Tray detection method, device and system

Abstract

The invention provides a tray detection method, device and system, and the method comprises the steps: responding to a received scheduling instruction sent by a tray scheduling system, scheduling a to-be-detected tray in a tray library to a detection region, scanning the to-be-detected tray in the detection region, and obtaining a scanning image, and performing precision detection on the to-be-detected target in the scanning image, generating a detection result of the to-be-detected tray, performing result marking on the detected tray according to the detection result, and scheduling the detected tray to a production line area or a repair area according to the result marking. According to the embodiment of the invention, automatic equipment is used for replacing manual operation of a mechanical detection tool, automatic precision detection of the tray is realized, automatic detection of the tray is combined with automatic scheduling of the tray, manual intervention is reduced, and the overall detection efficiency of the tray on a production line is remarkably improved.

Description

Technical Field

[0001] The present application relates to the field of vehicle manufacturing technology, and in particular to a pallet detection method, device and system. Background Art

[0002] As an important tool for carrying and transporting parts, pallets are widely used in high-end manufacturing fields such as automobiles. Their precision directly affects the assembly quality and efficiency of the production line. Therefore, extremely high requirements are placed on the size, shape and position accuracy of pallets.

[0003] At present, the accuracy inspection of pallets mainly relies on traditional mechanical inspection tools and is evaluated by manual sampling. The size and weight of traditional mechanical inspection tools are usually proportional to the size of the pallet being inspected. For smaller pallets, mechanical inspection tools can adapt well and the inspection efficiency is acceptable. However, when the pallet size is larger, the size and weight of the inspection tools will increase significantly. Its heavy weight makes it extremely difficult for one person to operate it. The inspection must be completed with the help of auxiliary lifting tools or the collaboration of multiple people. The operation is inconvenient and time-consuming. Therefore, the current manual use of mechanical inspection tools to perform accuracy inspection on pallets affects the inspection efficiency of pallets on the production line and cannot meet the inspection needs of pallets of different specifications. Summary of the Invention

[0004] The present application provides a pallet detection method, device and system to solve the problem that the current manual use of mechanical inspection tools to perform precision inspection of pallets affects the inspection efficiency of pallets on the production line and cannot meet the inspection requirements of pallets of different specifications.

[0005] A first aspect of an embodiment of the present application provides a pallet detection method, which is applied to a pallet detection system, wherein the pallet detection system communicates with a pallet scheduling system. The method includes: In response to receiving a dispatch instruction sent by the pallet dispatch system, dispatching the pallets to be inspected in the pallet library to the inspection area; Scanning the pallet to be inspected in the inspection area to obtain a scanned image, performing precision inspection on the target to be inspected in the scanned image, and generating an inspection result of the pallet to be inspected; Marking the inspected pallet according to the inspection results; wherein the result marking includes a qualified mark and a failed mark; According to the result mark, the pallet after inspection is dispatched to the production line area or the repair area.

[0006] Optionally, the pallet detection system and the pallet scheduling system communicate with a production management system, and in response to receiving a scheduling instruction sent by the pallet scheduling system, scheduling the pallets to be inspected in the pallet library to the inspection area includes: Monitoring the pallet scheduling system to determine whether an instruction sent by the pallet scheduling system has been received; wherein the pallet scheduling system is used to determine the pallet to be detected and generate a scheduling instruction based on the pallet information stored in the production management system; In response to receiving the dispatch instruction sent by the pallet dispatch system, the pallet to be inspected in the pallet library is acquired, and the pallet to be inspected is dispatched to the inspection area.

[0007] Optionally, the pallet detection system includes a mobile device, a detection camera, and a controller. The system scans the pallet to be detected in the detection area to obtain a scanned image, performs accuracy detection on the target to be detected in the scanned image, and generates a detection result of the pallet to be detected, including: Using the mobile device carrying the inspection camera to perform an overall scan of the pallet to be inspected in the inspection area to obtain a scanned image in a height map format; Converting the scanned image in the height map format to obtain a scanned image in the grayscale map format; Recognizing the scanned image in the grayscale format to obtain the target to be detected in the tray; Performing precision detection on the target to be detected and generating a detection result of the pallet to be detected.

[0008] Optionally, the identifying the scanned image in the grayscale format to obtain the target to be detected in the tray includes: Using a preset grayscale threshold to identify the scanned image in the grayscale image format, and identifying the pin area and the surface area of ​​the pallet; Screening the pin area according to the area of ​​the pallet to determine the target pin area, fitting the target pin area, and identifying the pin center; A minimum circumscribed rectangle is fitted to the surface area of ​​the tray, and the long side and the short side of the tray are identified.

[0009] Optionally, the performing precision detection on the target to be detected and generating a detection result of the pallet to be detected includes: Calculating the point-line distances from the center of the pin to the long side and the short side of the pallet, respectively, and generating a first precision detection result of the pallet based on the point-line distances; Determining points in the surface area of ​​the tray, and fitting the points to obtain a plane equation of the surface area of ​​the tray; The point-to-surface distance between the center of the pin and the plane equation of the surface area of ​​the pallet is calculated, and a second precision detection result of the pallet is generated according to the point-to-surface distance.

[0010] Optionally, the inspected pallet is marked according to the inspection result; wherein the result marking includes a qualified mark and a unqualified mark, including: Generating a result mark corresponding to the test result according to the test result, and marking a qualified mark or a failed mark on the pallet after the test; The inspection result and the result mark of the inspected pallet are uploaded to the pallet information of the production management system for storage.

[0011] Optionally, dispatching the inspected pallet to a production line area or a rework area according to the result mark includes: Sending the result mark to the pallet scheduling system; wherein the pallet scheduling system is used to generate a first instruction to schedule the pallet to the production line area according to the qualified mark, and generate a second instruction to schedule the pallet to the rework area according to the unqualified mark; In response to receiving the first instruction or the second instruction sent by the pallet scheduling system, the inspected pallet is scheduled to a production line area or a rework area.

