning situation of the camera 55 of the camera shooting module 20, and the scanning state includes scanning delay and normal scanning. For the scanning delay of the camera shooting module 20, the transport speed of the conveyor belt 51 can be reduced according to the re-scanning signal when the first orientation camera 21, the second orientation camera 22 and the third orientation camera 23 are turned on to scan the part to be scanned 52, so that the part to be scanned 52 can be scanned accordingly after the first orientation camera 21, the second orientation camera 22 and the third orientation camera 23 are turned on to scan.

[0108] As for how much the transport speed of the conveyor belt 51 is reduced, it needs to be determined according to how much scanning data is missing of the first orientation camera 21, the second orientation camera 22 and the third orientation camera 23. If there is a lot of missing, the transport speed of the conveyor belt 51 can be reduced or the first orientation camera 21, the second orientation camera 22 and the third orientation camera 23 can be replaced. If there is less missing, the transport speed of the conveyor belt 51 can be reduced appropriately. The specific value can be set according to the actual situation, which will not be described here. It should be noted that more and less are compared according to the preset value.

[0109] In one of the embodiments, updating the response time of the camera shooting module 20 according to the re-scanning signal includes the following steps:

[0110] S244, updating the scanning control signal based on the delay response time of the camera shooting module 20 and the delay response time and the first feedback signal.

[0111] S245, adjusting the scanning state of the part to be scanned 52 based on the updated scanning control signal.

[0112] The feedback data includes a first feedback signal, and the delay response time length represents a delay time length of the first orientation camera 21, the second orientation camera 22, and the third orientation camera 23 being turned on. When the first orientation camera 21, the second orientation camera 22, and the third orientation camera 23 are turned on with a delay, the scanning control signal can be updated according to the delay response time length and the first feedback signal. Specifically, after obtaining the first feedback signal, a corresponding waiting time length is added to the first feedback signal, and the first feedback signal is converted into a scanning control signal.

[0113] The implementation principle is:

[0114] Referring to Figure 2 and Figure 5 When the part to be scanned 52 is placed on the conveyor belt 51, the conveying process starts. Based on the 1# sensor 53 arranged on both sides of the conveyor belt 51, when the part enters the 1# sensor 53, the light propagation path is blocked, and the photoelectric conversion element inside the 1# sensor 53 quickly responds to convert the light signal into an electrical signal, and then generates a scanning trigger signal. The scanning trigger signal is transmitted to the camera of the camera shooting module 20 through a special data transmission line at a very fast speed.

[0115] At this time, the three 3D line structure light cameras located above and on both sides of the conveyor belt 51 simultaneously receive the scanning trigger signal and immediately start the scanning operation to obtain a point cloud data set.

[0116] When the part to be scanned 52 continuously moves along the conveyor belt 51 until it completely passes through the first scanning unit 11, the 2# sensor 55 repeats the above photoelectric conversion process to generate a scanning stop signal and transmit it to the camera shooting module 20. After receiving the signal, the three cameras of the camera shooting module 20 immediately stop scanning to ensure that the obtained data accurately corresponds to a single part.

[0117] Subsequently, the data processing module 30 processes the scattered point cloud data scanned by the three cameras according to an advanced point cloud registration algorithm, and uses the iterative closest point algorithm and its improved algorithm to accurately align the point cloud data obtained at different angles in three-dimensional space. After registration is completed, the data processing module 30 performs point cloud splicing operation to fuse these aligned point cloud data into a complete part three-dimensional point cloud model, and completely restores the real geometric shape of the part to be scanned 52.

[0118] Then, the data processing module 30 uses the built-in geometric size calculation algorithm to analyze the three-dimensional point cloud model of the data processing module 30 in detail, and accurately calculates the space distance between the corresponding feature points in the point cloud model by using the Euclidean distance formula and other mathematical methods. In the calculation of the key point position, the deviation between the theoretical position and the actual position of the key point is determined, and the accurate geometric and position size parameters are obtained.

[0119] After the calculation of the geometric and position size parameters is completed, the data processing module 30 compares the detection results obtained by detection and calculation with the initial data of the part stored in advance. In the comparison process, a reasonable size tolerance range is set in advance according to the industry standard and the production process requirement.

