Intelligent first part detection system and application equipment thereof

Abstract

The invention provides an intelligent first part detection system and application equipment thereof, and relates to the field of electronic equipment production, and the intelligent first part detection system comprises a pre-operation calibration module, a formal detection module, a three-dimensional visual detection module, an equipment health diagnosis module, a motion execution module and a central control module. By arranging the pre-operation calibration module, the pre-operation calibration module simulates the movement of a workpiece through an entity detection point, the power-off control unit monitors the position of the detection point in real time and cuts off a power supply at a proper time, and the inertial measurement unit records the position information at the power-off moment and after stopping. The parameter optimization unit calculates overshoot errors according to the data, changes of the conveying belt are adapted in real time, and the equipment positioning accuracy and the detection efficiency are improved.

Description

TECHNICAL FIELD

[0001] The present application relates to the field of electronic equipment production, in particular to an intelligent first-piece detection system and an application device thereof. BACKGROUND

[0002] In the field of electronic equipment production, the detection of the first piece in the same batch of workpieces is a key link to ensure product quality and production efficiency. Traditional first-piece detection systems usually adopt a fixed-position power-off control strategy, that is, a fixed power-off distance is preset, and when the workpiece reaches this position, the power supply of the conveying belt is cut off, and the first workpiece is moved to the detection station. However, due to mechanical inertia, residual power or equipment wear factors during the operation of the conveying belt, the actual stopping position often deviates greatly from the theoretical target position, which may cause the workpiece to fail to be accurately moved to the required area, and manual intervention is required for adjustment, affecting the detection efficiency and automation level.

[0003] For example, the Chinese invention patent (application number: 202011047183.4) discloses a "first-piece detection device and detection method", the specification discloses: including a positioning and loading assembly, a moving assembly and a probe rotating detection assembly, the positioning and loading assembly is used for loading and positioning a PCB board, the moving assembly is arranged above the positioning and loading assembly, and the probe rotating detection assembly is connected to the moving assembly to drive the PCB board to be detected by the moving assembly. Through the cooperation of the positioning and loading assembly, the moving assembly and the probe rotating detection assembly, the presence of defects in the PCB board before production can be quickly checked, and the defects in the product during the trial production stage can be found as early as possible, so that the product can be smoothly released for mass production; the first-piece detection device can improve the efficiency of the detection work, prevent errors caused by human errors during the detection process, realize short working hours during the detection process, and greatly save manpower and production costs; the above patent can prove the defects existing in the prior art.

[0004] Therefore, we improve it and propose an intelligent first-piece detection system and an application device thereof. SUMMARY

[0005] The purpose of the present application is to solve the problem that the inertia sliding of the current conveying equipment causes the workpiece to fail to be accurately positioned to the target station.

[0006] In order to achieve the above-mentioned purpose of the application, the present application provides the following intelligent first-piece detection system and application device thereof to improve the above-mentioned problems.

[0007] The present application is as follows:

[0008] An intelligent first-piece detection system, comprising:

[0009] Pre-run calibration module, simulating workpiece movement by physical detection points, dynamically learning inertia sliding characteristics after power-off of conveying belt, generating power-off position parameter L_optimal and pushing delay time T_optimal;

[0010] Formal detection module, performing positioning, power-off and pushing-out detection on real first workpiece based on L_optimal and T_optimal;

[0011] Three-dimensional vision detection module, three-dimensionally reconstructing workpiece and comparing with model library to realize defect detection;

[0012] Equipment health diagnosis module, evaluating system performance attenuation and triggering maintenance instruction;

[0013] Motion execution module, executing conveying belt start-stop and workpiece pushing-out reset operation;

[0014] Central control module, coordinating timing synchronization and data interaction of each module;

[0015] A plurality of physical detection points fixed on the surface of the conveying belt form an absolute position coordinate system.

[0016] As a preferred technical solution of the present application, the pre-run calibration module comprises:

[0017] Physical detection point unit, fixedly installing physical marker points with a spacing of 20-40 cm, randomly selecting detection points of target workstations>2 m;

[0018] Power-off control unit, cutting off power supply when the detection point is L away from the target workstation;

[0019] Inertia measurement unit, recording sliding distance ΔS after power-off;

[0020] Parameter optimization unit, adjusting L and T according to ΔS until the pushing device covers the detection point.

[0021] As a preferred technical solution of the present application, the formal detection module comprises:

[0022] Workpiece recognition unit, locking the first workpiece entering the detection area and distinguishing the physical detection points;

[0023] Real-time positioning unit, fusing the encoder and the detection point coordinates to track the workpiece position in real time;

[0024] Power-off unit, cutting off power when the workpiece is L_optimal away from the target workstation;

[0025] Push-out control unit, pushing out the workpiece to the detection workstation after a delay of T_optimal.

[0026] As a preferred technical solution of the present application, the three-dimensional vision detection module comprises:

[0027] a point cloud reconstruction unit for converting the workpiece image into a three-dimensional point cloud model;

[0028] a model matching unit for searching a three-dimensional model with a matching degree > 90% in a model library;

[0029] a multi-view analysis unit for comparing the workpiece and the model in 12 views;

[0030] a defect judgment unit for judging unqualification according to key size out-of-tolerance or accumulated defects.

[0031] As a preferred technical solution of the present application, the equipment health diagnosis module comprises:

[0032] a pre-operation verification unit for verifying the equipment state by calling L_optimal / T_optimal every day;

[0033] a performance attenuation evaluation unit for analyzing the fault source of increasing ΔS and rising matching failure rate;

[0034] a maintenance alarm unit for triggering yellow light maintenance reminder or red light shutdown alarm in stages.

[0035] As a preferred technical solution of the present application, the motion execution module comprises:

[0036] a conveyor belt driving unit for executing three-stage braking with a response of ≤10 ms;

[0037] a push device execution unit for controlled pushing out / resetting the workpiece and alarming when the overload resistance is > 500 N.

[0038] As a preferred technical solution of the present application, the central control module comprises:

[0039] a timing coordination unit for scheduling power-off instructions (≤10 ms), push triggering (≤50 ms) and visual starting (≤100 ms);

[0040] a data management unit for storing parameter library, detection library and equipment library and routing to each module.