[0012] Optionally, after dispatching the inspected pallet to a production line area or a rework area according to the result mark, the method further includes: When the pallet is dispatched to the repair area after inspection, a repair prompt message is generated and sent to the repair area; wherein the repair prompt message is used to prompt maintenance personnel to repair the pallet; Once the pallet repair is complete, the unqualified mark on the pallet will be removed and the repaired pallet will be dispatched to the inspection area for secondary inspection.

[0013] Based on the same inventive concept, a second aspect of an embodiment of the present application provides a pallet detection device, which is applied to a pallet detection system. The pallet detection system communicates with a pallet scheduling system. The device includes: a first scheduling module, configured to dispatch the pallets to be inspected in the pallet library to the inspection area in response to receiving a scheduling instruction sent by the pallet scheduling system; an accuracy detection module, configured to scan the pallet to be detected in the detection area to obtain a scanned image, perform accuracy detection on the target to be detected in the scanned image, and generate a detection result of the pallet to be detected; A result marking module, configured to mark the pallet after inspection according to the inspection result; wherein the result marking includes a qualified mark and a failed mark; The second scheduling module is used to schedule the inspected pallets to a production line area or a rework area according to the result mark.

[0014] Based on the same inventive concept, a third aspect of an embodiment of the present application provides a pallet detection system, wherein the pallet detection system communicates with a pallet scheduling system, and the pallet detection system and the pallet scheduling system communicate with a production management system, including: The pallet scheduling system is configured to determine the pallet to be inspected and generate a scheduling instruction based on the pallet information in the production management system, and to generate a first instruction for scheduling the pallet to a production line area based on the qualified mark, and to generate a second instruction for scheduling the pallet to a rework area based on the unqualified mark; The production management system is used to store pallet information and receive the inspection results and result marks of the inspected pallets uploaded by the pallet inspection system; The pallet detection system is used to execute the pallet detection method described above.

[0015] Compared with the prior art, this application has the following advantages: The present application provides a pallet inspection method that, in response to a dispatch instruction received from a pallet dispatch system, dispatches the pallets to be inspected in the pallet warehouse to the inspection area, scans the pallets to be inspected in the inspection area to obtain a scanned image, performs precision inspection on the target to be inspected in the scanned image, generates inspection results for the pallets to be inspected, marks the inspected pallets according to the inspection results, and dispatches the inspected pallets to the production line area or the rework area according to the marked results. The present application replaces manually operated mechanical inspection tools with automated equipment to achieve automatic precision inspection of pallets, automated scanning and inspection, and ensure the accuracy of the inspection results. The combination of automatic pallet inspection and automatic pallet dispatching greatly reduces manual intervention and operating steps, significantly improving the overall efficiency of pallet inspection on the production line and meeting the production needs of multiple varieties and batches of pallets. BRIEF DESCRIPTION OF THE DRAWINGS

[0016] Various other advantages and benefits will become apparent to those skilled in the art upon reading the detailed description of the preferred embodiment below. The accompanying drawings are for illustration purposes only and are not to be considered as limiting the present application. The same reference symbols are used throughout the drawings to represent the same components. In the drawings: Figure 1 This is a flowchart of the steps of a pallet detection method provided in an embodiment of the present application; Figure 2 yes Figure 1 Flowchart of step 101 in the pallet detection method provided in an embodiment of the present application; Figure 3 yes Figure 1 Flowchart of step 102 in the pallet detection method provided in an embodiment of the present application; Figure 4 yes Figure 1Flowchart of step 103 in the pallet detection method provided in an embodiment of the present application; Figure 5 yes Figure 1 Flowchart of step 104 in the pallet detection method provided in the embodiment of the present application; Figure 6 Schematic diagram of a scanning method for pallet detection provided in an embodiment of the present application; Figure 7 This is a schematic diagram of the accuracy detection of a pallet detection method provided in an embodiment of the present application; Figure 8 This is a structural diagram of a pallet detection device provided in an embodiment of the present application; Figure 9 It is a structural schematic diagram of a pallet detection system provided in an embodiment of the present application. DETAILED DESCRIPTION

[0017] In order to make the purpose, technical solutions and advantages of the embodiments of the present application clearer, each embodiment of the present application will be described in detail below with reference to the accompanying drawings. However, it will be understood by those skilled in the art that in each embodiment of the present application, many technical details are proposed in order to enable the reader to better understand the present application. However, even without these technical details and various changes and modifications based on the following embodiments, the technical solutions claimed in the present application can be implemented. The division of the following embodiments is for convenience of description and should not constitute any limitation on the specific implementation of the present application. The various embodiments can be combined with each other and referenced to each other under the premise of no contradiction.

[0018] The accuracy inspection of pallets mainly relies on traditional mechanical inspection tools and is evaluated by manual sampling. The size and weight of traditional mechanical inspection tools are usually proportional to the size of the pallet being inspected. For smaller pallets, mechanical inspection tools can adapt well and the inspection efficiency is acceptable. However, when the pallet size is larger, the size and weight of the inspection tools will increase significantly. Its heavy weight makes it extremely difficult for one person to operate. It must use auxiliary lifting tools or multiple people to complete the inspection. In addition, using traditional inspection tools to inspect the accuracy of a single pallet takes about 60 minutes. Each pallet requires a dedicated inspection tool. For a single vehicle model, for example, four sets need to be developed (one set each for the front and rear suspension combined pallets, and one set each for the battery pack EVR\EV combined pallet), which is very costly. Based on this, the present application proposes a pallet inspection method, device, and system.

[0019] Reference Figure 1 , Figure 1 This is a flow chart of a pallet detection method proposed in one embodiment of the present application. Figure 1 As shown, the method is applied to a pallet detection system, which communicates with a pallet scheduling system, and mainly includes the following steps: Step 101 : In response to receiving a dispatch instruction sent by a pallet dispatch system, dispatching a pallet to be inspected in a pallet library to an inspection area.

