Automobile interior trim part surface defect detecting and cutting integrated forming equipment and method

Abstract

The invention discloses automobile interior trim part surface defect detecting and cutting integrated forming equipment and method. The integrated forming equipment comprises a conveying unit used for conveying a workpiece; the workpiece transferring unit is at least used for transferring workpieces between the conveying unit and the workpiece fixing unit; the workpiece fixing unit is used for fixing a workpiece and enabling a to-be-cut area on the surface of the workpiece to be completely exposed; the image acquisition unit is used for acquiring an image of a to-be-cut area on the surface of the workpiece fixed by the workpiece fixing unit; the cutting processing unit is used for cutting the workpiece fixed by the workpiece fixing unit; and the control unit is connected with the conveying unit, the workpiece jacking unit, the workpiece fixing unit, the image acquisition unit and the cutting processing unit. Automatic feeding and discharging, surface defect detection, cutting workpiece arrangement, automatic path planning and online laser efficient low-damage cutting of the automotive upholstery are achieved, material waste is reduced, and the production efficiency is greatly improved.

Description

Technical Field

[0001] This invention belongs to the field of laser cutting processing technology, and specifically relates to an integrated forming equipment and method for surface texture defect detection and online laser cutting of automotive interior parts. Background Technology

[0002] In recent years, with the continuous development of the automotive manufacturing industry, there has been a significant demand for genuine aluminum sheets in automotive interior parts. Currently, manual inspection, manual arrangement of stamped parts, and mechanical stamping of genuine aluminum sheets for automotive interior parts face problems such as poor material utilization, low automation, and inability to adapt to large-scale, high-efficiency production, severely restricting production quality and efficiency. Genuine aluminum printed sheets for automotive interior parts are multi-layered materials with highly reflective surfaces, minute surface defects, and complex and diverse surfaces, exhibiting varying spectral reflectance and absorptivity, posing significant challenges to visual inspection and laser cutting. Currently, there is no integrated equipment for visual inspection and laser cutting of defects in automotive interior parts, either domestically or internationally. Summary of the Invention

[0003] The purpose of this invention is to provide an integrated molding equipment and method for detecting and cutting surface defects in automotive interior parts, thereby overcoming the shortcomings of the prior art.

[0004] To achieve the aforementioned objectives, the technical solution adopted by this invention includes:

[0005] This invention provides an integrated molding equipment for detecting surface texture defects in automotive interior parts and for online cutting, comprising:

[0006] A conveying unit, at least for conveying workpieces;

[0007] A workpiece transfer unit is used at least to transfer workpieces between a conveying unit and a workpiece fixing unit;

[0008] A workpiece fixing unit is used to fix the workpiece and to fully expose the area to be cut on the surface of the workpiece.

[0009] The image acquisition unit is used to acquire at least multiple local images of the area to be cut on the surface of the workpiece fixed by the workpiece fixing unit.

[0010] A cutting and processing unit, at least used for cutting a workpiece that is fixed by the workpiece fixing unit;

[0011] The control unit is connected to the conveying unit, the workpiece lifting unit, the workpiece fixing unit, the image acquisition unit, and the cutting processing unit. The control unit has at least the following functions: synthesizing multiple local images acquired by the image acquisition unit into a high-resolution overall image covering the entire workpiece; identifying the distribution location and size of texture defects on the workpiece surface through the overall image; forming a cutting path based on the distribution location and size of the texture defects; causing the cutting processing unit to perform a cutting action on the workpiece along the cutting path; and controlling the working state of the conveying unit, the workpiece lifting unit, and the workpiece fixing unit.

[0012] Another aspect of the present invention provides a method for integrated online cutting and forming of surface texture defects in automotive interior parts, comprising:

[0013] Provides integrated molding equipment for surface texture defect detection and online cutting of the aforementioned automotive interior parts;

[0014] The workpiece is transferred away from the conveying unit by the workpiece transfer unit, and the workpiece is fixed by the workpiece fixing unit, so that the area to be cut on the surface of the workpiece is fully exposed.

[0015] An image acquisition unit acquires an image of the area to be cut on the surface of the workpiece fixed by the workpiece fixing unit. A control unit identifies the distribution location and size of texture defects on the workpiece surface through the image and forms a cutting path based on the distribution location and size of the texture defects. Each cutting path corresponds to a workpiece.

[0016] The cutting processing unit performs a cutting action on the workpiece along the cutting path, and then the workpiece transfer unit transfers the cut workpiece to the conveying unit.