[0041] An intelligent first-piece detection equipment comprises a conveying rack and a conveying belt on the conveying rack, one side of the conveying rack is provided with a pushing assembly, the pushing assembly is provided with a blocking assembly close to one side of the conveying rack, the inside of the blocking assembly is provided with a supporting assembly, the inside of the pushing assembly is provided with a spring resistance assembly, the top of the pushing assembly is provided with a first control assembly fixed to one side of the conveying rack close to the pushing assembly, the side of the conveying rack away from the conveying rack is provided with a return table, and the side of the return table away from the conveying rack is provided with a second control assembly.

[0042] As a preferred technical scheme of the present application, the pushing assembly comprises two fixed seats, a lead screw is rotatably arranged between the two fixed seats, a moving table is drivingly connected to the lead screw, and a support plate is fixedly arranged at the top end of the moving table.

[0043] As a preferred technical scheme of the present application, the pushing assembly comprises a door arranged at the bottom end of the support plate and close to one side of the conveying frame, a one-way bearing is arranged at the top end of the support plate, a connecting rod is fixedly arranged at the front end of the door, the connecting rod is fixedly connected to the inside of the one-way bearing and rotatably connected to the support plate, a connecting plate is fixedly arranged at the front end of the door, an active door is arranged at the bottom end of the connecting plate, the active door is hingedly connected to the connecting plate through a torsion spring, and a baffle is fixedly arranged at the rear end of the connecting plate and in contact with the active door.

[0044] The support assembly comprises a support door arranged at the side of the door close to the lead screw, the top end of the support door is rotatably connected to the support plate through a torsion spring at the side close to the lead screw, and a limiting plate is arranged at the side of the front end of the support door close to the lead screw, and the limiting plate is fixedly connected to the support plate.

[0045] Compared with the prior art, the present application has the following beneficial effects:

[0046] In the scheme of the present application:

[0047] 1. The pre-operation calibration module is arranged to simulate the movement of the workpiece through the entity detection point, the power-off control unit monitors the position of the detection point in real time and cuts off the power supply at the appropriate time, the inertial measurement unit records the position information at the moment of power-off and after stopping, and the parameter optimization unit calculates the overshoot error according to these data, so as to adapt to the changes of the conveying belt in real time, improve the accuracy of equipment positioning and detection efficiency, and solve the problem that the workpiece cannot be accurately positioned to the target station due to the inertial sliding of the conveying equipment in the prior art.

[0048] 2. The workpiece recognition unit and the real-time positioning unit are arranged to accurately recognize and position the real workpiece, the workpiece recognition unit uses a shooting device to scan the conveying belt in real time, accurately distinguishes the workpiece from the entity detection point through the workpiece size and three-dimensional profile, and triggers the real-time positioning unit to start tracking, the real-time positioning unit combines the conveying belt encoder and the vision system, takes the nearest entity detection point as the absolute coordinate reference, and continuously outputs the real-time distance between the front edge of the workpiece and the target station, so as to solve the problems of detection error and production delay caused by inaccurate workpiece recognition and untimely positioning in the prior art.

[0049] 3. Through the three-dimensional visual detection module arranged, multi-dimensional and high-precision defect detection of the workpiece is realized, the model matching unit searches for a matching model in the preset three-dimensional model library and outputs a best matching model ID and a spatial pose, the multi-view analysis unit generates a theoretical view angle according to the model pose and compares with an actual shooting image layer by layer, and the defect judgment unit analyzes a difference report and outputs a final conclusion, so that the profile size, hole spacing, surface character printing and scratch of the workpiece and the like can be comprehensively and accurately detected, and the problem of single detection dimension and low accuracy in the prior art is solved;

[0050] 4. Through the equipment health diagnosis module arranged, the pre-operation verification unit is enabled to call optimal parameters to execute a calibration process at the first start of each day, and to store an overshoot to generate a fluctuation curve, the performance attenuation evaluation unit analyzes the performance attenuation trend of the system according to the overshoot, model matching failure rate, workpiece positioning deviation data and color deviation statistics, and the maintenance alarm unit triggers different levels of alarms according to the diagnosis conclusion, so that the problem of difficult timely discovery of system performance decline and potential failure in the prior art is solved. BRIEF DESCRIPTION OF DRAWINGS

[0051] Figure 1 The system flowchart of the intelligent first-piece detection system provided in the application is provided;

[0052] Figure 2 The system flowchart of the pre-operation calibration module in the intelligent first-piece detection system provided in the application is provided;

[0053] Figure 3 The system flowchart of the formal detection module in the intelligent first-piece detection system provided in the application is provided;

[0054] Figure 4 The system flowchart of the three-dimensional visual detection module in the intelligent first-piece detection system provided in the application is provided;

[0055] Figure 5 The system flowchart of the equipment health diagnosis module in the intelligent first-piece detection system provided in the application is provided;

[0056] Figure 6 The system flowchart of the motion execution module in the intelligent first-piece detection system provided in the application is provided;

[0057] Figure 7 The system flowchart of the central control module of the intelligent first-piece detection system provided in the application is provided;

[0058] Figure 8 The structural schematic diagram of the intelligent first-piece detection equipment provided in the application is provided;

[0059] Figure 9The structural schematic view of the pushing assembly in the intelligent first piece detection equipment provided in the application is shown in the figure.

[0060] Figure 10 The structural schematic view of the first control assembly in the intelligent first piece detection equipment provided in the application is shown in the figure.

[0061] Figure 11 The structural schematic view of the pushing and blocking assembly in the intelligent first piece detection equipment provided in the application is shown in the figure.

[0062] Figure 12 The structural schematic view of the return table and the pushing and blocking assembly in the intelligent first piece detection equipment provided in the application is shown in the figure.

[0063] Figure 13 The structural schematic view of the supporting assembly in the intelligent first piece detection equipment provided in the application is shown in the figure.