[0020] In the embodiment of the present application, in order to solve the problem that the current manual use of mechanical inspection tools to perform precision inspection on pallets affects the inspection efficiency of pallets on the production line and cannot meet the inspection requirements of pallets of different specifications, this embodiment uses automated equipment to replace manual operation and adopts multi-system collaborative interactive control to achieve automatic precision inspection of pallets. Specifically, refer to Figure 9 , shows a structural schematic diagram of a pallet detection system provided in an embodiment of the present application. The pallet detection system communicates with the pallet scheduling system. The pallet detection system and the pallet scheduling system also communicate with the production management system (MOM system). The pallet detection system includes a mobile device, a detection camera and a controller. The pallet scheduling system is used to determine the pallets to be detected and generate scheduling instructions based on the pallet information in the production management system, and schedule the pallets to the detection area, production line area or rework area.

[0021] Specifically, in response to receiving the scheduling instructions sent by the pallet scheduling system, the pallet detection system dispatches the pallets to be inspected in the pallet warehouse to the inspection area, obtains the pallets to be inspected from the pallet warehouse, and dispatches the pallets to be inspected to the inspection area. Specifically, the PLC (Programmable Logic Controller) in the pallet warehouse controls the storage roller bed and the travel mechanism, takes out the pallets to be inspected, and transports the pallets to the inspection area. The inspection area is an area divided on the production line for inspection accuracy. Mobile equipment, inspection cameras and controllers are set up in the inspection area to scan and inspect pallets.

[0022] Step 102 : Scan the pallet to be inspected in the inspection area to obtain a scanned image, perform precision inspection on the target to be inspected in the scanned image, and generate an inspection result of the pallet to be inspected.

[0023] In an embodiment of the present application, a pallet to be inspected is scanned in an inspection area to obtain a scanned image, and a precision inspection is performed on the target to be inspected in the scanned image to generate an inspection result of the pallet to be inspected. Specifically, a mobile device carrying a detection camera is used to scan the pallet as a whole to obtain overall data. The scanned image obtained by the detection camera is a height image, and the height image is converted into a grayscale image, thereby performing image recognition on the grayscale image to extract the target to be inspected in the pallet. The target to be inspected may be a tip, surface contour, hole position, edge or other target in the pallet, which is determined specifically according to the precision inspection requirements and is not specifically limited here. The extracted target to be inspected is precision inspected to generate an inspection result of the pallet.

[0024] Step 103 , marking the inspected pallet according to the inspection result; wherein the result marking includes a qualified mark and a unqualified mark.

[0025] Step 104 : dispatch the inspected pallets to the production line area or the repair area according to the result mark.

[0026] Specifically, the result mark corresponding to the test result is sent to the pallet scheduling system. The pallet scheduling system dynamically generates scheduling instructions based on the mark content, and schedules the inspected pallet to the target area (production line area or repair area). The scheduling operation is performed according to the instruction. The PLC serves as the control core, coordinating various devices to complete the transportation of the pallet and transport the pallet to the target area. After the pallet arrives at the target area, the status is fed back to the pallet scheduling system.

[0027] The present application provides a pallet inspection method that, in response to a dispatch instruction received from a pallet dispatch system, dispatches the pallets to be inspected in the pallet warehouse to the inspection area, scans the pallets to be inspected in the inspection area to obtain a scanned image, performs precision inspection on the target to be inspected in the scanned image, generates inspection results for the pallets to be inspected, marks the inspected pallets according to the inspection results, and dispatches the inspected pallets to the production line area or the rework area according to the marked results. The present application replaces manually operated mechanical inspection tools with automated equipment to achieve automatic precision inspection of pallets, automated scanning and inspection, and ensure the accuracy of the inspection results. The combination of automatic pallet inspection and automatic pallet dispatching greatly reduces manual intervention and operating steps, significantly improving the overall efficiency of pallet inspection on the production line and meeting the production needs of multiple varieties and batches of pallets.

[0028] Further, refer to Figure 2 , showing Figure 1 A flowchart of step 101 of a pallet detection method is provided. This method is substantially the same as the pallet detection method provided in the first embodiment of the present application. Step 101 may include: Step 1011: monitoring the pallet scheduling system to determine whether an instruction sent by the pallet scheduling system has been received; wherein the pallet scheduling system is used to determine the pallet to be inspected and generate a scheduling instruction based on the pallet information stored in the production management system; Step 1012 : In response to receiving the dispatch instruction sent by the pallet dispatch system, the pallet to be inspected in the pallet library is obtained, and the pallet to be inspected is dispatched to the inspection area.

[0029] It should be noted that in the embodiment of the present application, the dispatching instructions are generated by the pallet dispatching system based on the pallet information and production requirements stored in the production management system (MOM system). In order to respond to the detection requirements in a timely manner, the pallet detection system communicates with the pallet dispatching system, monitors the status of the pallet dispatching system in real time, and triggers subsequent actions when the dispatching instructions arrive. Among them, the dispatching instructions can include information such as the pallet number and target position. The MOM system can determine the type and quantity of pallets currently required based on the production plan. The pallet dispatching system selects the pallet to be inspected from the pallet library according to the needs of the MOM system and generates dispatching instructions. The pallet detection system can check the instruction queue of the pallet dispatching system in real time through polling or event-driven methods. When a new instruction is detected, it parses the instruction content and triggers the next action to ensure that the dispatching instructions can be responded to in a timely manner and reduce production waiting time.

[0030] In an embodiment of the present application, the pallet inspection system, in response to receiving a dispatch instruction, retrieves the pallet to be inspected from the pallet warehouse and dispatches it to the inspection area. Specifically, a PLC (Programmable Logic Controller) in the pallet warehouse controls the storage roller and travel mechanism to locate and retrieve the pallet to be inspected, and then transports the pallet to the inspection area via a conveyor system (such as a conveyor roller or rotary roller). An RFID reader in the pallet warehouse reads the pallet number and confirms the location of the pallet to be inspected. The travel mechanism and storage roller work together to move the pallet from its storage location in the pallet warehouse to the conveyor line. The PLC controls the conveyor roller, rotary roller, and other equipment to ensure smooth pallet transportation.

