Plate surface quality online detection adjusting device and method

Abstract

The invention discloses a plate surface quality on-line detection adjusting device and method.The plate surface quality on-line detection adjusting device comprises a conveying unit, a detection unit, a control unit and an adjusting unit which are arranged in sequence, the conveying unit is used for conveying plates, the detection unit is used for detecting the plate surface quality, and the control unit is electrically connected with the detection unit and the adjusting unit; the control unit is used for receiving data of the detection unit and controlling the adjusting unit to act, and the adjusting unit is used for adjusting plate production process parameters according to instructions of the control unit. And production process parameters are automatically adjusted according to detection results, the accuracy and efficiency of plate surface quality detection are improved, the defective rate is reduced, and intelligent and automatic control over the plate production process is achieved.

Description

Technical Field

[0001] The present invention relates to the technical field of plate production and processing, and in particular to an online detection and adjustment device and method for plate surface quality. Background Art

[0002] During the production and processing of sheet materials, surface quality is a key indicator of product quality. Surface defects such as scratches, pits, color differences, and impurities not only affect the aesthetics of the sheet material but may also reduce its mechanical and performance properties, ultimately impacting subsequent processing and the quality of the final product.

[0003] Currently, the surface quality of sheet metal products is mostly tested manually through visual inspection, a method with numerous drawbacks. First, manual inspection is inefficient and cannot meet the needs of modern large-scale industrial production. Second, inspection results are significantly influenced by the subjective factors of the inspectors, and different inspectors have different judgment standards, resulting in inconsistent and inaccurate inspection results. Third, manual inspection cannot achieve real-time online detection, and cannot promptly identify quality problems during the production process, making it difficult to effectively monitor and adjust the production process, which easily leads to the production of a large number of defective products and increased production costs.

[0004] Although some companies have begun adopting machine vision inspection technology to test the surface quality of sheet metal, existing machine vision inspection equipment often only performs a single inspection function and lacks real-time feedback and automatic adjustment capabilities for inspection results. When quality issues are detected on the sheet metal surface, manual intervention is still required to adjust production equipment or process parameters. This fails to form a closed-loop inspection and adjustment system, and cannot fundamentally solve sheet metal surface quality issues and reduce defective product rates. Therefore, it is necessary to design an online inspection and adjustment device and method for sheet metal surface quality. Summary of the Invention

[0005] The purpose of the present invention is to provide an on-line detection and adjustment device and method for plate surface quality to solve the problems raised in the above background technology.

[0006] To achieve the above-mentioned object, the present invention provides the following technical solution: an online detection and adjustment device for plate surface quality, comprising a conveying unit, a detection unit, a control unit and an adjustment unit arranged in sequence;

[0007] The conveying unit is used to convey the plate;

[0008] The detection unit is used to detect the surface quality of the plate;

[0009] The control unit is electrically connected to the detection unit and the adjustment unit respectively, and is used to receive data from the detection unit and control the action of the adjustment unit;

[0010] The adjustment unit is used to adjust the plate production process parameters according to the control unit instructions.

[0011] Preferably, the conveying unit includes a conveyor belt, a drive motor and a plurality of guide rollers; the drive motor is connected to the conveyor belt for driving the conveyor belt to operate; the plurality of guide rollers are distributed at intervals along the conveying direction of the conveyor belt, and the plurality of guide rollers are located on both sides of the conveyor belt for guiding the plate to be transported along the center line of the conveyor belt.

[0012] Preferably, the detection unit includes a machine vision detection module, a laser detection module, a color difference detection module and a material detection module; the machine vision detection module includes an industrial camera and an image acquisition card, the industrial camera is installed above the conveyor belt, and the image acquisition card is connected to the industrial camera;

[0013] The laser detection module includes a laser emitter and a laser receiver, which are arranged on both sides of the conveyor belt relative to each other, and the laser beam emitted by the laser emitter is irradiated on the surface of the plate at an oblique angle;

[0014] The color difference detection module adopts a colorimeter with a built-in standard color plate and a spectrum sensor, and the colorimeter is installed above the conveyor belt;

[0015] The material detection module adopts an eddy current flaw detector or an ultrasonic flaw detector, and the material detection module is arranged on one side of the conveyor belt.