[0017] Compared with existing technologies, the advantages of this invention include: Addressing the current problems in the inspection and processing of genuine aluminum sheets for automotive interior parts, this invention aims to break through key technologies for online artificial intelligence-based defect detection and forming quality control of automotive interior parts. It interconnects key modules such as machine vision inspection systems, laser cutting processing systems, automatic loading and unloading systems, and peripheral auxiliary systems to form an integrated equipment for visual inspection and laser cutting of automotive interior parts defects. This invention achieves automatic loading and unloading of automotive interior parts, surface defect detection, workpiece arrangement for cutting, automatic path planning, and efficient, low-damage online laser cutting, reducing material waste, significantly improving production efficiency, promoting technological upgrading of automotive interior parts manufacturers, filling a technological gap in the domestic automotive interior parts industry, and reaching international advanced levels. Attached Figure Description

[0018] Figure 1This is a schematic diagram of the structure of an integrated molding equipment for surface texture defect detection and online cutting of automotive interior parts provided by the present invention;

[0019] Figure 2 This is a schematic diagram of the workpiece and the workpiece receiving mechanism in this invention;

[0020] Figure 3 This is a schematic diagram of the blocking mechanism and the lifting mechanism in this invention;

[0021] Figure 4 This is a schematic diagram of the positioning plate in this invention;

[0022] Figure 5 This is a schematic diagram of the three-dimensional moving mechanism in this invention;

[0023] Figure 6 This is a schematic diagram illustrating the principle of image acquisition in an integrated molding equipment for surface texture defect detection and online cutting of automotive interior parts provided by the present invention. Detailed Implementation

[0024] In view of the shortcomings of the prior art, the inventors of this invention, through long-term research and extensive practice, have proposed the technical solution of this invention. The following will further explain and illustrate this technical solution, its implementation process, and its principles.

[0025] This invention provides an integrated molding equipment for detecting surface texture defects in automotive interior parts and for online cutting, comprising:

[0026] A conveying unit, at least for conveying workpieces;

[0027] A workpiece transfer unit is used at least to transfer workpieces between a conveying unit and a workpiece fixing unit;

[0028] A workpiece fixing unit is used to fix the workpiece and to fully expose the area to be cut on the surface of the workpiece.

[0029] The image acquisition unit is used to acquire at least multiple local images of the area to be cut on the surface of the workpiece fixed by the workpiece fixing unit.

[0030] A cutting and processing unit, at least used for cutting a workpiece that is fixed by the workpiece fixing unit;

[0031] The control unit is connected to the conveying unit, the workpiece lifting unit, the workpiece fixing unit, the image acquisition unit, and the cutting processing unit. The control unit has at least the following functions: synthesizing multiple local images acquired by the image acquisition unit into a high-resolution overall image covering the entire workpiece; identifying the distribution location and size of texture defects on the workpiece surface through the overall image; forming a cutting path based on the distribution location and size of the texture defects; causing the cutting processing unit to perform a cutting action on the workpiece along the cutting path; and controlling the working state of the conveying unit, the workpiece lifting unit, and the workpiece fixing unit.

[0032] Furthermore, the conveying unit includes a conveying mechanism and a workpiece receiving mechanism, the workpiece receiving mechanism being used to carry the workpiece.

[0033] The workpiece receiving mechanism is detachably mounted on the conveying mechanism. The workpiece receiving mechanism can travel along the first direction with the conveying mechanism, and the workpiece receiving mechanism can also detach from the conveying mechanism along the second direction, wherein the first direction and the second direction intersect.

[0034] Furthermore, the workpiece transfer unit includes a lifting mechanism and a blocking mechanism. The blocking mechanism is used to stop the workpiece in the moving state on the conveying unit. The lifting mechanism is used to remove the workpiece in the stopped state from the conveying unit and fix the workpiece by the workpiece fixing unit, and to transfer the processed workpiece to the conveying unit.

[0035] Furthermore, both the blocking mechanism and the lifting mechanism are capable of moving up and down along the second direction.

[0036] Furthermore, the workpiece fixing unit includes a fixing mechanism that can be detachably connected to the workpiece.

[0037] Furthermore, the fixing mechanism is an adsorption mechanism, which can fix the workpiece by adsorption, or the fixing mechanism is a clamping mechanism, which can fix the workpiece by mechanical clamping.

[0038] Furthermore, the adsorption mechanism is a magnetic adsorption mechanism or a negative pressure adsorption mechanism.

[0039] Furthermore, the fixing mechanism is a ring structure that matches the four edges of the workpiece.

[0040] Furthermore, the image acquisition unit includes an image acquisition mechanism, a light source, and a first three-dimensional moving mechanism. The image acquisition mechanism is used to acquire at least a partial image of the workpiece, and the light source is used to illuminate the workpiece fixed by the workpiece fixing unit. The light source and the image acquisition mechanism are mounted on the first three-dimensional moving mechanism and can move along at least one of the X-axis, Y-axis, and Z-axis of a three-dimensional coordinate system under the drive of the first three-dimensional moving mechanism. The light strip provided by the light source is incident on the workpiece, and the light strip after being reflected by the workpiece is received by the image acquisition mechanism to form a light stripe image.

[0041] Furthermore, the image acquisition mechanism includes at least one CCD camera.

[0042] Furthermore, each CCD camera, after acquiring a single frame of light bar image, stitches them together using the following formula:

[0043]

[0044] In the formula: I' is the grayscale matrix of the stitched weld image; I ij The grayscale matrix of the light stripe image; Δ ij J is the gray value matrix between adjacent light bars. The gray values ​​in this region are all set to 0. The gray value matrix of the light bar image and the gray value matrix of the region between the light bars use the same number of columns J; n is the number of light bar images to be stitched together.