[0064] The figure shows:

[0065] 1, conveying rack; 21, conveying belt; 22, support frame; 23, first camera; 24, identification point; 3, pushing assembly; 31, fixed seat; 32, lead screw; 33, moving table; 34, sliding rod; 35, support plate; 36, motor; 4, pushing and blocking assembly; 41, blocking door; 42, connecting plate; 43, movable door; 44, blocking plate; 45, connecting rod; 46, one-way bearing; 47, gear; 5, supporting assembly; 51, supporting door; 52, limiting plate; 6, elastic resistance assembly; 61, mounting hole; 62, fixed cylinder; 63, spring; 64, limiting block; 7, first control assembly; 71, fixed frame; 72, first rack; 8, second control assembly; 81, mounting frame; 82, second rack; 9, return table; 10, connecting table; 11, mounting table; 12, connecting seat; 13, second camera. DETAILED DESCRIPTION

[0066] In order for those skilled in the art to better understand the present application, the technical solutions in the embodiments of the present application will be described clearly and completely below in conjunction with the drawings in the embodiments of the present application. Obviously, the described embodiments are only a part of the embodiments of the present application, rather than all the embodiments. Based on the embodiments in the present application, all other embodiments obtained by those skilled in the art without creative labor should fall within the scope of protection of the present application.

[0067] In order for those skilled in the art to better understand the present application, the technical solutions in the embodiments of the present application will be described clearly and completely below in conjunction with the drawings in the embodiments of the present application. Obviously, the described embodiments are only a part of the embodiments of the present application, rather than all the embodiments. Based on the embodiments in the present application, all other embodiments obtained by those skilled in the art without creative labor should fall within the scope of protection of the present application.

[0068] It should be noted that the embodiments in the present application and the features and technical solutions in the embodiments can be combined with each other without conflict. It should be noted that the embodiments in the present application and the features and technical solutions in the embodiments can be combined with each other without conflict.

[0069] It should be noted that like reference numerals and characters refer to like items throughout the attached drawings and alternative embodiments thereof. No further definitions and explanations of such items are needed in the subsequent drawings.

[0070] Embodiment 1

[0071] Referring to Figure 1 An intelligent first-piece detection system includes:

[0072] A pre-operation calibration module simulates workpiece movement through physical detection points, dynamically learns the inertia sliding characteristics of the conveying belt after power-off, generates accurate power-off position parameters (L_optimal) and pushing delay time (T_optimal), and provides a control reference for formal detection.

[0073] A formal detection module performs accurate positioning, power-off, pushing detection, and resetting operations on real first-piece workpieces based on the optimal parameters (L_optimal, T_optimal) generated by the pre-operation calibration module, ensuring that the error of the workpiece entering the three-dimensional vision detection station is ≤20 mm.

[0074] A three-dimensional vision detection module uses a multi-view stereo vision system to perform three-dimensional reconstruction on the first-piece workpiece, realizes defect detection through a three-dimensional model library, outputs qualified / abnormal judgment, and guides the pushing device to perform resetting or alarm actions.

[0075] An equipment health diagnosis module assesses the performance decay trend of the conveying system, braking mechanism, and vision unit in real time based on the data of the pre-operation calibration and formal detection processes, triggers predictive maintenance instructions, and avoids production interruptions caused by sudden failures.

[0076] A motion execution module converts control system instructions into physical actions, accurately performs conveying belt start / stop, workpiece pushing, and resetting operations, and is the core execution layer connecting control logic and the physical world.

[0077] A central control module coordinates the timing synchronization and data interaction of all modules, realizes global scheduling from parameter learning to detection execution, and constructs a full-process data traceability chain.

[0078] Further, as shown in Figure 1 and Figure 2 The pre-operation calibration module includes:

[0079] Physical detection point unit, several physical marker points (such as reflective sheets) are fixedly installed on the surface of the conveying belt at an interval of 20-40 cm to form an absolute position coordinate system, and a detection point more than 2 m away from the target station is randomly selected as a calibration object each time pre-running; the physical detection point unit provides a target locking point for the power-off control unit; the physical detection point unit provides a position measurement reference for the inertial measurement unit;

[0080] Power-off control unit, real-time monitoring of the position of the selected detection point (through encoder pulse counting + visual auxiliary positioning), when the distance between the detection point and the target station reaches the current preset value L, the power of the conveying belt is immediately cut off to stop running, the initial value of L is set as an empirical parameter (such as 800 mm), and the subsequent L is dynamically adjusted by the parameter optimization unit; the power-off control unit receives the L value issued by the parameter optimization unit as the power-off trigger threshold; the physical detection point unit sends a "power-off event" signal to the inertial measurement unit to trigger displacement recording;

[0081] Inertial measurement unit, recording the real-time position P1 of the detection point at the moment of power-off, and recording the final position P2 of the detection point after the conveying belt completely stops, calculating the overshoot error: actual sliding distance ΔS = |P2-target station center coordinate|; the inertial measurement unit transmits ΔS to the parameter optimization unit as a calibration basis; the inertial measurement unit receives the "power-off event" signal from the power-off control unit as a start instruction;

[0082] Parameter optimization unit, the pushing device attempts to cover the detection point after stopping:

[0083] If successful: store the current L and T as optimal parameters (L_optimal, T_optimal), and synchronize to the central control module;

[0084] If failed: calculate a new power-off position: L_new = L_old + 0.7 x ΔS (inertial overshoot compensation), calculate a new pushing delay: T_new = T_old + (ΔS / average deceleration of the conveying belt) x 1.2 (vibration buffer reservation), restart the conveying belt, and re-execute the pre-running with new parameters, stop attempting after 3 consecutive failures, and trigger a maintenance alarm;

[0085] The parameter optimization unit receives the ΔS data from the inertial measurement unit as a calculation input; the parameter optimization unit issues the updated L value to the power-off control unit; the parameter optimization unit issues the updated T value to the pushing control unit (belonging to the formal detection module); the parameter optimization unit transmits the final L_optimal / T_optimal to the equipment health diagnosis module for morning verification.