[0016] Preferably, the control unit includes an industrial computer and a PLC controller; the industrial computer is connected to the machine vision detection module, laser detection module, color difference detection module and material detection module through a data transmission line; the PLC controller is electrically connected to the industrial computer and the adjustment unit respectively, for receiving instructions from the industrial computer and controlling the action of the actuator of the adjustment unit.

[0017] Preferably, the regulating unit includes a pressure regulating mechanism, a temperature regulating mechanism, a speed regulating mechanism and a cleaning mechanism; the regulating unit is installed on the plate processing equipment and is electrically connected to the control unit.

[0018] Preferably, the industrial camera model is Basler acA4112-30um or JAI GO-5000M-CXP; the image acquisition card model is DH-PFL9552 or National Instruments PCIe-1433.

[0019] Preferably, the industrial camera of the machine vision detection module is configured with at least three groups of light sources at different angles, including a top coaxial light source, a 45° annular light source and a 15° low-angle light source.

[0020] Preferably, a method for using a device for online detection and adjustment of plate surface quality comprises the following steps:

[0021] A. When the metal sheet is transported to the inspection area via a conveyor belt, the inspection unit starts working. The industrial camera captures images of the sheet surface at a frequency of 10 frames per second. The collected image data is transmitted to the control unit via the image acquisition card. The control unit uses the image processing algorithm to analyze the image.

[0022] B. The laser transmitter of the laser detection module emits a laser beam that irradiates the surface of the plate. The laser receiver receives the reflected laser signal in real time and analyzes and processes the laser signal.

[0023] C. The colorimeter compares the detected surface color information of the plate with the standard color plate. When the color deviation exceeds the preset threshold, the detection result is transmitted to the control unit in a timely manner;

[0024] D. The material detection module detects the metal sheet and transmits the detection results to the control unit;

[0025] E. After receiving the data transmitted by the detection unit, the control unit compares and analyzes it with the preset quality standards. If a scratch defect is detected on the sheet surface, the control unit calculates the required pressure adjustment amount for the pressure regulating mechanism based on the location, size, and severity of the scratch, and adjusts the working pressure of the metal sheet processing equipment;

[0026] F. If color difference is detected on the surface of the plate, the control unit will control the temperature regulating mechanism through the PLC controller to adjust the processing temperature according to the specific situation of the color difference;

[0027] G. When it is detected that there are impurities attached to the surface of the plate, the cleaning mechanism starts to ensure that the surface of the plate is clean.

[0028] H. The control unit monitors the operating status of the conveying unit, detection unit and adjustment unit in real time, and uploads the detection data and production status information to the workshop's production management system through the Ethernet interface. Managers can view the production progress and surface quality of the plates in real time through the production management system, and promptly identify and handle problems that arise during the production process.

[0029] Beneficial effects:

[0030] (1) The present invention has a high degree of intelligence. By integrating multiple detection technologies and automatic adjustment mechanisms, it can realize real-time online detection of the surface quality of the plate, and automatically adjust the production process parameters according to the detection results, thereby improving the accuracy and efficiency of the plate surface quality detection, reducing the defective rate, and realizing intelligent and automatic control of the plate production process.

[0031] (2) The present invention realizes the automated control of the entire process from plate surface quality detection to process parameter adjustment. The detection unit automatically collects plate surface quality data, the control unit analyzes and judges according to preset standards and generates control instructions, and the adjustment unit automatically adjusts the production process parameters according to the instructions, without the need for human intervention. This greatly improves production efficiency, reduces labor intensity, and reduces the impact of human factors on detection and adjustment results.