[0031] For example, the MOM system notifies the pallet scheduling system that type A pallet is needed based on the production plan. The pallet scheduling system generates a scheduling instruction, specifying to dispatch type A pallet numbered 001 from the pallet library to the inspection area. The RFID reader in the pallet library locates the pallet numbered 001, and the moving mechanism and storage roller bed move the pallet to the conveyor line. The pallet is then sent to the inspection area through the conveyor roller bed and rotating roller bed on the conveyor line. After the pallet arrives at the inspection area, the precision inspection work begins.

[0032] The embodiment of the present application realizes the efficient flow of pallets from the warehouse to the inspection area through real-time monitoring and automated scheduling, reduces manual intervention, speeds up pallet scheduling, adapts to the production needs of multiple varieties and multiple batches, and can improve the overall efficiency of pallet inspection on the production line.

[0033] Further, refer to Figure 3 , showing Figure 1A flowchart of step 102 of a pallet detection method is provided. This method is substantially the same as the pallet detection method provided in the first embodiment of the present application. The pallet detection system includes a mobile device, a detection camera, and a controller. Step 102 may include: Step 1021 : Use a mobile device carrying an inspection camera to perform an overall scan of the pallet to be inspected in the inspection area to obtain a scanned image in a height map format.

[0034] Step 1022 : Convert the scanned image in the height map format to obtain a scanned image in the grayscale map format.

[0035] Step 1023 , identifying the scanned image in grayscale format to obtain the object to be detected in the tray.

[0036] Step 1024 : perform precision detection on the target to be detected and generate a detection result of the pallet to be detected.

[0037] It should be noted that in the embodiments of the present application, a mobile device carrying an inspection camera is used to perform an overall scan of the pallet, obtain a scanned image in height map format, and record the three-dimensional height information of the pallet surface. The mobile device can be an AGV (automated guided vehicle) or a robotic arm, and the inspection camera can be a 3D camera or a laser scanner. The overall scan ensures that all areas of the pallet are detected, and the mobile device automatically completes the scan, reducing manual intervention. The 3D camera can be a laser line scan 3D camera, which is mainly composed of a laser projector, a high-precision CCD (charge coupled device) camera, and a laser controller. The laser projector projects an entire beam of laser light onto the surface of an object, making it easier for the camera to identify the laser light on the surface of the object. The high-precision CCD camera captures the entire object, extracts the laser brightness image, and obtains the object surface contour image.

[0038] For example, refer to Figure 6 , shows a scanning schematic diagram of a pallet detection method provided by an embodiment of the present application. The scanning path must cover the entire surface of the pallet to ensure that nothing is missed. The mobile device carries a 3D camera or laser scanner, which scans the pallet along a predetermined path. A height map is generated using 3D imaging technology, recording the height value of each pixel. The mobile device carries a laser line scanning 3D camera along the pallet direction (Y axis) to scan and obtain overall data. The image obtained by the 3D camera is a height image, which is converted into a grayscale image in the range of 0-255. The conversion formula is as follows: G(x,y) = 255*(D(x,y)-Dmin) / (Dmax-Dmin) Where G(x,y) is the grayscale value at the pixel position (x,y); D(x,y) is the depth value at the same position (x,y); Dmin is the minimum depth value in the depth map; and Dmax is the maximum depth value in the depth map.

[0039] Specifically, the mobile device moves along a predetermined path, and the camera collects data at a fixed frequency. A height map is generated by processing the point cloud data. The height map data is uploaded to the industrial computer in the pallet detection system in real time for subsequent processing. The industrial computer converts the scanned image in the height map format into a grayscale image format. The grayscale image represents height information in grayscale values, which is convenient for subsequent image processing. Specifically, the height value in the height map can be mapped to a grayscale value through an image processing algorithm. The resolution of the grayscale image needs to be consistent with the height. Figure 1 The image processing algorithm can be a linear or nonlinear mapping function to convert the height value into a grayscale value, and the grayscale image is smoothed. The grayscale image is easier to recognize and analyze in the subsequent image, so as to perform image recognition on the grayscale image and extract the target to be detected in the pallet. The target to be detected can be the tip, surface contour, hole position, edge and other targets in the pallet. The specific target is determined according to the precision detection requirements and is not specifically limited here. Finally, the extracted target to be detected is precision-detected to generate the pallet detection result (such as qualified or unqualified). The detection result needs to be uploaded to the pallet scheduling system and MOM system in real time.

[0040] The embodiment of the present application achieves high-precision automated inspection of pallets through 3D scanning, image processing and precision inspection. The overall scanning and identification covers all key areas of the pallet, ensuring the accuracy of the inspection results, reducing manual intervention, significantly improving the efficiency of pallet inspection, and ensuring the stable operation of the production line.

[0041] Specifically, step 1023 recognizes the scanned image in grayscale format to obtain the target to be detected in the tray, which may include the following steps: Sub-step 01, using a preset grayscale threshold to identify the scanned image in grayscale format, and identifying the pin area and the surface area of ​​the pallet; Sub-step 02: screening the pin area according to the area of ​​the pallet, determining the target pin area, fitting the target pin area, and identifying the pin center; Sub-step 03: Fitting a minimum circumscribed rectangle to the surface area of ​​the pallet to identify the long side and the short side of the pallet.

[0042] It should be noted that in the above steps, the scanned image in grayscale format is recognized to extract the target to be detected in the pallet, which includes the pin area, the pin center, the pallet surface area, the long side of the pallet and the short side of the pallet. Specifically, the grayscale image is segmented using a preset grayscale threshold to identify the pin area and the pallet surface area. Figure 7, shows a precision detection schematic diagram of a pallet detection method provided in an embodiment of the present application, wherein the image is divided into a pin area and a pallet surface area through binarization processing to generate a binary image, wherein the pin area is white and the pallet surface area is black. The segmentation result needs to accurately distinguish the pin area and the pallet surface area, wherein a suitable grayscale threshold is pre-set according to the grayscale difference between the pin and the pallet surface, and the setting of the grayscale threshold needs to be adjusted according to the actual image. For example, the grayscale value range of the pin area is [200, 255], and the grayscale value range of the pallet surface area is [50, 199], which is not specifically limited here.