[0086] Example 2

[0087] The intelligent first-piece detection system provided in Example 1 is further optimized, specifically, as Figure 1 andFigure 3 As shown, the formal detection module includes:

[0088] The workpiece recognition unit scans the conveying belt in real time by a shooting device, and locks immediately when the first workpiece enters the detection area (3-4 meters away from the target station); the workpiece recognition unit actively distinguishes the workpiece and the physical detection point: the workpiece size is greater than 5 cm and has a three-dimensional profile, and the detection point is a fixed small-size mark (1 cm in diameter); the workpiece recognition unit triggers the real-time positioning unit to start tracking; the workpiece recognition unit sends a "first piece locking" signal to the central control module, and prohibits recognizing other workpieces;

[0089] The real-time positioning unit feeds back the workpiece movement distance in real time (accuracy 0.1-15 mm) through the conveying belt encoder, takes the nearest physical detection point as the absolute coordinate reference, and compensates the belt slip error every 100 ms by the vision system, and continuously outputs the real-time distance between the workpiece leading edge and the target station; the real-time positioning unit receives the L_optimal parameter issued by the pre-operation calibration module; when the distance = L_optimal, the real-time positioning unit sends a trigger instruction to the power-off unit;

[0090] The power-off unit receives the "arrival at L_optimal" instruction from the real-time positioning unit, and executes the command of cutting off the main power supply of the conveying belt; the power-off unit receives the brake optimization parameter (such as the brake force adjustment value after maintenance) from the equipment health diagnosis module;

[0091] The push-out control unit receives the "conveying belt completely stops" signal, starts a T_optimal millisecond delay, and extends the pushing device to push the workpiece into the detection station; after receiving the three-dimensional vision detection result, if it is qualified, the push-out control unit executes the reset action (retracts the push-out part and puts the workpiece back to the edge area of the conveying belt); if it is unqualified, the push-out control unit locks the workpiece in the push-out state and waits for manual processing.

[0092] Further, as shown in Figure 1 、 Figure 3 and Figure 4 , the three-dimensional vision detection module includes:

[0093] The point cloud reconstruction unit triggers 1-4 camera devices to shoot when the workpiece is pushed into the detection station; converts the workpiece image into a three-dimensional point cloud model, automatically removes background interference (such as desktop texture), and retains pure point cloud data of the workpiece; the point cloud reconstruction unit receives the "workpiece in position" signal from the pushing control unit as a starting instruction; the point cloud reconstruction unit provides standardized point cloud data for the model matching unit;

[0094] A model matching unit searches for a three-dimensional model with a similarity > 90% to the current point cloud in a preset three-dimensional model library, preferentially matches a model of a latest production batch (reduces a search range), and if a first matching fails, rotates the three-dimensional model by 15° to re-match (up to 8 times of rotation to cover a full angle), and outputs a best-matched model ID and a spatial pose; the model matching unit receives output data of the point cloud reconstruction unit; and the model matching unit transmits a model ID and a spatial pose parameter of successful matching to the multi-view analysis unit;

[0095] The multi-view analysis unit generates 12 theoretical views (one direction every 30°) according to the spatial pose of the matched model, and performs layer-by-layer comparison between an actually photographed workpiece image and a CAD rendering image of a corresponding view: contour size, hole spacing (tolerance ± 1 mm), surface character printing, scratch (pixel difference analysis), and RGB channel deviation (ΔE > 5 is abnormal); the multi-view analysis unit receives model pose data of the model matching unit; and the multi-view analysis unit outputs a difference report of each view to the defect judgment unit;

[0096] The defect judgment unit analyzes the multi-view difference report: acceptable deviation is marked as green (such as an allowed burr area); and unacceptable deviation is marked as red (such as unmodeled welding residue);

[0097] Judgment rule: 1 key size out of tolerance (such as a pin width) → immediately judged as unqualified; and 3 non-key features out of tolerance (such as surface scratches) → accumulated to trigger unqualified;

[0098] Output final conclusion: qualified: sends a “reset” instruction to the pushing device; and unqualified: activates an audible and light alarm and locks the workpiece coordinate.

[0099] Embodiment 3

[0100] The intelligent first-piece detection system provided in Embodiment 1 or 2 is further optimized, and specifically, as shown in Figure 1 and Figure 5 The device health diagnosis module includes:

[0101] A pre-operation verification unit: when first started each day, calls optimal parameters (L_optimal, T_optimal) of a pre-operation calibration module, and randomly selects 3 entity detection points to execute a calibration process;

[0102] Judgment rule: if the pushing device covers the detection points (error ≤ 0.5 mm) in 3 tests → increases speed by 20% to enter a formal production mode; and if any one time is out of tolerance → stops the system and activates a maintenance alarm unit;

[0103] The pre-operation verification unit stores the overshoot amount AS of each verification, generates a weekly / monthly fluctuation curve, and outputs specific data of verification failure (such as the overshoot value) to the performance degradation evaluation unit.

[0104] The performance degradation evaluation unit performs data analysis: the overshoot amount AS continuously increases, indicating that the guide rail friction coefficient is rising (lubrication is required); the model matching failure rate is rising, indicating that the lens is contaminated or the light source is aging (cleaning is required); the performance degradation evaluation unit receives the workpiece positioning deviation data from the formal detection module; the performance degradation evaluation unit receives the color deviation AE statistics from the three-dimensional vision detection module; and the performance degradation evaluation unit sends a diagnostic conclusion to the maintenance alarm unit.

[0105] The maintenance alarm unit has an alarm mechanism: first-level alarm (yellow light): non-critical performance degradation (such as an increase of 5% in AS), which pushes a maintenance reminder to the MES system; second-level alarm (red light): critical function failure (such as consecutive failures in morning inspection), which immediately stops the machine and displays the fault code.

[0106] Further, as shown in Figure 1 and Figure 6 , the motion execution module includes:

[0107] The conveyor belt driving unit receives the start / stop instructions from the central control module, drives the motor to control the operation of the conveyor belt (speed range 0.1-2.5 m / s), and is directly controlled by the power-off unit of the formal detection module.

[0108] The push device execution unit receives instructions from the push-out control unit, is powered on, the push-out part is extended, and the workpiece is pushed into the detection station; the reset recovery stage (only for detection of qualified workpieces): the device controls the extension part to retract and brings the workpiece back to the designated edge area of the conveyor belt; if the extension resistance of the push device is greater than 500 N, the overload protection is triggered and an alarm is given (risk of workpiece jamming); the push device execution unit receives instructions (action trigger / reset signal) from the push-out control unit of the formal detection module; and the push device execution unit sends a "workpiece is in position" mechanical feedback signal to the three-dimensional vision detection module.