[0032] The above description is only an overview of the technical solutions of the embodiments of the present application. In order to more clearly understand the technical means of the embodiments of the present application, they can be implemented according to the contents of the specification. In addition, in order to make the above and other purposes, features and advantages of the embodiments of the present application more obvious and easy to understand, the specific implementation methods of the present application are specifically listed below. BRIEF DESCRIPTION OF THE DRAWINGS

[0033] Figure 1 It is a schematic diagram of the structure of the present invention;

[0034] Figure 2 This is a control principle block diagram of the present invention;

[0035] Figure 3 It is a flowchart of the present invention;

[0036] In the figure: conveyor belt 1, drive motor 2, guide roller 3, machine vision detection module 4, laser detection module 5, color difference detection module 6, material detection module 7, industrial camera 8, image acquisition card 9, laser transmitter 10, laser receiver 11, industrial computer 12, PLC controller 13, adjustment unit 14, pressure adjustment mechanism 15, temperature adjustment mechanism 16, speed adjustment mechanism 17, cleaning mechanism 18. DETAILED DESCRIPTION

[0037] To make the purpose, technical solutions, and advantages of the embodiments of this application more clear, the technical solutions in the embodiments of this application will be clearly and completely described below in conjunction with the drawings in the embodiments of this application. Obviously, the described embodiments are part of the embodiments of this application, not all of the embodiments. Based on the embodiments in this application, all other embodiments obtained by ordinary technicians in this field without making creative efforts are within the scope of protection of this application.

[0038] Unless otherwise defined, all technical and scientific terms used herein have the same meaning as commonly understood by those skilled in the art to which this application belongs; the terms used in the specification of the application are only for the purpose of describing specific embodiments and are not intended to limit this application; the terms "including" and "having" and any variations thereof in the specification, claims and drawings of this application are intended to cover non-exclusive inclusions.

[0039] References to "embodiments" herein mean that a particular feature, structure, or characteristic described in connection with the embodiments may be included in at least one embodiment of the present application. The appearance of the phrase "embodiment" in various places in the specification does not necessarily refer to the same embodiment, nor does it necessarily refer to independent or alternative embodiments that are mutually exclusive of other embodiments. It is understood, both explicitly and implicitly, by those skilled in the art that the embodiments described herein may be combined with other embodiments.

[0040] The directional words appearing in the following description are all directions shown in the drawings and do not limit the specific structure of this application. For example, in the description of this application, the terms "center", "longitudinal", "lateral", "length", "width", "thickness", "up", "down", "front", "back", "left", "right", "vertical", "horizontal", "top", "bottom", "inside", "outside", "clockwise", "counterclockwise", "axial", "radial", "circumferential", etc., which indicate directions or positional relationships, are based on the directions or positional relationships shown in the drawings and are only for the convenience of describing this application and simplifying the description. They do not indicate or imply that the device or element referred to must have a specific direction, be constructed and operate in a specific direction, and therefore should not be understood as limiting this application.

[0041] In addition, the terms "first", "second", etc. in the description and claims of this application or the above-mentioned drawings are used to distinguish different objects, rather than to describe a specific order, and may explicitly or implicitly include one or more such features.

[0042] In the description of this application, it should be noted that, unless otherwise clearly specified and limited, the terms "installed", "connected", and "connected" should be understood in a broad sense. For example, the "connection" or "connection" of a mechanical structure may refer to a physical connection. For example, the physical connection may be a fixed connection, such as a fixed connection through a fixing member, such as a fixed connection through a screw, bolt, or other fixing member; the physical connection may also be a detachable connection, such as a mutual snap connection or snap connection; the physical connection may also be an integral connection, such as a connection formed by welding, bonding, or integral molding. For those skilled in the art, the specific meanings of the above terms in this application can be understood according to specific circumstances.

[0043] In order to enable those skilled in the art to better understand the solution of the present application, the technical solution in the embodiments of the present application will be clearly and completely described below in conjunction with the accompanying drawings.

[0044] See also Figure 1-Figure 3 The present invention discloses an online detection and adjustment device for plate surface quality, comprising a conveying unit, a detection unit, a control unit and an adjustment unit arranged in sequence;

[0045] The conveying unit is used to convey the plate;

[0046] The detection unit is used to detect the surface quality of the plate;

[0047] The control unit is electrically connected to the detection unit and the adjustment unit respectively, and is used to receive data from the detection unit and control the action of the adjustment unit;

[0048] The adjustment unit is used to adjust the plate production process parameters according to the control unit instructions.

