Full-automatic visual inspection machine for transformer
By designing a fully automatic visual inspection machine for transformers, integrating a feeding conveyor belt, a rotating fixture table, and a multi-faceted visual inspection mechanism, the error problems in transformer appearance and pin inspection were solved, achieving efficient and accurate fully automatic inspection.
Patent Information
- Application Number
- CN202511162255.2
- Authority / Receiving Office
- CN · China
- Patent Type
- Applications(China)
- Current Assignee / Owner
- Filing Date
- 2025-08-19
- Publication Date
- 2025-11-21
AI Technical Summary
Existing transformer testing equipment is prone to errors in appearance and pin inspection, and has low testing efficiency, which cannot meet the needs of lean production.
A fully automatic visual inspection machine for transformers was designed. It adopts an integrated production line with feeding and unloading conveyor belts, and combines a pin visual inspection mechanism, a rotating fixture table, a positioning module and a multi-faceted visual inspection mechanism to realize fully automatic multi-angle inspection of transformers.
It has achieved fully automated transformer testing, improved testing flexibility and accuracy, eliminated misjudgments, and met the needs of lean manufacturing.
Smart Images
Figure CN120992489A_ABST
Abstract
Description
Technical Field
[0001] This invention relates to the field of transformer inspection technology, and in particular to a fully automatic visual inspection machine for transformers. Background Technology
[0002] After the transformer is manufactured through the winding and soldering assembly process, its appearance needs to be inspected for defects in order to avoid any defects that could affect the quality of the transformer's production.
[0003] In existing technologies, there are generally several inspection methods. One method involves manually inspecting the transformer visually to determine its passability. However, prolonged use of the human eye can cause eye fatigue, leading to a risk of misjudgment. Existing transformer visual inspection equipment on the market typically requires manual placement of the transformer on a testing platform at a fixed angle and surface. This method is not flexible enough, carries the risk of missing certain angles, has a low detection rate, and is prone to misjudgment. Furthermore, manual loading and unloading are time-consuming and labor-intensive, resulting in low work efficiency and failing to meet the needs of lean manufacturing.
[0004] Another method involves photographing all six sides of the transformer using a multi-faceted inspection device. However, to inspect each side, the transformer must be removed and repositioned during the inspection process. This cumbersome procedure causes unnecessary inconvenience for users and slows down the visual inspection of the transformer.
[0005] The transformer's coils are wrapped with a layer of tape, primarily serving to provide insulation, structural stability, improve electrical performance, and protect internal components. Each side of the transformer has a row of pins, and it's necessary to simultaneously inspect the spacing and alignment of these pins to ensure they meet standards. When photographing all six sides of the transformer, the pins are also captured. Therefore, the pins are inspected simultaneously during the visual inspection of the transformer's six sides. However, the camera uses a supplementary lighting source. This light is reflected when it hits the tape on the transformer, and the pins also reflect the light, resulting in a mixture of reflected light from the tape and pins. When analyzing the images, it may be difficult to identify the boundaries of the pin areas, potentially leading to inaccuracies in the measurement of pin spacing and alignment. Summary of the Invention
[0006] The purpose of this invention is to solve the above-mentioned problems by designing a fully automatic visual inspection machine for transformers, which solves the problem that existing transformer inspection equipment is prone to errors when inspecting the appearance and pins of transformers.
[0007] The technical solution of the present invention to achieve the above objectives is a fully automatic visual inspection machine for transformers, used to inspect the appearance of transformers and the pins on both sides, including: The loading conveyor belt and the unloading conveyor belt are respectively used to connect with the transformer production line to transport transformers for loading and unloading. A pin visual inspection mechanism includes a first light source assembly and a first camera capable of capturing images of the transformer pins through the first light source assembly. The first light source assembly has a clearance groove, and each of the inner walls on both sides of the clearance groove has a slit that allows light to pass through and converges on the pins on both sides of the transformer. The first positioning module is used to support the transformer in the clearance groove and make the pin height on both sides of the transformer match the height of the slit. A first rotating fixture table has multiple positioning fixtures that can rotate around a center, and the positioning fixtures are used to position the transformer. The first PPU transfer mechanism is used to transfer the transformer on the feeding conveyor belt to the first positioning module and to transfer the transformer on the first positioning module to one of the positioning fixtures. The bottom surface visual inspection mechanism is used to capture images of the bottom surface of the transformer during the process of transferring the transformer from the feeding conveyor belt to the first positioning module; The top-face visual inspection mechanism is used to photograph the top surface of the transformer located on the positioning fixture; The second positioning module is used to position the transformer and control its rotation. At least two side vision detection mechanisms are diagonally distributed relative to the transformer placed on the second positioning module; The second PPU transfer mechanism is used to transfer the transformer from the positioning fixture to the second positioning module and to remove the transformer located on the second positioning module to complete the unloading.