[0045] Furthermore, the image acquisition unit also includes a first polarization mechanism and a second polarization mechanism. The first polarization mechanism is disposed at the front end of the light emitting end of the light source, and the second polarization mechanism is disposed at the front end of the acquisition end of the image acquisition mechanism.

[0046] Furthermore, the image acquisition unit also includes at least one light source, which is used to illuminate the workpiece fixed by the workpiece fixing unit.

[0047] Furthermore, the light source is disposed on the first three-dimensional moving mechanism.

[0048] Furthermore, the cutting processing unit includes a cutting mechanism and a second three-dimensional moving mechanism. The cutting mechanism is at least used to perform a cutting action on the workpiece. The cutting mechanism is disposed on the second three-dimensional moving mechanism and can move along at least one of the X-axis, Y-axis, and Z-axis of a three-dimensional coordinate system under the drive of the second three-dimensional moving mechanism.

[0049] Furthermore, the cutting mechanism includes a laser cutting mechanism.

[0050] Furthermore, the integrated molding equipment for surface texture defect detection and online cutting of automotive interior parts also includes a dust collection unit, which is at least used to collect the dust generated when the cutting processing unit cuts the workpiece.

[0051] Furthermore, the dust collection unit includes a dust collection hopper and a dust treatment mechanism. The dust collection hopper is arranged below the workpiece fixing unit along the direction of gravity and is used at least to collect the dust. The dust treatment mechanism is connected to the dust collection hopper and is used to purify the dust.

[0052] Another aspect of the present invention provides a method for integrated online cutting and forming of surface texture defects in automotive interior parts, comprising:

[0053] Provides integrated molding equipment for surface texture defect detection and online cutting of the aforementioned automotive interior parts;

[0054] The workpiece is transferred away from the conveying unit by the workpiece transfer unit, and the workpiece is fixed by the workpiece fixing unit, so that the area to be cut on the surface of the workpiece is fully exposed.

[0055] An image acquisition unit acquires an image of the area to be cut on the surface of the workpiece fixed by the workpiece fixing unit. A control unit identifies the distribution location and size of texture defects on the workpiece surface through the image and forms a cutting path based on the distribution location and size of the texture defects. Each cutting path corresponds to a workpiece.

[0056] The cutting processing unit performs a cutting action on the workpiece along the cutting path, and then the workpiece transfer unit transfers the cut workpiece to the conveying unit.

[0057] Furthermore, the integrated method for detecting surface texture defects in automotive interior parts and for online cutting and molding also includes:

[0058] Each CCD camera, after acquiring a single frame of light bar image, combines them using the following formula:

[0059]

[0060] In the formula: I is the grayscale matrix of the stitched weld image; I ij The grayscale matrix of the light stripe image; Δ ij is the gray value matrix between adjacent light bars, where the gray values ​​of this region are all set to 0. The gray value matrix of the light bar image and the gray value matrix of the region between the light bars use the same number of columns j; n is the number of light bar images that need to be stitched together.

[0061] Furthermore, the integrated molding method for surface texture defect detection and online cutting of automotive interior parts also includes: collecting the dust generated during the cutting process of the workpiece and purifying the collected dust.

[0062] The following will further explain the technical solution, its implementation process and principle in conjunction with the accompanying drawings and specific implementation examples. Unless otherwise specified, the chain or belt conveyor mechanism, servo motor, three-dimensional moving platform / gantry, laser cutting mechanism, CCD camera, cooling mechanism, dust purifier, vacuum pump, controller and other components used in the embodiments of the present invention are all known to those skilled in the art and can be obtained commercially. The circuit connection structure and control program between the various functional mechanisms in the integrated molding equipment for surface texture defect detection and online cutting of automotive interior parts in the embodiments of the present invention are all known to those skilled in the art and can be obtained commercially. No product model or other limitations are imposed on the various functional mechanisms here.

[0063] Please see Figure 1 An integrated molding equipment for surface texture defect detection and online cutting of automotive interior parts includes an equipment frame and a conveying unit, a workpiece transfer unit, a workpiece fixing unit, an image acquisition unit, a cutting and processing unit, a dust collection unit, and a control unit mounted on the equipment frame. The conveying unit, workpiece transfer unit, workpiece fixing unit, image acquisition unit, cutting and processing unit, and dust collection unit are connected to the control unit, which can regulate the working status of the conveying unit, workpiece transfer unit, workpiece fixing unit, image acquisition unit, cutting and processing unit, and dust collection unit.

[0064] Specifically, the equipment frame includes a cutting and processing outer shell 1 and a cutting and processing base 6. The cutting and processing outer shell 1 is fixed on the cutting and processing base 6, and both the cutting and processing outer shell 1 and the cutting and processing base 6 enclose an installation and operation space.