[0049] In the present invention, the conveying unit includes a conveyor belt 1, a drive motor 2 and a plurality of guide rollers 3; the drive motor 2 is connected to the conveyor belt 1 for driving the conveyor belt 1 to operate, and the conveyor belt is made of high-strength, wear-resistant rubber material with a smooth surface to avoid secondary damage to the surface of the plate; the plurality of guide rollers 3 are distributed at intervals along the conveying direction of the conveyor belt, and the plurality of guide rollers 3 are located on both sides of the conveyor belt 1, for guiding the plate to be transported along the center line of the conveyor belt.

[0050] In the present invention, the detection unit includes a machine vision detection module 4, a laser detection module 5, a color difference detection module 6, and a material detection module 7. The machine vision detection module 4 includes an industrial camera 8 and an image acquisition card 9. The industrial camera 8 is installed above the conveyor belt 1 and captures images of the plate surface at a certain frequency. The image acquisition card 9 is connected to the industrial camera 8 and, through image processing algorithms, can detect defects such as scratches, pits, cracks, and impurity adhesion on the plate surface and determine the location, size, and shape of the defects. The industrial camera model is Basler acA4112-30um or JAI GO-5000M-CXP; the image acquisition card model is DH-PFL9552 or National Instruments PCIe-1433. The industrial camera of the machine vision detection module is equipped with at least three sets of light sources at different angles, including a top coaxial light source, a 45° ring light source, and a 15° low-angle light source.

[0051] The laser detection module 5 comprises a laser emitter 10 and a laser receiver 11, which are positioned opposite each other on either side of the conveyor belt 1. The laser beam emitted by the laser emitter 10 illuminates the surface of the sheet material at an oblique angle. The laser beam emitted by the laser emitter 10 illuminates the surface of the sheet material at a specific angle, and the laser receiver receives the laser signal reflected from the surface. Based on the changes in the reflected laser signal, parameters such as the sheet material's surface flatness and thickness uniformity can be detected. The laser detection module enables high-precision detection of the sheet material's surface microscopic topography, with detection accuracy reaching the micron level.

[0052] The color difference detection module 6 uses a colorimeter with a built-in standard color plate and a spectrum sensor. The colorimeter is installed above the conveyor belt 1 to detect the color information of the plate surface in real time and compare and analyze it with the color data of the standard color plate. It can accurately detect color difference problems on the plate surface, including color deviation, color unevenness, etc.

[0053] The material detection module 5 uses an eddy current flaw detector or an ultrasonic flaw detector. The eddy current flaw detector can detect defects such as pores and inclusions inside metal plates, and the ultrasonic flaw detector can be used to detect the internal structural integrity and density uniformity of non-metallic plates such as wooden plates and plastic plates. The material detection module 5 is arranged on one side of the conveyor belt 1.

[0054] In this invention, the control unit includes an industrial computer 12 and a programmable logic controller 13. The industrial computer 12 is connected to the machine vision inspection module 4, laser inspection module 5, color difference inspection module 6, and material inspection module 7 via data transmission lines. The PLC controller 13 is electrically connected to the industrial computer 12 and the adjustment unit 14, respectively, to receive instructions from the industrial computer and control the actuators of the adjustment unit. The industrial computer runs specialized inspection and control software, processes, analyzes, and stores data collected by the inspection unit, and evaluates and determines the surface quality of the sheet material using pre-set quality standards. When quality issues are detected on the sheet material surface, the industrial computer generates appropriate control instructions based on the type and severity of the issue.

[0055] The regulating unit 14 includes a pressure regulating mechanism 15, a temperature regulating mechanism 16, a speed regulating mechanism 17, and a cleaning mechanism 18. The regulating unit 14 is mounted on the sheet metal processing equipment and is electrically connected to the control unit. Based on the control unit's instructions, the regulating unit automatically adjusts relevant process parameters during sheet metal production to improve sheet metal surface quality.