[0043] Specifically, pin regions are screened based on their area to determine the target pin region. The target pin region is then geometrically fitted to identify the pin center. The area of ​​each pin region can be calculated, and regions within a preset area range are screened. A circle is fitted to the pin region to determine the circle's center. The coordinates and radius of the center of the fitted circle are then obtained, and the pin center is then determined. Area screening and geometric fitting ensure the accuracy of the pin center coordinates. In this embodiment, a minimum bounding rectangle is fitted to the pallet surface area to identify the long and short sides of the pallet. The minimum bounding rectangle is fitted to the pallet surface area, and the long and short sides of the pallet are determined based on the rectangle's side lengths. Specifically, the coordinates of the rectangle's four vertices and the rotation angle are obtained. The lengths of the rectangle's long and short sides are calculated based on the vertex coordinates. The identified long and short sides can be used for pallet positioning and posture adjustment.

[0044] The embodiment of the present application processes the grayscale image to segment the pin area and the pallet surface area, thereby achieving accurate identification of the pallet pin area, pin center, pallet surface area, and long and short sides. The identification results can be used for pallet positioning and precision detection, reducing manual intervention and improving the efficiency of pallet detection.

[0045] Specifically, step 1024 performs precision detection on the target to be detected and generates a detection result of the pallet to be detected, which may specifically include the following steps: Sub-step 01, calculating the point-line distances from the pin center to the long side and the short side of the pallet, and generating a first precision detection result of the pallet based on the point-line distances; Sub-step 02, determining points on the surface area of ​​the pallet, and fitting the points to obtain a plane equation of the surface area of ​​the pallet; Sub-step 03, calculating the point-to-surface distance between the pin center and the plane equation of the pallet surface area, and generating a second precision detection result of the pallet based on the point-to-surface distance.

[0046] In the embodiment of the present application, in the above steps, the extracted target to be inspected is precision-tested to generate pallet inspection results, including a first precision test result and a second precision test result. The results are uploaded to the pallet dispatch system and the MOM system in real time. The first precision test result is the result of the pin's XY precision test, and the second precision test result is the result of the pin's Z precision test.

[0047] Specifically, the point-to-line distance from the center of the pin to the long and short sides of the pallet is calculated, and a first accuracy test result is generated based on the point-to-line distance. The point-to-line distance can be used to detect the relative position accuracy of the pin and the edge of the pallet. By calculating the distance from a point to a line, the calculated distance is compared with a preset threshold to determine whether it is qualified. The preset threshold must be set according to the design requirements of the pallet. The calculation of the point-to-line distance is based on the geometric equations of the long and short sides of the pallet, which can be determined by the vertex coordinates of the minimum circumscribed rectangle. The distance from the center of the pin to the long and short sides is calculated using the point-to-line distance formula. The calculated distance is compared with the preset threshold. If the distance is within the threshold range, it is marked as qualified; otherwise, it is marked as unqualified.

[0048] In an embodiment of the present application, points in the surface area of ​​the pallet are determined, and the points are fitted to obtain the plane equation of the surface area of ​​the pallet. The point selection must cover the surface area of ​​the pallet to ensure the fitting accuracy. A number of points are evenly selected from the surface area of ​​the pallet, and the coordinates of the points can be obtained through scanning data. The point-to-plane distance between the center of the pin and the plane equation of the surface area of ​​the pallet is calculated, and a second precision test result is generated based on the point-to-plane distance. The distance from the point to the plane is calculated. The point-to-plane distance can be used to detect the vertical position accuracy of the pin and the surface of the pallet. The calculated distance is compared with a preset threshold to determine whether it is qualified. The preset threshold needs to be set according to the design requirements of the pallet. The calculation of the point-to-plane distance needs to be based on the plane equation of the surface area of ​​the pallet. The calculated distance is compared with the preset threshold. If the distance is within the threshold range, it is marked as qualified; otherwise, it is marked as unqualified.

[0049] The embodiment of the present application realizes the automated detection of the position and surface accuracy of the pallet pins through point-line distance calculation, plane equation fitting and point-surface distance calculation, ensures the accuracy of the detection results, and can simultaneously detect the position accuracy of the pins and the edge and surface of the pallet, reduce manual intervention and improve detection efficiency.

[0050] Further, refer to Figure 4 , showing Figure 1 A flowchart of step 103 of a pallet detection method is provided. This method is substantially the same as the pallet detection method provided in the first embodiment of the present application. Step 103 may include: Step 1031: Generate a result mark corresponding to the test result according to the test result, and mark a qualified mark or a failed mark on the tested pallet; Step 1032 : Upload the inspection result and result mark of the inspected pallet to the pallet information of the production management system for storage.

[0051] It should be noted that in the embodiment of the present application, a corresponding result mark is generated according to the test result, wherein the result mark includes a qualified mark or a unqualified mark, so that a qualified mark or an unqualified mark is marked on the pallet after inspection. The result mark can be a physical mark (such as a label, inkjet code) or a digital mark (such as RFID, barcode). The marking method must be compatible with the production management system, and the marking position must be unified for quick identification. No specific limitation is made here.

[0052] Specifically, the inspection results and result tags of the inspected pallets are uploaded to the production management system (MOM system), which updates the pallet information in the production management system and stores the inspection results and tag status. Data uploaded to the MOM system, including the pallet number, inspection results, result tags, and inspection time, must be uploaded in real time and accurately to ensure that pallet information in the MOM system is updated promptly. After receiving the data, the MOM system updates the pallet information database. The MOM system shares data with other systems (such as the pallet scheduling system) to optimize production management, allowing qualified pallets to be dispatched to the production line for use and unqualified pallets to be dispatched to the repair area for repair.

[0053] The embodiment of the present application realizes the automatic recording and management of pallet inspection results by generating result marks, marking pallets and uploading inspection results, automatic marking and data uploading, reduces manual intervention, and records the inspection results and marking status throughout the process for easy traceability, significantly improving the efficiency and accuracy of pallet management and ensuring the stable operation of the production line.