[0065] For details, please refer to Figure 1 and Figure 2 The conveying unit is mainly used to convey workpieces, which are automotive interior trim panels before and after cutting. Specifically, the conveying unit includes a conveying mechanism 7 and a workpiece receiving mechanism 25. The conveying mechanism 7 is installed in the middle area inside the cutting base 6 and runs continuously along a first direction. The workpiece receiving mechanism 25 is used to carry the workpiece 24. The workpiece receiving mechanism 25 is detachably mounted on the conveying mechanism 7. The workpiece receiving mechanism 25 can travel along the first direction with the conveying mechanism 7, and it can also detach from the conveying mechanism 7 along a second direction, where the first and second directions intersect. For example, the conveying mechanism 7 can be a chain conveyor or a belt conveyor, etc.

[0066] Please refer to the following for details. Figure 3 The workpiece transfer unit is used at least to transfer workpieces between the conveying unit and the workpiece fixing unit. Specifically, the workpiece transfer unit includes a lifting mechanism 22 and a blocking mechanism 21. The blocking mechanism 21 is used to block and stop the workpiece in the moving state on the conveying mechanism 7, and the lifting mechanism 22 is used to remove the stopped workpiece from the conveying unit and fix the workpiece by the workpiece fixing unit, as well as to transfer the processed workpiece to the conveying mechanism 7.

[0067] Specifically, both the blocking mechanism 21 and the lifting mechanism 22 can move up and down in the second direction. After the moving part of the blocking mechanism 21 rises, it is located on the moving trajectory of the workpiece receiving mechanism 25, thereby blocking and stopping the moving receiving mechanism 25, and causing the workpiece on the workpiece receiving mechanism 25 to stop synchronously. When the workpiece receiving mechanism 25 is blocked and stopped by the blocking mechanism 21, the moving part of the lifting mechanism 22 rises and lifts the workpiece receiving mechanism 25 upward in the second direction, thereby taking the workpiece receiving mechanism 25 and the workpiece away from the conveying mechanism 7 together, until the workpiece can be fixed by the workpiece fixing unit.

[0068] Specifically, both the blocking mechanism 21 and the lifting mechanism 22 can be linear drive mechanisms, wherein the travel of the moving part in the blocking mechanism 21 is less than the travel of the moving part in the lifting mechanism 22. For example, both the blocking mechanism 21 and the lifting mechanism 22 can be linear drive cylinders, etc.

[0069] Specifically, the blocking mechanism 21 and the lifting mechanism 22 can both be fixed on the conveying mechanism 7. It is understood that the blocking mechanism 21 and the lifting mechanism 22 are both fixed on the frame of the conveying mechanism 7 and will not affect the operation of the conveying mechanism 7 or its conveying of workpieces.

[0070] Understandably, both the blocking mechanism 21 and the lifting mechanism 22 are connected to the control unit, which can control the working status of the blocking mechanism 21 and the lifting mechanism 22.

[0071] Specifically, the workpiece fixing unit is used at least to fix the workpiece lifted by the lifting mechanism 22 and to fully expose the area to be cut on the surface of the workpiece so that the image acquisition unit can fully acquire the image of the workpiece and the cutting processing unit can perform the cutting operation on the workpiece.

[0072] Please refer to the following for details. Figure 4The workpiece fixing unit includes an inverted positioning plate 23, a vacuum pump 11, and a vacuum adsorption pipe 12. The positioning plate 23 has a ring-shaped structure and is fixed in the upper area inside the cutting base 6. Multiple adsorption holes are provided on the fixing surface of the positioning plate 23, spaced apart along the circumferential direction. These holes are connected to the vacuum pump 11 via the vacuum adsorption pipe 12. When the vacuum pump 11 operates, it can adsorb and fix the workpiece on the fixing surface of the positioning plate 23. It is understood that when fixing the workpiece, the ring-shaped positioning plate 23 contacts the four edges of the workpiece and does not cover / obstruct the area to be cut on the workpiece surface.

[0073] Of course, the above mainly introduced the case of fixing the workpiece by negative pressure adsorption. The workpiece fixing unit can also be a magnetic attachment mechanism, such as a magnet. This requires that the workpiece can be magnetically adsorbed, or that the workpiece is equipped with a magnet or ferromagnet. In addition, the workpiece fixing unit can also be a clamping mechanism.

[0074] Understandably, vacuum pump 11 is connected to a control unit, which can control the operating status of vacuum pump 11.

[0075] Please refer to the following for details. Figure 5 and Figure 6 The image acquisition unit is used at least to acquire images of the area to be cut on the surface of the workpiece fixed by the workpiece fixing unit. Specifically, the image acquisition unit includes an image acquisition mechanism 19, at least one light source 20, a first polarization mechanism 31, a second polarization mechanism 32, and a first three-dimensional moving mechanism. The image acquisition mechanism 19 and at least one light source 20 are mounted on the first three-dimensional moving mechanism. The first polarization mechanism 31 is disposed at the front end of the light-emitting end of the light source 20, and the second polarization mechanism 32 is disposed at the front end of the acquisition end of the image acquisition mechanism 19. The light strip provided by the light source 20 passes through the first polarization mechanism 31 and is incident on the workpiece. The light strip reflected by the workpiece passes through the second polarization mechanism 32 and is received by the image acquisition mechanism 19 to form a light stripe image.