[0109] Further, as shown in Figure 1 and Figure 7 , the central control module includes:

[0110] Timing coordination unit, hard real-time event scheduling: power-off instruction response (≤10 ms): receive the power-off unit signal of the formal detection module, and immediately trigger the power-off of the conveyor belt driving unit; pushing device trigger (≤50 ms): after the conveyor belt stops, delay T_optimal milliseconds, send the action instruction to the pushing device execution unit; visual scanning start (≤100 ms): after the pushing device is in place, activate the three-dimensional visual detection module synchronously; the timing coordination unit receives event requests from each module (such as pre-run completion, workpiece locking); the timing coordination unit issues action instructions to the motion execution module (time tolerance ±1 ms);

[0111] Data management unit, full life cycle data pool: parameter library: store the pre-run calibrated L_optimal / T_optimal / ΔS historical sequence; detection library: record the visual detection report of each workpiece (including point cloud model, defect image); device library: archive braking time, matching failure rate and other performance indicators;

[0112] Data routing: the data management unit transmits L_optimal of the pre-run module to the real-time positioning unit of the formal detection module; the data management unit pushes the visual detection result to the pushing device execution unit (reset / locking decision).

[0113] Embodiment 4

[0114] Please refer to Figure 8 、 Figure 9 、 Figure 10 、 Figure 11 、 Figure 12 and Figure 13 , an intelligent first piece detection device, which comprises a conveying rack 1 and a conveying belt 21 on the conveying rack 1, the conveying rack 1 includes but is not limited to a belt conveyor, and the conveying belt 21 is a belt on the conveying rack 1 for conveying workpieces. By starting the conveying rack 1, the conveying belt 21 is driven to move the workpieces on the conveying belt 21. A plurality of identification points 24 are fixedly arranged on the outer side of the conveying belt 21 at equal intervals, and the identification points 24 include but are not limited to stickers. The identification points 24 are used to be detected by a first camera 23 for simulating the movement of the workpieces in advance.

[0115] A support frame 22 is fixedly arranged at the top end of the conveying rack 1, and the first camera 23 is arranged at the front end of the support frame 22. A pushing assembly 3 is arranged on one side of the conveying rack 1, and a pushing and blocking assembly 4 is arranged near the one side of the conveying rack 1. The pushing assembly 3 is used to drive the pushing and blocking assembly 4 to move and push the workpieces on the conveying belt 21 to a mounting table 11. A supporting assembly 5 is arranged in the pushing and blocking assembly 4, and an elastic resistance assembly 6 is arranged in the pushing assembly 3. The elastic resistance assembly 6 is used to increase the stability when the pushing and blocking assembly 4 hooks the workpieces back.

[0116] The upper side of the pushing assembly 3 is provided with a first control assembly 7 fixed to the conveying frame 1 near the side of the pushing assembly 3, and the conveying frame 1 is provided with a return table 9 away from the conveying frame 1. The bottom end of the return table 9 is fixedly provided with a mounting table 11 located on the side of the conveying frame 1. The mounting table 11 is lower than the conveying belt 21, so that the pushing assembly 3 pushes the workpiece on the conveying belt 21 to the mounting table 11 through the blocking assembly 4, so that the workpiece falls on the top end of the mounting table 11, avoiding the workpiece being blocked by the mounting table 11 when moving due to the mounting table 11 being higher than the conveying belt 21. The return table 9 is provided with a second control assembly 8 away from the conveying frame 1. The first control assembly 7 and the second control assembly 8 are used to control the flipping of the blocking assembly 4, so as to switch the state, so that when the pushing assembly 3 drives the blocking assembly 4 to move away from the mounting table 11, the workpiece on the mounting table 11 can be hooked back, and the workpiece is returned to the conveying belt 21 by cooperating with the return table 9;

[0117] Further, as shown in Figure 8 、 Figure 10 and Figure 12 , the upper side of the return table 9 away from the connecting table 10 is provided with a slope, and the slope is provided with a sliding groove. When the blocking assembly 4 approaches the mounting table 11 through the pushing assembly 3, the blocking assembly 4 contacts the side of the return table 9 which is not provided with a slope, so that the blocking assembly 4 is flipped, and the pushed workpiece is moved to the side of the return table 9 provided with a slope. The workpiece is detected by the second camera 13. After the detection is completed and it is found that the workpiece has no problem, the pushing assembly 3 drives the blocking assembly 4 to retract, hooks back the workpiece, and gradually raises the workpiece by cooperating with the slope and the sliding groove on the return table 9, so as to be higher than the height of the conveying belt 21. The sliding groove provided on the slope makes the front and back of the top end of the return table 9 protrude, so as to form a fence to prevent the workpiece from falling. The blocking assembly 4 continues to move, so as to move the workpiece to the conveying belt 21, and make the workpiece fall on the conveying frame 1;

[0118] Further, as shown in Figure 8 , the front end of the mounting table 11 is fixedly provided with a plurality of connecting seats 12. The top end of the connecting seat 12 is provided with a second camera 13. The second camera 13 is provided with an alarm lamp and a loudspeaker. The workpiece on the mounting table 11 is photographed by the second camera 13, and the three-dimensional drawing of the corresponding workpiece is compared, so as to distinguish whether the workpiece has a problem. When the color or shape on the workpiece is obviously different from the three-dimensional drawing, it is judged that the workpiece has a problem. The alarm lamp is brightened to prompt, and the second camera 13 emits sound to remind the user.

[0119] Further, as shown in Figure 8 and Figure 9As shown, the lower part of the pushing assembly 3 is provided with a connecting table 10, the pushing assembly 3 comprises two fixed seats 31 fixedly connected with the top end of the connecting table 10, a lead screw 32 rotatably arranged between the two fixed seats 31, a sliding rod 34 fixedly connected with the two fixed seats 31 arranged at the front and rear of the lead screw 32, a moving table 33 drivingly connected with the lead screw 32, the lead screw 32 and the moving table 33 being drivingly connected through a ball screw pair, the moving table 33 being slidingly connected with the sliding rod 34, the top end of the moving table 33 being fixedly provided with a support plate 35, the bottom end of the support plate 35 being slidingly connected with the fixed seat 31 close to one side of the conveying rack 1, for increasing the stability during movement, the fixed seat 31 away from the conveying rack 1 on the side away from the conveying rack 1 of the moving table 33 being fixedly provided with a motor 36, the output end of the motor 36 being fixedly connected with the lead screw 32 through the fixed seat 31, the lead screw 32 driving the moving table 33 and the support plate 35 to move by starting the motor 36.