[0056] Working principle: A method for using a device for online detection and adjustment of plate surface quality includes the following steps:

[0057] A. When the metal sheet is transported to the inspection area via a conveyor belt, the inspection unit starts working. The industrial camera captures images of the sheet surface at a frequency of 10 frames per second. The collected image data is transmitted to the control unit via the image acquisition card. The control unit uses the image processing algorithm to analyze the image.

[0058] B. The laser transmitter of the laser detection module emits a laser beam that irradiates the surface of the plate. The laser receiver receives the reflected laser signal in real time and analyzes and processes the laser signal.

[0059] C. The colorimeter compares the detected surface color information of the plate with the standard color plate. When the color deviation exceeds the preset threshold, the detection result is transmitted to the control unit in a timely manner;

[0060] D. The material detection module detects the metal sheet and transmits the detection results to the control unit;

[0061] E. After receiving the data transmitted by the detection unit, the control unit compares and analyzes it with the preset quality standards. If a scratch defect is detected on the sheet surface, the control unit calculates the required pressure adjustment amount for the pressure regulating mechanism based on the location, size, and severity of the scratch, and adjusts the working pressure of the metal sheet processing equipment;

[0062] F. If color difference is detected on the surface of the plate, the control unit will control the temperature regulating mechanism through the PLC controller to adjust the processing temperature according to the specific situation of the color difference;

[0063] G. When it is detected that there are impurities attached to the surface of the plate, the cleaning mechanism starts to ensure that the surface of the plate is clean.

[0064] H. The control unit monitors the operating status of the conveying unit, detection unit and adjustment unit in real time, and uploads the detection data and production status information to the workshop's production management system through the Ethernet interface. Managers can view the production progress and surface quality of the plates in real time through the production management system, and promptly identify and handle problems that arise during the production process.

[0065] Through practical application verification, it was found that after adopting the plate surface quality online detection and adjustment device of the present invention, the plate defective rate of the metal plate production enterprise was reduced from the original 9% to below 1%, the product quality was significantly improved, the production efficiency was increased by 40%, and good economic and social benefits were achieved.

[0066] To sum up, the present invention has a high degree of intelligence. By integrating multiple detection technologies and automatic adjustment mechanisms, it can realize real-time online detection of the surface quality of the plate, and automatically adjust the production process parameters according to the detection results, thereby improving the accuracy and efficiency of the plate surface quality detection, reducing the defective rate, and realizing intelligent and automatic control of the plate production process.

[0067] As described above, the above embodiments are only used to illustrate the technical solutions of the present application, rather than to limit them. Although the present application has been described in detail with reference to the above embodiments, those skilled in the art should understand that they can still modify the technical solutions described in the above embodiments, or make equivalent replacements for some of the technical features therein. However, these modifications or replacements do not deviate the essence of the corresponding technical solutions from the spirit and scope of the technical solutions of the embodiments of the present application.

Claims

1. A device for online detection and adjustment of plate surface quality, characterized by: It includes a conveying unit, a detection unit, a control unit and an adjustment unit which are arranged in sequence; The conveying unit is used to convey the plate; The detection unit is used to detect the surface quality of the plate; The control unit is electrically connected to the detection unit and the adjustment unit respectively, and is used to receive data from the detection unit and control the action of the adjustment unit; The adjustment unit is used to adjust the plate production process parameters according to the control unit instructions.

2. The on-line detection and adjustment device for plate surface quality according to claim 1, characterized in that: The conveying unit comprises a conveyor belt (1), a drive motor (2) and a plurality of guide rollers (3); the drive motor (2) is in transmission connection with the conveyor belt (1) and is used to drive the conveyor belt (1) to operate; the plurality of guide rollers (3) are spaced apart along the conveying direction of the conveyor belt, and the plurality of guide rollers (3) are located on both sides of the conveyor belt (1) and are used to guide the plate to be transported along the center line of the conveyor belt.