[0076] Specifically, the image acquisition mechanism 19 is used at least to acquire images of the workpiece, and the light source 20 is used at least to illuminate the workpiece fixed by the workpiece fixing unit, to assist the image acquisition mechanism 19 in acquiring images of the workpiece. The image acquisition mechanism 19 is mounted on the first three-dimensional moving mechanism and can move along at least one of the X-axis, Y-axis, and Z-axis of a three-dimensional coordinate system under the drive of the first three-dimensional moving mechanism. The image acquisition mechanism 19 scans the workpiece under the drive of the first three-dimensional moving mechanism and stitches the imaging results into a complete image with a wide coverage, uniform imaging brightness, and high resolution, thereby accurately identifying the location and size of texture defects on the workpiece surface. More specifically, the image acquisition mechanism 19 includes at least one CCD camera, preferably a linear CCD camera, and the first polarization mechanism 31 and the second polarization mechanism 32 can be polarizers, etc.

[0077] Specifically, the first three-dimensional moving mechanism may include an XYZ moving gantry 14, XYZ moving axes (i.e., including X, Y, and Z axes) 16, and a pulse servo drive motor 13. The XYZ moving gantry 14 is fixed to the cutting processing base 6 and located inside the cutting processing housing 1. The pulse servo drive motor 13 and the XYZ moving axes 16 are fixed to the XYZ moving gantry 14. The image acquisition mechanism 19 is fixed to a push-broom moving fixed bracket 15. The push-broom moving fixed bracket 15 is movably engaged with the XYZ moving axes 16 and is also connected to the pulse servo drive motor 13, enabling it to move along the X, Y, or Z axes under the drive of the pulse servo drive motor 13. It is understood that the pulse servo drive motor 13 includes at least three sets of pulse servo drive motors, each corresponding to one of the X, Y, or Z axes. More specifically, the light source 20 may be fixedly mounted on the push-broom moving fixed bracket 15.

[0078] It should be noted that, in the specific process of scanning and imaging the workpiece with the image acquisition mechanism 19, the image acquisition mechanism 19 can be moved only along the X-axis or Y-axis, or the image acquisition mechanism 19 can be moved along the X-axis or Y-axis and raised and lowered along the Z-axis, thereby obtaining an image of the workpiece.

[0079] Specifically, the pulse servo drive motor 13, the image acquisition mechanism 19, and the light source 20 are all connected to the control unit. The control unit can control the working status of the pulse servo drive motor 13, the image acquisition mechanism 19, and the light source 20, as well as receive the images acquired by the image acquisition mechanism 19 and analyze the images to identify the distribution location and size of the texture defects on the workpiece surface and form a cutting path based on the distribution location and size of the texture defects.

[0080] This invention includes a large field-of-view, high-resolution polarization imaging system based on three-way pushbroom stitching, such as... Figure 6 As shown, the system uses three parallel linear CCD cameras as a complete push-broom imaging system, i.e., image acquisition mechanism. The push-broom imaging system is fixed on the bracket and arranged vertically, while the automotive interior aluminum printed sheet (i.e., workpiece) 33 is placed on the moving platform and moves along the guide rail 34 to pass through the push-broom imaging system, finally completing the scanning of the automotive interior aluminum printed sheet. After acquiring the image, the linear CCD cameras use a stitching algorithm to combine the images from multiple cameras into a high-resolution image with a large width, uniform imaging, and covering the entire aluminum printed sheet.

[0081] To address the high reflectivity of genuine aluminum printed panels for automotive interior parts, a polarization mechanism filters and eliminates the reflectivity of the workpiece surface. A first polarization mechanism 31 is installed in front of a light source (e.g., a line laser) 20, and a second polarization mechanism 32 is installed in front of a CCD camera. The light source 20 is fixed by a bracket. When the light source 20 illuminates the workpiece, the resulting light streaks pass through the first polarization mechanism 31, are reflected by the workpiece 33, and then pass through the second polarization mechanism 32 before being received by the CCD camera. Finally, the image is stitched, detected, and displayed in the controller. The irradiance of the light source on the workpiece surface is uniform, eliminating the problem of light concentration and suppressing stray light, thus improving the imaging quality of defects on the surface of the workpiece under test.

[0082] Specifically, each CCD camera, after acquiring a single frame of light bar image (which can be any image), stitches them together using the following formula:

[0083]

[0084] In the formula: I' is the grayscale matrix of the stitched weld image; I ij The grayscale matrix of the light stripe image; Δ ij is the gray value matrix between adjacent light bars, where the gray values ​​of this region are all set to 0. The gray value matrix of the light bar image and the gray value matrix of the region between the light bars use the same number of columns j; n is the number of light bar images that need to be stitched together.

[0085] Specifically, the cutting processing unit is at least used to cut the workpiece fixed by the workpiece fixing unit according to a specified cutting path. More specifically, the cutting processing unit includes a cutting mechanism and a second three-dimensional moving mechanism. The cutting mechanism is at least used to perform cutting actions on the workpiece. The cutting mechanism is mounted on the second three-dimensional moving mechanism and can move along at least one of the X-axis, Y-axis, and Z-axis of a three-dimensional coordinate system under the drive of the second three-dimensional moving mechanism.