[0120] Further, as shown in Figure 8 、 Figure 9 、 Figure 10 、 Figure 11 、 Figure 12 and Figure 13 , the pushing assembly 4 comprises a blocking door 41 located at the bottom end of the support plate 35 close to one side of the conveying rack 1, the top end of the support plate 35 being provided with a one-way bearing 46, the front end of the top end of the blocking door 41 being fixedly provided with a connecting rod 45, the connecting rod 45 being fixedly connected with the inside of the one-way bearing 46 and being rotatably connected with the support plate 35 through the support plate 35; the outside of the one-way bearing 46 being fixedly provided with a gear 47, the front end of the blocking door 41 being obliquely fixedly provided with a connecting plate 42, the bottom end of the connecting plate 42 being provided with a movable door 43, the movable door 43 being hingedly connected with the connecting plate 42 through a torsional spring, the movable door 43 being driven to flip in the direction of the baffle plate 44 and being in contact with the baffle plate 44 through the elastic force of the torsional spring, and the movable door 43 being blocked by the baffle plate 44 from further flipping, the rear end of the connecting plate 42 being fixedly provided with the baffle plate 44 in contact with the movable door 43;

[0121] Further, as shown in Figure 8 、 Figure 9 、 Figure 10 、 Figure 11 and Figure 13As shown, the first control assembly 7 includes a first rack 72 engaged with the rear end of the gear 47, and the first rack 72 is fixedly arranged on the side close to the connecting table 10 and is fixedly connected with the transmission frame 1; the second control assembly 8 includes a second rack 82 located on one side of the gear 47, and the second rack 82 is fixedly arranged on the side away from the connecting table 10 and is fixedly connected with the mounting table 11; the mounting rack 81 and the second rack 82 are located on the side away from the connecting table 10 of the return table 9, and the toothed surface of the second rack 82 is opposite to the first rack 72 and faces the rear end; when the one-way bearing 46 moves close to the second rack 82, the one-way bearing 46 is in contact with the teeth on the second rack 82, and continues to move to drive the shutter 41 and the connecting plate 42 to overturn through the one-way bearing 46 and the gear 47.

[0122] Further, as shown in Figure 9 、 Figure 10 、 Figure 11 、 Figure 12 and Figure 13 , the support assembly 5 includes a support door 51 located on the side of the shutter 41 close to the lead screw 32, and the top end of the support door 51 close to the side of the lead screw 32 is rotationally connected with the support plate 35 through a torsion spring; the support door 51 is driven to move close to the limiting plate 52 and contact the limiting plate 52 through the rotational connection and the elastic force of the torsion spring, and the support door 51 is blocked from further rotating by the limiting plate 52; the front end of the support door 51 close to the lead screw 32 is provided with a limiting plate 52, and the limiting plate 52 is used to block the support door 51 from further rotating and is fixedly connected with the support plate 35.

[0123] Further, as shown in Figure 11 、 Figure 12 and Figure 13 , the elastic resistance assembly 6 includes a mounting hole 61 opened in the bottom end of the support plate 35, a fixed cylinder 62 fixedly arranged in the inside of the mounting hole 61, a spring 63 fixedly arranged in the inside of the fixed cylinder 62, and a limiting block 64 fixedly arranged at the bottom end of the spring 63; the limiting block 64 is slidingly connected with the inside of the fixed cylinder 62, and the bottom end of the limiting block 64 extends below the support plate 35; the side surface of the bottom end of the limiting block 64 is obliquely arranged, so that the bottom end of the limiting block 64 presents a conical structure; when the connecting plate 42 or the shutter 41 reaches a certain rotating force, the spring 63 is broken through by the oblique surface of the side surface of the limiting block 64, and the limiting block 64 is extruded back to the inside of the fixed cylinder 62 through the oblique surface of the bottom end of the limiting block 64, so that the push-blocking assembly 4 continues to rotate; after the push-blocking assembly 4 passes through the limiting block 64, the limiting block 64 is bounced back to the original position by the elastic force of the spring 63.

[0124] The use process of the intelligent first piece detection system and the application device thereof provided by the application is as follows:

[0125] Before the equipment is officially put into operation, a preliminary operation is performed, the conveyor frame 1 is started to make the conveyor belt 21 run, and any identification point 24 on the conveyor belt 21 is randomly locked by the No. 1 camera 23. After locking, the attention of other identification points 24 is cancelled and the identification point 24 is continuously locked. The identification point 24 simulates the state of the workpiece moving through the conveyor belt 21. Then, when it is about to pass through the pushing component 3, the conveyor frame 1 is controlled to cut off the power and stop running. At this time, due to the residual power and inertia after the operation is stopped, the conveyor belt 21 will continue to run for a distance. At this time, the motor 36 is started to make the screw 32 drive the moving platform 33 and the support plate 35 to move toward the mounting platform 11. The No. 1 camera 23 observes whether the end of the support plate 35 and the push-blocking component 4 can pass through and cover the identification point 24 normally. If not, the gap between them is judged, the power-off timing of the conveyor frame 1 is adjusted, the pushing component 3 is controlled to retract, and the conveyor frame 1 is restarted until the locked identification point 24 can stably stop on one side of the pushing component 3 after stopping running, so that the pushing component 3 can start to cover the workpiece normally, and the downtime is recorded;

[0126] Then, the formal operation begins, the conveyor frame 1 is started, and the workpiece is placed in the middle position on the conveyor belt 21. At this time, the No. 1 camera 23 does not lock the identification point 24. The No. 1 camera 23 analyzes the workpiece on the conveyor belt 21. When a workpiece is detected moving, the first workpiece that moves is locked. According to the last correct stop timing in the pre-operation, when the workpiece moves to the specified position, the power supply of the conveyor frame 1 is disconnected, causing the conveyor frame 1 to stop. The workpiece continues to move due to inertia and stops when the push component 3 approaches the side of the mounting table 11.