[0120] If all parameters are within the tolerance range, the part is determined to be qualified, the part classification mechanism 40 generates a qualified signal, and transmits the signal to the part classification mechanism 40 through the data communication interface. After receiving the qualified signal, the part classification mechanism 40 controls the corresponding mechanical structure to guide the part to the qualified conveying belt 56. If any parameter exceeds the tolerance range, the part classification mechanism 40 determines that the part is unqualified, the part classification mechanism 40 generates an unqualified signal and transmits it to the part classification mechanism 40, and the part classification mechanism 40 drives the mechanical structure to move the part to be scanned 52 to the unqualified conveying belt 57, completes the automatic classification process of the part to be scanned 52, and realizes efficient and accurate control of the quality of the parts in the warehouse.

[0121] It should be understood that although each step in the flowchart of the accompanying drawings is displayed in sequence according to the direction of the arrow, these steps are not necessarily executed in sequence according to the direction of the arrow. Unless otherwise specified herein, the execution of these steps is not strictly limited in sequence, and they can be executed in other orders.

[0122] The above are the preferred embodiments of the present application, which do not limit the protection scope of the present application, therefore: any equivalent changes made on the structure, shape, principle of the present application should be covered within the protection scope of the present application.

Claims

1. A three-dimensional scanning-based size detection system for parts in storage, characterized by, The application relates to a scanning device for scanning a part, which comprises the following parts: a scanning control module (10) for acquiring feedback data of a scanning area in real time and generating a scanning control signal according to the feedback data; a camera shooting module (20) connected with the scanning control module (10) to receive the scanning control signal and adjust a scanning state of a part to be scanned (52) according to the scanning control signal, acquire a point cloud data set based on triangulation, and the point cloud data set comprises point cloud data corresponding to different angles of the part to be scanned (52); a data processing module (30) connected with the camera shooting module (20) to receive the point cloud data set, generate a three-dimensional point cloud model based on the point cloud data set, perform size calculation based on the three-dimensional point cloud model to acquire shape and position size parameters, and generate a detection result corresponding to the part to be scanned (52) according to the shape and position size parameters and preset parameters; a part classification mechanism (40) connected with the data processing module (30) to receive the detection result and perform a classification operation on the part to be scanned (52) according to the detection result; wherein, before the three-dimensional point cloud model is generated based on the point cloud data set, the following steps are further included: a part type and a running position of the part to be scanned are acquired, and corresponding feature point cloud data is acquired in a preset database based on the part type; the feature point cloud data is matched in the point cloud data set, and it is judged whether corresponding data can be matched; if corresponding data cannot be matched, a running stop signal is generated, and the running stop signal is used to control a conveyor belt (51) to stop; the part to be scanned is re-scanned based on the running position, to acquire updated point cloud data corresponding to the running position, and the updated point cloud data is used to replace point cloud data of the corresponding running position; after the part to be scanned is re-scanned based on the running position, the following steps are further included: the scanning state of the camera shooting module (20) is acquired based on a re-scanning signal, and it is judged whether the scanning state belongs to scanning delay; if the scanning state belongs to scanning delay, the transportation speed of the conveyor belt (51) is adjusted according to the re-scanning signal; if the scanning state does not belong to scanning delay, the response time of the camera shooting module (20) is updated according to the re-scanning signal.

2. The three-dimensional scan-based dimension detection system for binning of parts as claimed in claim 1, wherein, The scanning control signal comprises a scanning trigger signal and a scanning stop signal corresponding to the scanning trigger signal, and the feedback data comprises a first feedback signal and a second feedback signal, the scanning control module (10) comprises a first scanning unit (11) and a second scanning unit (12), the first scanning unit (11) is used for acquiring the first feedback signal of a first pair of radiation regions in real time, and judging whether the first feedback signal exists interruption, if so, the first scanning unit (11) generates the scanning trigger signal, and sends the scanning trigger signal to the camera shooting module (20) to control the camera shooting module (20) to scan the part to be scanned (52); The second scanning unit (12) is used for acquiring the second feedback signal of a corresponding second pair of radiation regions in real time, and judging whether the second feedback signal exists interruption, if so, the second scanning unit (12) generates the scanning stop signal, and sends the scanning stop signal to the camera shooting module (20) to control the camera shooting module (20) to stop scanning the part to be scanned (52).