[0086] Specifically, the structure of the second three-dimensional moving mechanism can be the same as that of the first three-dimensional moving mechanism. More specifically, the structure of the second three-dimensional moving mechanism and the structure of the first three-dimensional moving mechanism can share a set of XYZ moving gantry and XYZ moving axis, but the cutting mechanism is driven independently, that is, the servo drive motors used in the cutting processing unit and the image acquisition unit are independent.

[0087] Specifically, the cutting mechanism is fixed on the Z-axis moving fixed plate, which is movably mounted on the Z-axis of the XYZ moving axis and can move along the X, Y, and Z axes of the XYZ moving axis.

[0088] Specifically, the cutting mechanism includes a laser cutting mechanism, which includes a laser cutting head 18, an optical fiber 2, a fiber laser controller 15, and a laser water chiller 4. The laser cutting head 18 is fixedly mounted on the Z-axis moving fixed plate and connected to the fiber laser controller 15 via the optical fiber 2. It can be understood that the fiber laser controller 15 does not need to move, so it does not need to be mounted on the second three-dimensional moving mechanism. The laser water chiller 4 is thermally connected to the fiber laser controller 15 and is at least used to cool the fiber laser controller 15.

[0089] Specifically, the cutting mechanism also includes a vision monitoring camera 17, which is also fixed on the Z-axis moving fixed plate. The vision monitoring camera 17 is used at least to monitor the cutting path of the cutting mechanism and the implementation status of cutting the workpiece in real time, so as to adjust the working status of the cutting mechanism.

[0090] Specifically, the servo motor and fiber laser controller 15 connected to the Z-axis moving fixed plate are both connected to the control unit, which can control the working status of the servo motor and fiber laser controller 15.

[0091] Specifically, the dust collection unit is at least used to collect dust generated when the cutting unit cuts the workpiece. Specifically, the dust collection unit includes a dust hopper 8, a dust collection pipe 9, and a dust treatment mechanism 10. The dust hopper 8 is connected to the dust treatment mechanism 10 via the dust collection pipe 9. The dust hopper 8 is positioned below the workpiece fixing unit along the direction of gravity and is at least used to collect dust. The dust treatment mechanism 10 is used to purify the dust; for example, the dust treatment mechanism 10 can be a fume purifier, etc.

[0092] Specifically, the control unit includes a PLC / detection controller 3, etc. The PLC / detection controller is set on the cutting and processing housing 1, and the control panel of the PLC / detection controller 3 is embedded in the cutting and processing housing 1.

[0093] The method for processing automotive interior parts using the integrated equipment for surface texture defect detection and online cutting can include the following steps:

[0094] The workpiece 24 (i.e., automotive interior panel) to be processed is placed on the workpiece receiving mechanism 25 and moves along the first direction together with the workpiece receiving mechanism 25 under the transmission of the conveying mechanism 7 until the blocking mechanism 21 rises and stops the moving workpiece receiving mechanism 25, causing the lifting mechanism 22 to rise and lift the workpiece receiving mechanism 25 together with the workpiece 24 upward. The workpiece receiving mechanism 25 and the workpiece 24 are taken away from the conveying mechanism 7 until the workpiece 24 is attracted and fixed by the positioning plate 23.

[0095] The pulse servo drive motor 13 drives the image acquisition mechanism 19 to move along the XYZ moving axis 16. Under the working action of the image acquisition mechanism 19 and the light source 20, the workpiece 24 is scanned. The imaging results are stitched into a complete image with a wide coverage, uniform imaging brightness and high resolution. This accurately identifies the location and size of surface texture defects on the workpiece and feeds it back to the control unit for optimal laser cutting path planning, part arrangement and automatic avoidance of defect points, thereby maximizing material utilization. After the scanning is completed, the pulse servo drive motor 13 moves the image acquisition mechanism 19 back to the origin.

[0096] According to the instructions of the control unit, the pulse servo drive motor 13 drives the laser cutting head 18 to move, and under the recognition and monitoring feedback of the vision monitoring camera 17, the laser cutting head 18 achieves automatic focusing and completes the cutting process. After the processing is completed, it returns to the origin along the XYZ movement axis.

[0097] Positioning plate 23 releases workpiece 24, workpiece 24 falls back onto workpiece receiving mechanism 25. At the same time, lifting mechanism 22 drives workpiece receiving mechanism 25 to descend until workpiece receiving mechanism 25 falls back onto conveying mechanism 7. At the same time, blocking mechanism 21 descends, and workpiece 24 and workpiece receiving mechanism 25 continue to be conveyed forward under the conveying of conveying mechanism 7.

[0098] Similarly, the process is repeated cyclically. Dust generated during laser cutting is collected and purified through the dust collection hopper 8, dust collection pipe 9, and dust treatment mechanism 10. Laser cutting parameters and real-time internal processing status can be adjusted and monitored through the PC control panel embedded in the cutting processing housing 1. The cutting processing housing 1 effectively prevents laser damage to the operator's eyesight.