[0054] Further, refer to Figure 5 , showing Figure 1 A flowchart of step 104 of a pallet detection method is provided. This method is substantially the same as the pallet detection method provided in the first embodiment of the present application. Step 104 may include: Step 1041: Send the result mark to the pallet scheduling system; wherein the pallet scheduling system is used to generate a first instruction to schedule the pallet to the production line area based on the qualified mark, and generate a second instruction to schedule the pallet to the repair area based on the unqualified mark; Step 1042 : In response to receiving the first instruction or the second instruction sent by the pallet scheduling system, the inspected pallet is scheduled to a production line area or a rework area.

[0055] It should be noted that in the embodiment of the present application, the result mark corresponding to the detection result is sent to the pallet scheduling system, and the pallet scheduling system dynamically generates a scheduling instruction based on the mark content. Specifically, if it is a qualified mark, a first instruction is generated to schedule the pallet to the production line area; if it is an unqualified mark, a second instruction is generated to schedule the pallet to the rework area, wherein the result mark needs to be bound to the pallet number. The pallet detection system can package the pallet number and the result mark and send them to the pallet scheduling system to ensure the accuracy of the scheduling instruction.

[0056] Specifically, in response to receiving the first instruction or the second instruction sent by the pallet scheduling system, the inspected pallet is scheduled to the target area (production line area or rework area), and the pallet conveying system (including conveying rollers, rotating rollers, transfer machines, etc.) performs the scheduling operation according to the instruction. The PLC serves as the control core and coordinates various equipment to complete the conveying of the pallet. The PLC of the pallet conveying system receives the scheduling instruction, analyzes the target position, and plans the optimal conveying path according to the target position. The PLC controls the conveying rollers, rotating rollers and other equipment to transport the pallet to the target area. After the pallet arrives at the target area, the status is fed back to the pallet scheduling system.

[0057] The embodiment of the present application realizes automatic scheduling after pallet inspection by sending result marks, generating scheduling instructions and executing scheduling operations, significantly improving the efficiency of pallet circulation, controlling and ensuring that pallets accurately reach the target area, reducing manual intervention, and ensuring the stable operation of the production process.

[0058] In some embodiments, after dispatching the inspected pallet to the production line area or the rework area according to the result mark in step 104, the following steps may also be performed: When the pallet is dispatched to the repair area after inspection, a repair prompt message is generated and sent to the repair area; wherein the repair prompt message is used to prompt maintenance personnel to repair the pallet; Once the pallet repair is complete, the unqualified mark on the pallet will be removed and the repaired pallet will be dispatched to the inspection area for secondary inspection.

[0059] In an embodiment of the present application, when the pallet after inspection is dispatched to the repair area, a repair prompt message is generated and sent to the repair area to prompt the maintenance personnel to repair the pallet, wherein the repair prompt message includes the pallet number, fault type, inspection result, etc. When the pallet repair is completed, the unqualified mark of the pallet is cleared, and the repaired pallet is dispatched to the inspection area for secondary inspection. Specifically, after the repair is completed, the maintenance personnel confirms the repair status through the terminal or mobile device in the repair area, automatically clears the unqualified mark of the pallet, and generates a dispatch instruction to send the pallet to the inspection area. The secondary inspection must ensure that the accuracy of the pallet meets the requirements. The repaired pallet is dispatched to the inspection area for secondary inspection, and the result mark is regenerated according to the secondary inspection result. The secondary inspection process is the same as the initial inspection, including scanning, recognition, precision inspection and other steps, which will not be repeated here. If the secondary inspection is qualified, a qualified mark is generated and dispatched to the production line area. If the secondary inspection is still unqualified, an unqualified mark is generated and it is re-dispatched to the repair area.

[0060] The embodiments of the present application realize the automation and closed-loop management of the pallet rework process by generating rework prompt information, monitoring the rework completion status, clearing unqualified marks, and performing secondary inspections. The rework prompt information and automatic scheduling reduce manual intervention and improve rework efficiency. The secondary inspection ensures that the reworked pallet meets the precision requirements, thereby improving the quality and efficiency of pallet rework, reducing the production failure rate, and ensuring the stable operation of the production line.

[0061] Reference Figure 8 Based on the same inventive concept, a second aspect of an embodiment of the present application provides a pallet detection device, which is applied to a pallet detection system. The pallet detection system communicates with a pallet scheduling system. The pallet detection device 200 includes: A first scheduling module 201 is configured to schedule the pallets to be inspected in the pallet library to the inspection area in response to receiving a scheduling instruction sent by the pallet scheduling system; The precision detection module 202 is configured to scan the pallet to be detected in the detection area to obtain a scanned image, perform precision detection on the target to be detected in the scanned image, and generate a detection result of the pallet to be detected; A result marking module 203 is used to mark the pallet after the inspection according to the inspection result; wherein the result marking includes a qualified mark and a failed mark; The second scheduling module 204 is configured to schedule the inspected pallets to a production line area or a repair area according to the result mark.

[0062] Furthermore, the pallet detection system and the pallet scheduling system communicate with the production management system, and the first scheduling module 201 includes: a monitoring submodule, configured to monitor the pallet scheduling system and determine whether an instruction sent by the pallet scheduling system has been received; wherein the pallet scheduling system is configured to determine the pallet to be detected and generate a scheduling instruction based on the pallet information stored in the production management system; The first scheduling submodule is configured to, in response to receiving a scheduling instruction sent by the pallet scheduling system, obtain a pallet to be inspected in a pallet library and schedule the pallet to be inspected to a detection area.

[0063] Furthermore, the pallet detection system includes a mobile device, a detection camera, and a controller, and the accuracy detection module 202 includes: A scanning submodule, configured to use the mobile device carrying the inspection camera to perform an overall scan of the pallet to be inspected in the inspection area to obtain a scanned image in a height map format; a conversion submodule, configured to convert the scanned image in the height map format to obtain a scanned image in the grayscale map format; an identification submodule, configured to identify the scanned image in the grayscale format to obtain an object to be detected in the tray; The detection submodule is used to perform precision detection on the target to be detected and generate a detection result of the pallet to be detected.