[0008] Furthermore, the pin vision inspection mechanism also includes an adjustment platform that can adjust its front and rear positions, a stand that is vertically set on the adjustment platform, a light source fixing plate and a camera fixing plate that can slide up and down relative to the stand. The light source fixing plate is located above the camera fixing plate. The first light source assembly and the first camera are respectively mounted on the light source fixing plate and the camera fixing plate. The light source fixing plate has a clearance hole in the middle.
[0009] Furthermore, the first light source assembly includes a light source plate, two light source emitting blocks respectively disposed on both sides of the light source plate, a clearance groove formed between the two light source emitting blocks, a slit on the opposite side of the two light source emitting blocks, and a clearance hole in the middle of the light source plate.
[0010] Furthermore, a baffle is provided on each side of the upper part of the feeding conveyor belt, and a guide channel is formed between the two baffles. The width of the feed end of the guide channel gradually decreases along the conveying direction.
[0011] Furthermore, the discharge end of the feeding conveyor belt is provided with a stop plate and a pressure plate. The stop plate is transversely cut across the discharge end of the guide channel. The stop plate is provided with a sensor for detecting the transformer position and a magnet for attracting the transformer. The pressure plate is fixed on one of the baffles, and one side of the pressure plate extends directly above the discharge end of the guide channel. There is an appropriate distance between the pressure plate and the stop plate to grip the transformer.
[0012] Furthermore, the first positioning module includes a first support frame and a tray fixed on the first support frame. The tray is horizontally positioned and has a groove for positioning the transformer. The two sides of the groove are recessed inward along the width direction of the tray so as to expose the two rows of pins on both sides of the transformer to the field of view of the first camera.
[0013] Furthermore, the first rotary fixture table includes an indexing plate, a rotary motor for driving the indexing plate to rotate, a motor mounting base for mounting the rotary motor, and four positioning fixtures respectively distributed around the rotation center of the indexing plate. The middle of the positioning fixture has an upward protrusion forming a support portion, and the upward protrusion of the support portion forms a positioning portion for positioning the two ends of the transformer.
[0014] Furthermore, the second positioning module includes a stand, a base plate located above the stand, a rotary motor for driving the base plate to rotate, and a positioning fixture mounted on the base plate. The rotary motor is vertically fixed on the stand, a sensing plate is provided on one side of the base plate, and a photoelectric sensor that cooperates with the sensing plate is provided on the stand.
[0015] Furthermore, the vision inspection machine also includes a third positioning module and a second rotary fixture table that serve as a transition, as well as a material transfer mechanism for transferring the transformer from the second rotary fixture table to the material unloading conveyor belt.
[0016] Furthermore, the material feeding and transplanting mechanism includes a truss, a horizontal moving module mounted on the truss, a sliding plate mounted on the horizontal moving module, a slide block that can slide up and down relative to the sliding plate, a lifting cylinder that drives the slide block to move up and down, a finger cylinder mounted on the slide block, and two grippers respectively mounted on the finger cylinders. A buffer is provided on the sliding plate, and the buffer is located above the slide block. A connector is provided on the outside of the finger cylinder, and the lower end of the connector extends between the two grippers. A buffer is provided at the lower end of the connector.
[0017] Its advantages over existing technologies are: The visual inspection machine of this invention can be connected to the transformer production line via the feeding and unloading conveyor belts, integrating the inspection process into the transformer production process, thereby realizing fully automated transformer production without the need for separate inspection of the produced transformers.
[0018] The transformer, conveyed by the first PPU transfer mechanism, is picked up from the feeding conveyor belt and transferred over the bottom visual inspection mechanism to the first positioning module. The bottom visual inspection mechanism captures images of the transformer's bottom surface during this transfer, simultaneously scanning the barcode. The first positioning module supports the transformer within a clearance groove on the first light source assembly. Light emitted from the first light source assembly passes through slits on both sides of the clearance groove and focuses on the two rows of pins on either side of the transformer, avoiding illumination of other areas. A camera then captures images of the pins from bottom to top. The resulting images show concentrated light in the pin area, providing a clearer outline and reducing measurement errors.
[0019] Next, the first PPU transfer mechanism synchronously transfers the transformer from the first positioning module to the first rotating fixture. The first rotating fixture rotates and transfers the transformer to the area below the top visual inspection mechanism to complete the imaging of the transformer's top surface. Then, the first rotating fixture rotates and transfers the transformer to the area below the second PPU transfer mechanism, which synchronously transfers the transformer to the second positioning module. At least two diagonally distributed side visual inspection mechanisms will then image the sides of the transformer. The second positioning module controls the transformer to rotate until all four sides of the transformer are imaged, ultimately forming a panoramic view of the sides. The four corners are not imaged. Finally, the second PPU transfer mechanism completes the unloading process.