[0099] Specifically, each CCD camera, after acquiring a single frame of light bar image (which can be any image), stitches them together using the following formula:

[0100]

[0101] In the formula: I' is the grayscale matrix of the stitched weld image; I ij The grayscale matrix of the light stripe image; Δ ij is the gray value matrix between adjacent light bars, where the gray values ​​of this region are all set to 0. The gray value matrix of the light bar image and the gray value matrix of the region between the light bars use the same number of columns j; n is the number of light bar images that need to be stitched together.

[0102] After acquiring a series of images, the horizontally arranged multi-line array cameras first need to correct the images to eliminate unevenness and ensure image integrity and consistency. Then, image matching is used to find common regions between the images, thereby determining the stitching points. The image matching employs algorithms for object detection, feature extraction, and feature matching. Based on the common regions, multiple images are stitched together into a complete image of the aluminum workpiece for automotive interior parts using image fusion. During the fusion process, considering issues of image brightness, color, and contrast, Poisson mixture processing is used to achieve image fusion. Finally, the images are scaled and cropped to adjust the size of the stitched image to suit the application scenario.

[0103] This invention includes an AI-based real-time online detection and quality evaluation algorithm for surface defects in automotive interior parts, and deploys a deep learning detection model algorithm for surface defects in automotive interior parts. After receiving the stitched images, the detection algorithm extracts the geometric features of the defects, selects the geometric features, generates a heat map of the defects, and finally identifies and locates the defects, thus achieving defect detection. The deep learning-based AI online detection system for surface defects in automotive interior parts is highly efficient and can effectively manage the quality data of interior parts products, providing necessary support for the quality control system.

[0104] This invention includes a set of interior component laser cutting path optimization and defect point automatic avoidance software, which can achieve the following functions: based on the defect location and shape information, it reproduces the defect in the laser cutting control software and optimizes the arrangement of interior components of different sizes on the real aluminum sheet to maximize material utilization; and generates a laser cutting path based on the arrangement of interior components on the real aluminum sheet.

[0105] This invention uses a linear CCD camera to scan automotive interior panel materials, stitching the images together to form a complete image with wide coverage, uniform brightness, and high resolution. This allows for precise identification of the location and size of surface texture defects in the automotive interior panel materials, which are then fed back to the PC image processing system in the control unit for optimal laser cutting path planning, parts arrangement, and automatic defect avoidance, maximizing material utilization. Based on system feedback, the laser cutting head and machine vision monitoring automatically rise, fall, focus, cut, and monitor quality on the XYZ gantry.

[0106] To achieve dust collection and purification, operator vision protection, and real-time monitoring of internal processing conditions during laser cutting, this invention uses a dust collection hopper, dust collection pipe, and fume purifier to collect and purify dust during processing. The laser cutting processing housing can effectively prevent laser from harming the operator's eyes. The PC control panel embedded in the laser cutting processing housing can adjust the laser cutting process parameters and monitor the internal processing conditions in real time.

[0107] It should be understood that the above embodiments are merely illustrative of the technical concept and features of the present invention, and are intended to enable those skilled in the art to understand the content of the present invention and implement it accordingly. They should not be construed as limiting the scope of protection of the present invention. All equivalent changes or modifications made in accordance with the spirit and essence of the present invention should be covered within the scope of protection of the present invention.

Claims

1. An integrated molding equipment for surface texture defect detection and online cutting of automotive interior parts, characterized in that, include: A conveying unit, at least for conveying workpieces; A workpiece transfer unit is used at least to transfer workpieces between a conveying unit and a workpiece fixing unit; A workpiece fixing unit is used to fix the workpiece and to fully expose the area to be cut on the surface of the workpiece. The image acquisition unit is used to acquire at least multiple local images of the area to be cut on the surface of the workpiece fixed by the workpiece fixing unit. A cutting and processing unit, at least used for cutting a workpiece that is fixed by the workpiece fixing unit; The control unit is connected to the conveying unit, the workpiece lifting unit, the workpiece fixing unit, the image acquisition unit, and the cutting processing unit. The control unit has at least the following functions: synthesizing multiple local images acquired by the image acquisition unit into a high-resolution overall image covering the entire workpiece; identifying the distribution location and size of texture defects on the workpiece surface through the overall image; forming a cutting path based on the distribution location and size of the texture defects; causing the cutting processing unit to perform a cutting action on the workpiece along the cutting path; and controlling the working state of the conveying unit, the workpiece lifting unit, and the workpiece fixing unit.

2. The integrated molding equipment for surface texture defect detection and online cutting of automotive interior parts according to claim 1, characterized in that: The conveying unit includes a conveying mechanism and a workpiece receiving mechanism, wherein the workpiece receiving mechanism is used to carry the workpiece. The workpiece receiving mechanism is detachably mounted on the conveying mechanism. The workpiece receiving mechanism can travel along the first direction with the conveying mechanism, and the workpiece receiving mechanism can also detach from the conveying mechanism along the second direction, wherein the first direction and the second direction intersect.

3. The integrated molding equipment for surface texture defect detection and online cutting of automotive interior parts according to claim 2, characterized in that: The workpiece transfer unit includes a lifting mechanism and a blocking mechanism. The blocking mechanism is used to stop the workpiece in the moving state on the conveying unit. The lifting mechanism is used to remove the stopped workpiece from the conveying unit and fix the workpiece by the workpiece fixing unit, and to transfer the processed workpiece to the conveying unit.