[0064] Furthermore, the identification submodule includes: a first recognition unit, configured to recognize the scanned image in grayscale format using a preset grayscale threshold, and identify the pin area and the surface area of ​​the pallet; A second recognition unit is configured to screen the pin area according to the area of ​​the pallet, determine a target pin area, perform fitting on the target pin area, and identify the pin center; The third recognition unit is configured to fit a minimum circumscribed rectangle to the surface area of ​​the tray and identify the long side and the short side of the tray.

[0065] Furthermore, the detection submodule includes: a first generating unit, configured to calculate the point-line distances from the center of the pin to the long side and the short side of the pallet, respectively, and generate a first precision detection result of the pallet according to the point-line distances; a fitting unit, configured to determine points in the surface area of ​​the tray and to obtain a plane equation of the surface area of ​​the tray by fitting the points; The second generating unit is used to calculate the point-to-surface distance between the center of the pin and the plane equation of the surface area of ​​the pallet, and generate a second precision detection result of the pallet according to the point-to-surface distance.

[0066] Furthermore, the result marking module 203 includes: a marking submodule, configured to generate a result mark corresponding to the test result according to the test result, and mark a qualified mark or a failed mark on the pallet after the test; The uploading submodule is used to upload the detection result and the result mark of the detected pallet to the pallet information of the production management system for storage.

[0067] Furthermore, the second scheduling module 204 includes: a sending submodule, configured to send the result mark to the pallet scheduling system; wherein the pallet scheduling system is configured to generate a first instruction for scheduling the pallet to a production line area based on the qualified mark, and to generate a second instruction for scheduling the pallet to a rework area based on the unqualified mark; The second scheduling submodule is configured to schedule the inspected pallet to a production line area or a rework area in response to receiving the first instruction or the second instruction sent by the pallet scheduling system.

[0068] Furthermore, the device further comprises: A repair prompt module is used to generate repair prompt information when the pallet after inspection is dispatched to the repair area, and send the repair prompt information to the repair area; wherein the repair prompt information is used to prompt maintenance personnel to repair the pallet; The secondary inspection module is used to monitor the completion of pallet repair, remove the unqualified mark on the pallet, and dispatch the repaired pallet to the inspection area for secondary inspection.

[0069] As for the device embodiment, since it is basically similar to the method embodiment, the description is relatively simple, and the relevant parts can be referred to the partial description of the method embodiment.

[0070] Reference Figure 9 Based on the same inventive concept, a third aspect of an embodiment of the present application provides a pallet detection system, wherein the pallet detection system communicates with a pallet scheduling system, and the pallet detection system and the pallet scheduling system communicate with a production management system, including: The pallet scheduling system is configured to determine the pallet to be inspected and generate a scheduling instruction based on the pallet information in the production management system, and to generate a first instruction for scheduling the pallet to a production line area based on the qualified mark, and to generate a second instruction for scheduling the pallet to a rework area based on the unqualified mark; The production management system is used to store pallet information and receive the inspection results and result marks of the inspected pallets uploaded by the pallet inspection system; The pallet detection system is used to execute the pallet detection method described above.

[0071] As for the system embodiment, since it is basically similar to the method embodiment, the description is relatively simple, and the relevant parts can be referred to the partial description of the method embodiment.

[0072] The various embodiments in this specification are described in a progressive manner, and each embodiment focuses on the differences from other embodiments. The same or similar parts between the various embodiments can be referenced to each other.

[0073] Those skilled in the art will appreciate that the embodiments of the present application can be provided as methods, devices, or computer program products. Therefore, the present application can adopt the form of a complete hardware embodiment, a complete software embodiment, or an embodiment combining software and hardware. Moreover, the present application can adopt the form of a computer program product implemented on one or more computer-usable storage media (including but not limited to magnetic disk storage, CD-ROM, optical storage, etc.) containing computer-usable program code.

[0074] The embodiments of the present application are described with reference to the flowcharts and / or block diagrams of the methods, terminal devices (systems), and computer program products according to the embodiments of the present application. It should be understood that each process and / or box in the flowchart and / or block diagram, as well as the combination of the processes and / or boxes in the flowchart and / or block diagram, can be implemented by computer program instructions. These computer program instructions can be provided to a processor of a general-purpose computer, a special-purpose computer, an embedded processor, or other programmable data processing terminal device to produce a machine, so that the instructions executed by the processor of the computer or other programmable data processing terminal device generate instructions for implementing the steps in the process. Figure 1 a process or multiple processes and / or boxes Figure 1 A device that provides the functions specified in a block or multiple blocks.

[0075] These computer program instructions may also be stored in a computer readable memory that can direct a computer or other programmable data processing terminal device to operate in a specific manner, so that the instructions stored in the computer readable memory produce a manufactured product including an instruction device, which implements the process Figure 1 a process or multiple processes and / or boxes Figure 1 The function specified in one or more boxes.

[0076] These computer program instructions can also be loaded onto a computer or other programmable data processing terminal device so that a series of operating steps are executed on the computer or other programmable terminal device to produce a computer-implemented process, thereby providing instructions for executing on the computer or other programmable terminal device to implement the process. Figure 1 a process or multiple processes and / or boxes Figure 1 A step that specifies a function in one or more boxes.

[0077] Although preferred embodiments of the present invention have been described, those skilled in the art may make additional changes and modifications to these embodiments once they become aware of the basic inventive concepts. Therefore, the appended claims are intended to be interpreted as including the preferred embodiments and all changes and modifications that fall within the scope of the embodiments of the present invention.

[0078] Finally, it should be noted that, in this document, relational terms such as first and second, etc., are used only to distinguish one entity or operation from another entity or operation, and do not necessarily require or imply any actual relationship or order between these entities or operations. Moreover, the terms "comprises," "comprising," or any other variations thereof are intended to cover non-exclusive inclusion, such that a process, method, article, or terminal device that includes a series of elements includes not only those elements, but also other elements not explicitly listed, or elements inherent to such process, method, article, or terminal device. In the absence of further limitations, an element defined by the phrase "comprising a ..." does not exclude the presence of additional identical elements in the process, method, article, or terminal device that includes the element.