3. The three-dimensional scan-based dimension detection system for binning of parts as claimed in claim 2, wherein, The scanning control module (10) further comprises a signal conversion unit (13), the signal conversion unit (13) is used for receiving the first feedback signal or the second feedback signal, and generating a corresponding scanning control signal based on the first feedback signal or the second feedback signal.

4. The three-dimensional scan-based dimension detection system for binning of parts as claimed in claim 2, wherein, The camera shooting module (20) comprises a first azimuth camera (21), a second azimuth camera (22) and a third azimuth camera (23), the first azimuth camera (21), the second azimuth camera (22) and the third azimuth camera (23) are started based on the scanning trigger signal to scan the part to be scanned (52), and the first azimuth camera (21), the second azimuth camera (22) and the third azimuth camera (23) are closed based on the scanning stop signal to stop scanning the part to be scanned (52).

5. The three-dimensional scan-based dimension detection system for binning of parts as claimed in claim 1, wherein, The data processing module (30) comprises a model generation unit (31), a parameter calculation unit (32) and a detection judgment unit (33); The model generation unit (31) acquires point cloud data corresponding to different angles according to the point cloud data set, aligns the point cloud data at different angles in a three-dimensional space based on a point cloud registration algorithm, and acquires a three-dimensional point cloud model; The parameter calculation unit (32) acquires linear dimensions and key points based on the three-dimensional point cloud model, calculates the linear dimensions based on a Euclidean distance formula, and calculates the deviation of the key points based on a least square method, to acquire a geometric and position size parameter; The detection judgment unit (33) generates a detection result corresponding to the part to be scanned (52) based on the geometric and position size parameter and a preset parameter.

6. The three-dimensional scan-based dimension detection system for binning of parts as claimed in claim 5, wherein, The data processing module (30) further comprises a signal generation unit (34) configured to receive the detection result sent by the detection judgment unit (33), and determine whether the detection result is qualified; if yes, a qualified signal is generated, and the qualified signal is used to control the part classification mechanism (40) to start according to a first preset mode; if no, an unqualified signal is generated, and the unqualified signal is used to control the part classification mechanism (40) to start according to a second preset mode.

7. A three-dimensional scanning-based part warehouse entry size detection method, applied to the three-dimensional scanning-based part warehouse entry size detection device of any one of claims 1-6, the device comprising a conveyor belt (51), the conveyor belt (51) being used to transport a part to be scanned, characterized in that, The method comprises the following steps: Real-time acquisition of feedback data of the scanning area, and generation of a scanning control signal based on the feedback data; Adjustment of the scanning state of the part to be scanned based on the scanning control signal, acquisition of a point cloud data set based on the triangulation method, the point cloud data set comprising point cloud data corresponding to different angles of the part to be scanned; Generation of a three-dimensional point cloud model based on the point cloud data set, and size calculation based on the three-dimensional point cloud model to obtain shape and position size parameters; Generation of a detection result corresponding to the part to be scanned based on the shape and position size parameters and preset parameters, and classification of the part to be scanned based on the detection result; Before generating the three-dimensional point cloud model based on the point cloud data set, the following steps are further included: Acquisition of the part type and running position of the part to be scanned, and acquisition of corresponding feature point cloud data in a preset database based on the part type; Matching of the feature point cloud data in the point cloud data set, and determination of whether corresponding data can be matched; If corresponding data cannot be matched, a running stop signal is generated, and the running stop signal is used to control the conveyor belt (51) to stop; Re-scanning of the part to be scanned based on the running position to obtain updated point cloud data corresponding to the running position, and replacement of the point cloud data corresponding to the running position with the updated point cloud data; After re-scanning the part to be scanned based on the running position, the following steps are further included: Determination of whether the scanning state of the camera shooting module (20) belongs to scanning delay based on the re-scanning signal; If the scanning state belongs to scanning delay, the transportation speed of the conveyor belt (51) is adjusted based on the re-scanning signal; If the scanning state does not belong to scanning delay, the response time of the camera shooting module (20) is updated based on the re-scanning signal.

8. The three-dimensional scan-based dimension detection method for parts put-in warehouse according to claim 7, characterized in that, The feedback data comprises a first feedback signal, and the updating of the response time of the camera shooting module (20) based on the re-scanning signal comprises the following steps: Updating of the scanning control signal based on the delay response time of the camera shooting module (20) and the delay response time and the first feedback signal; Adjustment of the scanning state of the part to be scanned based on the updated scanning control signal.

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