[0020] This vision inspection machine integrates functions such as loading, barcode scanning, appearance photography, and unloading. It has a high degree of automation, enabling multi-faceted and multi-angle inspection of products. The inspection is flexible, improves the detection rate, and eliminates misjudgments. At the same time, as a fully automated device, it saves time and labor, meets the needs of lean production, and is conducive to large-scale automated mass production. Attached Figure Description
[0021] Figure 1 This is a schematic diagram of the structure of the fully automatic visual inspection machine for transformers of the present invention; Figure 2 This is a structural diagram of the feeding conveyor belt; Figure 3 This is a schematic diagram of the bottom surface visual inspection mechanism; Figure 4 This is a schematic diagram of the regulating table; Figure 5 This is a schematic diagram of the structure when the pin vision inspection mechanism and the first positioning module are in cooperation; Figure 6 This is a schematic diagram of the pin vision inspection mechanism; Figure 7 This is a schematic diagram of the first light source assembly in the pin vision inspection mechanism; Figure 8 This is a structural schematic diagram of the first positioning module; Figure 9 This is a schematic diagram of the first PPU transplanting mechanism; Figure 10 This is a structural schematic diagram of the first PPU transplanting mechanism from another perspective; Figure 11 This is a schematic diagram of the structure of the first rotary fixture table; Figure 12 This is a schematic diagram of the positioning fixture; Figure 13 This is a schematic diagram of the structure when the second positioning module and the four side vision detection mechanisms work together; Figure 14 This is a schematic diagram of the structure of the second positioning module; Figure 15 This is a structural diagram of the third positioning module; Figure 16 This is a schematic diagram of the material feeding and transplanting mechanism; Figure 17 This is a schematic diagram of the structure of the feeding and transferring mechanism when the finger cylinder, gripper, and buffer work together.
[0022] In the diagram, 1. Frame; 2. Feeding conveyor belt; 21. Baffle; 211. Waist-shaped hole; 22. Stop plate; 23. Pressure plate; 3. Bottom surface vision inspection mechanism; 31. Third camera; 32. Ring light source assembly; 33. Adjustment table; 331. Base; 332. Slide table; 3321. Sliding part; 333. Wedge block; 334. Knob; 34. Stand; 35. Light source fixing plate; 36. Camera fixing plate; 4. Pin vision inspection mechanism; 41. First light source assembly; 411. Light source plate; 412. Light source emitting block; 4121. Slit; 42. First camera; 401. Clearance groove; 5. First PPU transplanting mechanism; 51. Mounting bracket; 52. Vertical plate; 53. Follower plate; 54. Connecting plate; 55. Cam; 56. Gripping assembly; 57. Drive motor; 6. First positioning module; 61. First support 62. Support frame; 63. Sensor; 7. Top surface visual inspection mechanism; 8. First rotating fixture table; 81. Motor mounting base; 82. Rotary motor; 83. Indexing plate; 9. Second positioning module; 91. Second support frame; 92. Base plate; 10. Side visual inspection mechanism; 11. Second PPU transfer mechanism; 12. Third positioning module; 121. Third support frame; 13. Second rotating fixture table; 14. Unloading and transfer mechanism; 141. Truss; 142. Horizontal movement module; 143. Sliding plate; 144. Slide seat; 145. Lifting cylinder; 146. Finger cylinder; 147. Gripper; 148. Connector; 149. Buffer; 15. Unloading conveyor belt; 16. Transformer; 17. Positioning fixture; 171. Support part; 172. Positioning part; 18. Photoelectric sensor; 19. Sensing plate. Detailed Implementation
[0023] The technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. All other embodiments obtained by those skilled in the art based on the embodiments of the present invention without creative effort are within the scope of protection of the present invention.
[0024] like Figure 1 As shown, a preferred embodiment of the present invention proposes a fully automatic visual inspection machine for transformers. This visual inspection machine adopts automation technology and integrates inspection and loading / unloading, and can complete the overall appearance inspection of transformers 16 in batches.
[0025] The transformer 16 has a row of pins on each side leading out from inside the transformer 16, and the coils on the transformer 16 are wrapped with tape. When evaluating the appearance quality of the transformer 16, it is necessary to inspect all appearances of the transformer 16, including the pins, tape and the whole, including whether the pin spacing and row spacing are qualified, whether there are cold solder joints or missing solder joints, whether the tape is damaged, whether the bottom marking of the transformer 16 is qualified, whether the magnetic core is damaged, etc.