[0079] The above is a detailed introduction to the pallet detection method, device and system provided by the present application. Specific examples are used in this article to illustrate the principles and implementation methods of the present application. The description of the above embodiments is only used to help understand the method and core ideas of the present application. At the same time, for those skilled in the art, according to the ideas of the present application, there will be changes in the specific implementation methods and application scope. In summary, the content of this specification should not be understood as limiting the present application.

Claims

1. A pallet detection method, characterized in that: Applied to a pallet detection system that communicates with a pallet scheduling system, the method includes: In response to receiving a dispatch instruction sent by the pallet dispatch system, dispatching the pallets to be inspected in the pallet library to the inspection area; Scanning the pallet to be inspected in the inspection area to obtain a scanned image, performing precision inspection on the target to be inspected in the scanned image, and generating an inspection result of the pallet to be inspected; Marking the inspected pallet according to the inspection results; wherein the result marking includes a qualified mark and a failed mark; According to the result mark, the pallet after inspection is dispatched to the production line area or the repair area.

2. The pallet detection method according to claim 1, characterized in that: The pallet detection system and the pallet scheduling system communicate with the production management system, and in response to receiving a scheduling instruction sent by the pallet scheduling system, dispatching the pallets to be inspected in the pallet library to the inspection area includes: Monitoring the pallet scheduling system to determine whether an instruction sent by the pallet scheduling system has been received; wherein the pallet scheduling system is used to determine the pallet to be detected and generate a scheduling instruction based on the pallet information stored in the production management system; In response to receiving the dispatch instruction sent by the pallet dispatch system, the pallet to be inspected in the pallet library is acquired, and the pallet to be inspected is dispatched to the inspection area.

3. The pallet detection method according to claim 1, wherein the pallet detection system comprises a mobile device, a detection camera, and a controller, wherein: The method comprises scanning the pallet to be detected in the detection area to obtain a scanned image, performing precision detection on the target to be detected in the scanned image, and generating a detection result of the pallet to be detected, including: Using the mobile device carrying the inspection camera to perform an overall scan of the pallet to be inspected in the inspection area to obtain a scanned image in a height map format; Converting the scanned image in the height map format to obtain a scanned image in the grayscale map format; Recognizing the scanned image in the grayscale format to obtain the target to be detected in the tray; Performing precision detection on the target to be detected and generating a detection result of the pallet to be detected.

4. The pallet detection method according to claim 3, characterized in that: The step of identifying the scanned image in grayscale format to obtain the target to be detected in the tray includes: Using a preset grayscale threshold to identify the scanned image in the grayscale image format, and identifying the pin area and the surface area of ​​the pallet; Screening the pin area according to the area of ​​the pallet to determine the target pin area, fitting the target pin area, and identifying the pin center; A minimum circumscribed rectangle is fitted to the surface area of ​​the tray, and the long side and the short side of the tray are identified.

5. The pallet detection method according to claim 4, characterized in that: The performing precision detection on the target to be detected and generating a detection result of the pallet to be detected includes: Calculating the point-line distances from the center of the pin to the long side and the short side of the pallet, respectively, and generating a first precision detection result of the pallet based on the point-line distances; Determining points in the surface area of ​​the tray, and fitting the points to obtain a plane equation of the surface area of ​​the tray; The point-to-surface distance between the center of the pin and the plane equation of the surface area of ​​the pallet is calculated, and a second precision detection result of the pallet is generated according to the point-to-surface distance.

6. The pallet detection method according to claim 2, characterized in that: The result marking is performed on the pallet after the inspection according to the inspection result; wherein the result marking includes a qualified mark and a unqualified mark, including: Generating a result mark corresponding to the test result according to the test result, and marking a qualified mark or a failed mark on the pallet after the test; The inspection result and the result mark of the inspected pallet are uploaded to the pallet information of the production management system for storage.

7. The pallet detection method according to claim 1, characterized in that: The step of dispatching the inspected pallet to a production line area or a repair area according to the result mark includes: Sending the result mark to the pallet scheduling system; wherein the pallet scheduling system is used to generate a first instruction to schedule the pallet to the production line area according to the qualified mark, and generate a second instruction to schedule the pallet to the rework area according to the unqualified mark; In response to receiving the first instruction or the second instruction sent by the pallet scheduling system, the inspected pallet is scheduled to a production line area or a rework area.

8. The pallet detection method according to claim 1, characterized in that: After dispatching the inspected pallet to a production line area or a rework area according to the result mark, the method further includes: When the pallet is dispatched to the repair area after inspection, a repair prompt message is generated and sent to the repair area; wherein the repair prompt message is used to prompt maintenance personnel to repair the pallet; Once the pallet repair is complete, the unqualified mark on the pallet will be removed and the repaired pallet will be dispatched to the inspection area for secondary inspection.

9. A pallet detection device, characterized in that: Applied to a pallet detection system that communicates with a pallet scheduling system, the device comprises: a first scheduling module, configured to dispatch the pallets to be inspected in the pallet library to the inspection area in response to receiving a scheduling instruction sent by the pallet scheduling system; an accuracy detection module, configured to scan the pallet to be detected in the detection area to obtain a scanned image, perform accuracy detection on the target to be detected in the scanned image, and generate a detection result of the pallet to be detected; A result marking module, configured to mark the pallet after inspection according to the inspection result; wherein the result marking includes a qualified mark and a failed mark; The second scheduling module is used to schedule the inspected pallets to a production line area or a rework area according to the result mark.

10. A pallet detection system, characterized in that: The pallet detection system communicates with the pallet scheduling system, and the pallet detection system and the pallet scheduling system communicate with the production management system, including: The pallet scheduling system is configured to determine the pallet to be inspected and generate a scheduling instruction based on the pallet information in the production management system, and to generate a first instruction for scheduling the pallet to a production line area based on the qualified mark, and to generate a second instruction for scheduling the pallet to a rework area based on the unqualified mark; The production management system is used to store pallet information and receive the inspection results and result marks of the inspected pallets uploaded by the pallet inspection system; The pallet detection system is used to execute the pallet detection method according to any one of claims 1 to 8.

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