3. The on-line detection and adjustment device for plate surface quality according to claim 1, characterized in that: The detection unit includes a machine vision detection module (4), a laser detection module (5), a color difference detection module (6), and a material detection module (7); the machine vision detection module (4) includes an industrial camera (8) and an image acquisition card (9), the industrial camera (8) is installed above the conveyor belt (1), and the image acquisition card (9) is connected to the industrial camera (8); The laser detection module (5) comprises a laser emitter (10) and a laser receiver (11), wherein the laser emitter (10) and the laser receiver (11) are arranged on both sides of the conveyor belt (1) relative to each other, and the laser beam emitted by the laser emitter (10) is irradiated on the surface of the plate at an inclined angle; The color difference detection module (6) adopts a colorimeter with a built-in standard color plate and a spectrum sensor, and the colorimeter is installed above the conveyor belt (1); The material detection module (7) adopts an eddy current flaw detector or an ultrasonic flaw detector, and the material detection module (7) is arranged on one side of the conveyor belt (1).

4. The on-line detection and adjustment device for plate surface quality according to claim 1, characterized in that: The control unit comprises an industrial computer (12) and a PLC controller (13); the industrial computer (12) is connected to a machine vision detection module (4), a laser detection module (5), a color difference detection module (6), and a material detection module (7) via a data transmission line; the PLC controller (13) is electrically connected to the industrial computer (12) and the adjustment unit (14) respectively, and is used to receive instructions from the industrial computer and control the action of the adjustment unit actuator.

5. The on-line detection and adjustment device for plate surface quality according to claim 1, characterized in that: The regulating unit (14) comprises a pressure regulating mechanism (15), a temperature regulating mechanism (16), a speed regulating mechanism (17) and a cleaning mechanism (18); the regulating unit (14) is installed on the plate processing equipment and is electrically connected to the control unit.

6. The on-line detection and adjustment device for plate surface quality according to claim 3, characterized in that: The industrial camera model is Basler acA4112-30um or JAI GO-5000M-CXP; the image acquisition card model is DH-PFL9552 or National Instruments PCIe-1433.

7. The on-line detection and adjustment device for plate surface quality according to claim 3, characterized in that: The industrial camera of the machine vision detection module is configured with at least three groups of light sources at different angles, including a top coaxial light source, a 45° annular light source, and a 15° low-angle light source.

8. A method for using the device for online detection and adjustment of plate surface quality according to claim 1, characterized in that: The following steps are involved: A. When the metal sheet is transported to the inspection area via a conveyor belt, the inspection unit starts working. The industrial camera captures images of the sheet surface at a frequency of 10 frames per second. The collected image data is transmitted to the control unit via the image acquisition card. The control unit uses the image processing algorithm to analyze the image. B. The laser transmitter of the laser detection module emits a laser beam that irradiates the surface of the plate. The laser receiver receives the reflected laser signal in real time and analyzes and processes the laser signal. C. The colorimeter compares the detected surface color information of the plate with the standard color plate. When the color deviation exceeds the preset threshold, the detection result is transmitted to the control unit in a timely manner; D. The material detection module detects the metal sheet and transmits the detection results to the control unit; E. After receiving the data transmitted by the detection unit, the control unit compares and analyzes it with the preset quality standards. If a scratch defect is detected on the plate surface, the control unit calculates the pressure adjustment required by the pressure regulating mechanism based on the location, size and severity of the scratch, and adjusts the working pressure of the metal plate processing equipment; F. If color difference is detected on the surface of the plate, the control unit will control the temperature regulating mechanism through the PLC controller to adjust the processing temperature according to the specific situation of the color difference; G. When it is detected that there are impurities attached to the surface of the plate, the cleaning mechanism starts to ensure that the surface of the plate is clean; H. The control unit monitors the operating status of the conveying unit, detection unit and adjustment unit in real time, and uploads the detection data and production status information to the workshop's production management system through the Ethernet interface. Managers can view the production progress and surface quality of the plates in real time through the production management system, and promptly identify and handle problems that arise during the production process.

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