[0127] At this time, the motor 36 is started to move the movable platform 33 and the support plate 35. At this time, the one-way bearing 46 also moves accordingly. Due to the engagement with the No. 1 rack 72, the gear 47 is driven to rotate in one direction. Since the one-way bearing 46 can only move in one direction, it will not drive the connecting rod 45 and the baffle 41 to rotate and flip. The first workpiece is pushed toward the mounting platform 11 through the baffle 41. When the workpiece is pushed onto the mounting platform 11, the movable door 43 also contacts the side of the return platform 9 without the inclined surface. The rear end of the movable door 43 is supported by the baffle 44. Figure 12 As shown, the coordinated movement causes the movable door 43 to flip sideways, driving the blocking door 41 to tilt, thereby pushing the workpiece being pushed on the blocking door 41 to the side of the return platform 9. At this time, the workpiece is located within the angle between the return platform 9 and the blocking door 41. The pushing component 3 continues to move the pushing and blocking component 4, thereby pushing the workpiece and pushing it along the inclined surface formed by the blocking door 41 to the side of the return platform 9 close to the second control component 8, that is, the side with the inclined surface, and into the shooting range of the second camera 13;

[0128] The pushing assembly 3 continues to move, causing the workpiece to detach from the blocking door 41 along the inclination of the blocking door 41, and the movable door 43 is also separated from the return platform 9 and moved gradually away from the workpiece to ensure that the rotation of the pushing assembly 4 does not contact the workpiece. The gear 47 contacts the second rack 82 through the movement of the pushing assembly 3, and the rearward teeth of the second rack 82 mesh with the gear 47. The coordinated movement drives the gear 47 to rotate in the other direction, which is opposite to the initial rotation direction, thereby driving the connecting rod 45, the blocking door 41 and the connecting plate 42 to flip through the one-way bearing 46 until they are flipped about 325 degrees. Figure 13 As shown, during the turning process, the connecting plate 42 passes through the limiting block 64, and then the blocking door 41 passes through the limiting block 64, so that the blocking door 41 contacts the supporting door 51. At this time, the moving function of the pushing component 3 is stopped, so that the supporting plate 35 no longer moves. The blocking door 41 is located between the supporting door 51 and the limiting block 64, and the movable door 43 is located at the front end;

[0129] The workpiece on the mounting table 11 is photographed by the No. 2 camera 13, and the three-dimensional drawing of the workpiece is compared to determine whether there is a problem with the workpiece. When no problem is found after the inspection, the motor 36 is controlled to rotate in the opposite direction, thereby driving the movable table 33 and the support plate 35 to move away from the mounting table 11 through the screw 32, and the push-block assembly 4 also moves accordingly. The gear 47 rotates by meshing with the No. 2 rack 82. At this time, the one-way bearing 46 will not drive the connecting rod 45 and the blocking door 41 to flip, and the push-block assembly 4 continues to move until it disengages from the No. 2 rack 82. The movable door 43 contacts the workpiece on one side of the return table 9 and pushes it onto the inclined surface of the return table 9, so that the workpiece slides inside the slide groove. During the pushing process, the movable door 4 3 will drive the blocking door 41 to tilt back due to resistance. At this time, the blocking door 41 contacts the limiting block 64 and is blocked by the elastic force of the spring 63. At this time, the thrust of the blocking door 41 on the limiting block 64 is not enough to break through the elastic force of the spring 63 to retract the limiting block 64, thus preventing the blocking door 41 from rotating. The movable door 43 changes its angle through the hinge adaptability with the connecting plate 42, but the elastic force of the torsion spring enables the movable door 43 to maintain a certain force to continuously push the workpiece and keep in contact with the inclined surface on the return platform 9, so as to gradually push the workpiece upward and exceed the height of the conveyor belt 21, cooperate with the movement and separation from the return platform 9 and fall onto the conveyor belt 21. The movable door 43 is reset to contact the baffle 44 by the elastic force of the torsion spring and continues to push the workpiece.

[0130] The movement of the pushing assembly 3 brings the workpiece back to one side of the conveying belt 21, at this time the gear 47 returns to the original position and engages with the first gear rack 72, and through the one-way bearing 46 drives the connecting rod 45 and the blocking door 41 to flip, and through the movable door 43 pushes the workpiece to push it between the movable door 43 and the supporting door 51, the blocking door 41 rotates to push the supporting door 51 through the engagement of the gear 47 and the first gear rack 72, and exceeds the elastic force of the torsional spring on the supporting door 51 to make the supporting door 51 flip, until the blocking door 41 returns to the original state, the blocking door 41 rotates a circle after a round of pushing and retraction, and returns to the original state, at this time the blocking door 41 also disengages from the supporting door 51, and the supporting door 51 is bounced back to contact the limiting plate 52 through the elastic force of the torsional spring, and returns to the side close to the lead screw 32 of the blocking door 41, and is supported at the rear end of the blocking door 41;

[0131] At this time the detection process is completed, the conveyor frame 1 is restarted, the conveying belt 21 resumes operation, and the workpiece pushed by the movable door 43 to between the supporting door 51 and the movable door 43 is also driven to move by the conveying belt 21, contacts the supporting door 51 and breaks through the elastic force of the torsional spring on the supporting door 51, drives the supporting door 51 to flip and open, and the detected workpiece continues to move on the conveying belt 21, until the workpiece disengages from the supporting door 51, the supporting door 51 returns to the original position through the elastic force of the torsional spring and contacts the limiting plate 52 for support, thereby completing the detection of the first workpiece, and the detected workpiece is also brought back to the conveying belt 21 close to the one side, which is different from the positions of other workpieces on the conveying belt 21, and forms a more obvious difference, so that when multiple batches of different workpieces are on the conveying belt 21 at the same time, the user can also distinguish the position of the first workpiece, so that the multiple batches of different workpieces are distinguished more conveniently.

[0132] In the present application, unless specifically defined and limited otherwise, the terms "mounting", "connection", "connecting", "fixed", and the like should be understood broadly, for example, can be fixed connection, or detachable connection, or integrated; can be mechanical connection, or electrical connection or communication with each other; can be directly connected, or indirectly connected through an intermediate medium, can be the internal communication of two elements or the interaction relationship between two elements, unless otherwise specifically limited. For those skilled in the art, the specific meaning of the above terms in the present application can be understood according to the specific circumstances.