4. The integrated molding equipment for surface texture defect detection and online cutting of automotive interior parts according to claim 3, characterized in that: Both the blocking mechanism and the lifting mechanism are capable of moving up and down in the second direction.

5. The integrated molding equipment for surface texture defect detection and online cutting of automotive interior parts according to claim 1, characterized in that: The workpiece fixing unit includes a fixing mechanism that can be detachably connected to the workpiece; And / or, the fixing mechanism is an adsorption mechanism, which can fix the workpiece by adsorption, or the fixing mechanism is a clamping mechanism, which can fix the workpiece by mechanical clamping; And / or, the adsorption mechanism is a magnetic adsorption mechanism or a negative pressure adsorption mechanism; And / or, the fixing mechanism is a ring structure that matches the four edges of the workpiece.

6. The integrated molding equipment for surface texture defect detection and online cutting of automotive interior parts according to claim 1, characterized in that: The image acquisition unit includes an image acquisition mechanism, a light source, and a first three-dimensional moving mechanism. The image acquisition mechanism is used to acquire at least a partial image of the workpiece, and the light source is used to illuminate the workpiece fixed by the workpiece fixing unit. The light source and the image acquisition mechanism are mounted on the first three-dimensional moving mechanism and can move along at least one of the X-axis, Y-axis, and Z-axis of a three-dimensional coordinate system under the drive of the first three-dimensional moving mechanism. The light strip provided by the light source is incident on the workpiece, and the light strip after reflection by the workpiece is received by the image acquisition mechanism to form a light stripe image. And / or, the image acquisition mechanism includes at least one CCD camera; And / or, each CCD camera, after acquiring a single frame of light bar image, combines them using the following formula: In the formula: I' is the grayscale matrix of the stitched weld image; I ij The grayscale matrix of the light stripe image; Δ ij is the gray value matrix between adjacent light bars, where the gray values ​​are all set to 0. The gray value matrix of the light bar image and the gray value matrix of the region between the light bars use the same number of columns j; n is the number of light bar images to be stitched together. And / or, the image acquisition unit further includes a first polarization mechanism and a second polarization mechanism, wherein the first polarization mechanism is disposed at the front end of the light emitting end of the light source, and the second polarization mechanism is disposed at the front end of the acquisition end of the image acquisition mechanism.

7. The integrated molding equipment for surface texture defect detection and online cutting of automotive interior parts according to claim 1, characterized in that: The cutting processing unit includes a cutting mechanism and a second three-dimensional moving mechanism. The cutting mechanism is at least used to perform a cutting action on the workpiece. The cutting mechanism is mounted on the second three-dimensional moving mechanism and can move along at least one of the X-axis, Y-axis, and Z-axis of a three-dimensional coordinate system under the drive of the second three-dimensional moving mechanism. And / or, the cutting mechanism includes a laser cutting mechanism.

8. The integrated molding equipment for surface texture defect detection and online cutting of automotive interior parts according to claim 1, characterized in that, Also includes: A dust collection unit, which is at least used to collect dust generated when the cutting processing unit cuts the workpiece; And / or, the dust collection unit includes a dust collection hopper and a dust treatment mechanism. The dust collection hopper is disposed below the workpiece fixing unit along the direction of gravity and is used at least to collect the dust. The dust treatment mechanism is connected to the dust collection hopper and is used to purify the dust.

9. A method for integrated online cutting and forming of surface texture defects in automotive interior parts, characterized in that, include: Provides an integrated molding equipment for surface texture defect detection and online cutting of automotive interior parts as described in any one of claims 1-8; The workpiece is transferred away from the conveying unit by the workpiece transfer unit, and the workpiece is fixed by the workpiece fixing unit, so that the area to be cut on the surface of the workpiece is fully exposed. An image acquisition unit acquires an image of the area to be cut on the surface of the workpiece fixed by the workpiece fixing unit. A control unit identifies the distribution location and size of texture defects on the workpiece surface through the image and forms a cutting path based on the distribution location and size of the texture defects. Each cutting path corresponds to a workpiece. The cutting processing unit performs a cutting action on the workpiece along the cutting path, and then the workpiece transfer unit transfers the cut workpiece to the conveying unit.

10. The integrated method for surface texture defect detection and online cutting of automotive interior parts according to claim 9, characterized in that, Also includes: Each CCD camera, after acquiring a single frame of light bar image, combines them using the following formula: In the formula: I' is the grayscale matrix of the stitched weld image; I ij The grayscale matrix of the light stripe image; Δ ij It is the gray value matrix between adjacent light stripes. The gray values ​​in this region are all set to 0. The gray value matrix of the light stripe image and the gray value matrix of the region between the light stripes use the same number of columns j. n is the number of light bar images that need to be stitched together; Preferably, the integrated method for detecting surface texture defects in automotive interior parts and online cutting further includes: collecting the dust generated during the cutting process of the workpiece and purifying the collected dust.

Images