[0133] Obviously, the above-described embodiments are only some embodiments but not all the embodiments of the present application, the preferred embodiments of the present application are shown in the drawings, but do not limit the patent scope of the present application. The present application can be implemented in many different forms, and conversely, the purpose of providing these embodiments is to make the disclosure of the present application more thorough and comprehensive. Although the present application has been described in detail with reference to the foregoing embodiments, those skilled in the art can still modify the technical solutions recorded in the foregoing specific embodiments, or make equivalent replacements to some technical features therein. Any equivalent structure made by using the content of the present application specification and drawings, directly or indirectly applied to other related technical fields, is also within the patent protection scope of the present application.

Claims

1. An intelligent first article detection system, characterized in that: include: Pre-run calibration module, used to simulate workpiece motion through physical detection points, dynamically learn the coasting characteristics of the conveyor belt after power failure, and generate power failure position parameters L_optimal and push delay time T_optimal; The formal inspection module performs positioning, power-off, and ejection inspections on the actual first workpiece based on L_optimal and T_optimal; 3D visual inspection module, which reconstructs the workpiece in 3D and compares it with the model library to detect defects; Equipment health diagnostic module, which assesses system performance degradation and triggers maintenance instructions; Motion execution module, which executes the start and stop of the conveyor belt and the ejection and reset of the workpiece; Central control module coordinates the timing synchronization and data interaction of each module; Several physical detection points fixed on the conveyor belt surface form an absolute position coordinate system.

2. The intelligent first article detection system according to claim 1, characterized in that: The pre-run calibration module includes: Physical detection point unit, fixed installation of physical marking points with a spacing of 20-40cm, randomly selects detection points that are greater than 2m from the target station; The power-off control unit cuts off the power supply when the distance between the detection point and the target position is L; Inertial measurement unit, records the sliding distance ΔS after power failure; The parameter optimization unit adjusts L and T according to ΔS until the pushing device covers the detection point.

3. The intelligent first article detection system according to claim 2, characterized in that: The formal detection module includes: Workpiece identification unit, which locks the first workpiece entering the inspection area and distinguishes the physical inspection points; Real-time positioning unit, integrating encoder and detection point coordinates to track workpiece position in real time; The power-off unit cuts off the power when the distance between the workpiece and the target position is L_optimal; The control unit is ejected and the workpiece is ejected to the inspection station after a delay of T_optimal.

4. The intelligent first article detection system according to claim 3, characterized in that: The three-dimensional visual detection module includes: Point cloud reconstruction unit, converting the workpiece image into a three-dimensional point cloud model; Model matching unit, searching the model library for 3D models with a matching degree greater than 90%; Multi-view analysis unit, comparing the differences between the workpiece and the model from 12 different viewpoints; The defect judgment unit determines failure based on critical dimension deviations or accumulated defects.

5. The intelligent first article detection system according to claim 4, characterized in that: The device health diagnosis module includes: Pre-run verification unit, call L_optimal / T_optimal daily to verify equipment status; Performance degradation assessment unit, analyzing the root causes of faults such as increased ΔS and matching failure rate; The maintenance alarm unit triggers yellow light maintenance reminder or red light shutdown alarm in different levels.

6. The intelligent first article detection system according to claim 5, characterized in that: The motion execution module includes: The conveyor belt drive unit performs three-stage braking with a response time of ≤10ms; The push device execution unit is used to push out / reset the workpiece in a controlled manner, and an alarm will be issued when the overload resistance is greater than 500N.

7. The intelligent first article detection system according to claim 6, characterized in that: The central control module includes: Timing coordination unit, scheduling power-off instructions (≤10ms), push triggers (≤50ms), and visual activation (≤100ms); The data management unit stores the parameter library, detection library and equipment library, and routes them to each module.

8. An intelligent first article inspection device, using the intelligent first article inspection system according to claim 7, characterized in that: The invention comprises a conveyor frame (1) and a conveyor belt (21) on the conveyor frame (1); a pushing assembly (3) is provided on one side of the conveyor frame (1); a pushing assembly (4) is provided on the side of the pushing assembly (3) close to the conveyor frame (1); a supporting assembly (5) is provided inside the pushing assembly (4); a spring resistance assembly (6) is provided inside the pushing assembly (3); a first control assembly (7) fixed on the side of the conveyor frame (1) close to the pushing assembly (3) is provided above the pushing assembly (3); a return platform (9) is provided on the side of the conveyor frame (1) away from the conveyor frame (1); and a second control assembly (8) is provided on the side of the return platform (9) away from the conveyor frame (1).

9. The intelligent first article detection equipment according to claim 8, characterized in that: The pushing assembly (3) comprises two fixed seats (31), a lead screw (32) is rotatably provided between the two fixed seats (31), a movable platform (33) is transmission-connected to the lead screw (32), and a support plate (35) is fixedly provided at the top end of the movable platform (33).

10. The intelligent first article detection equipment according to claim 9, characterized in that: The push-blocking assembly (4) includes a blocking door (41) located at the bottom end of the support plate (35) close to the side of the conveyor frame (1), the top end of the support plate (35) is provided with a one-way bearing (46), and a connecting rod (45) is fixedly provided in front of the top end of the blocking door (41), and the connecting rod (45) passes through the support plate (35) and is fixedly connected to the inside of the one-way bearing (46), and is rotatably connected to the support plate (35); the front end of the blocking door (41) is tiltedly fixed with a connecting plate (42), the bottom end of the connecting plate (42) is provided with a movable door (43), the movable door (43) is hinged to the connecting plate (42) through a torsion spring, and the rear end of the connecting plate (42) is fixed with a blocking plate (44) in contact with the movable door (43); The support assembly (5) comprises a support door (51) located on a side of the stop door (41) close to the lead screw (32); a top end of the support door (51) close to the lead screw (32) is rotatably connected to a support plate (35) via a torsion spring; a front end of the support door (51) close to the lead screw (32) is provided with a limiting plate (52); and the limiting plate (52) is fixedly connected to the support plate (35).

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