[0026] For details, please refer to Figure 1 The fully automatic visual inspection machine for transformer 16 mainly includes a machine base, a feeding conveyor belt 2, a first PPU transfer mechanism 5, a bottom visual inspection mechanism 3, a pin visual inspection mechanism 4, a first positioning module 6, a first rotating fixture table 8, a second PPU transfer mechanism 11, a side visual inspection mechanism 10, a second positioning module 9, a top visual inspection mechanism 7, a third positioning module 12, a second rotating fixture table 13, a discharge transfer mechanism 14, and a discharge conveyor belt 15.
[0027] The feeding conveyor belt 2 and the unloading conveyor belt 15 are respectively installed on Figure 1 The left and right sides of the machine shown are used to connect the vision inspection machine to the production line of transformer 16. The feeding conveyor belt 2 is used to connect with the incoming material direction of the production line, and the unloading conveyor belt 15 is used to connect with the unloading direction of the production line. Both the feeding conveyor belt 2 and the unloading conveyor belt 15 are belt conveyors.
[0028] like Figure 2 As shown, the feeding conveyor belt 2 is equipped with two baffles 21, located on both sides of the conveyor belt, with the bottom surface of the baffles 21 close to the conveyor belt. A guide channel is formed between the two baffles 21, through which the transformer 16 from the production line is conveyed onto the feeding conveyor belt 2 and enters the guide channel. The width of the guide channel is slightly larger than the size of the transformer 16. The guide channel mainly serves to guide the conveying of the transformer 16 and prevent it from deviating too much from its intended position.
[0029] The width of the entrance to the guide channel gradually decreases along the conveying direction so that the transformer 16 flowing from the production line can enter the middle guide channel under the action of the inclined surface on the baffle 21.
[0030] Multiple oblong holes 211 are provided on each baffle 21, and the multiple oblong holes 211 are evenly distributed along the length of the baffle 21. Each oblong hole 211 extends along the width of the baffle 21, and a bolt is provided in the oblong hole 211. The baffle 21 is fixed to the feeding conveyor belt 2 by the bolt. The distance between two baffles 21 (i.e. the width of the guide channel) can be adjusted by the oblong holes 211 to accommodate transformers 16 of different sizes.
[0031] A stop plate 22 and a pressure plate 23 are located at the end of the baffle 21, near the discharge end of the feeding conveyor belt 2. A fixing block is installed on each side of the feeding conveyor belt 2 near the discharge end, and the fixing blocks are bolted to the feeding conveyor belt 2. The stop plate 22 is positioned horizontally above the discharge end of the feeding conveyor belt 2, and its two ends are connected to the two fixing blocks by screws. When the transformer 16 is conveyed to the position of the stop plate 22, it will be blocked by the stop plate 22.
[0032] A sensor (not shown in the figure) is installed in the middle area of the stop plate 22, facing the incoming material direction. This sensor is a proximity sensor used to detect whether the transformer 16 is approaching the stop plate 22. A magnet (not shown in the figure) is provided in the middle area of the stop plate 22, on the side facing the incoming material direction. When the transformer 16 approaches the magnet, the magnet will attract the product, thus playing a preliminary positioning role.
[0033] The pressure plate 23 is fixedly installed on one of the baffles 21 by screws. One side of the pressure plate 23 extends directly above the discharge end of the guide channel, and there is a certain gap between the pressure plate 23 and the stop plate 22. The size of the gap is sufficient for the removal and placement of a transformer 16.
[0034] Since the transformers 16 on the feeding conveyor belt 2 are conveyed backwards in close proximity to each other, when the product reaches the position of the stop plate 22 and is attracted and positioned by the magnet, the product will be sucked up from the area enclosed by the stop plate 22, the two baffles 21 and the pressure plate 23. The pressure plate 23 will press down the products in the rear row to prevent them from tilting upwards and falling off the feeding conveyor belt 2.
[0035] like Figure 1 As shown, the bottom surface visual inspection mechanism 3, the pin visual inspection mechanism 4, and the first positioning module 6 are sequentially installed on the machine base, near the discharge end of the feeding conveyor belt 2. The bottom surface visual inspection mechanism 3 is located between the feeding conveyor belt 2 and the pin visual inspection mechanism 4.
[0036] See Figure 3 The bottom-surface visual inspection mechanism 3 consists of an adjustment table 33, a stand 34, a light source fixing plate 35, a camera fixing plate 36, a ring light source assembly 32, and a third camera 31. The stand 34 is vertically fixed to the adjustment table 33. The light source fixing plate 35 and the camera fixing plate 36 are slidably connected to the slide rails on the stand 34 via sliders. The light source fixing plate 35 is located above the camera fixing plate 36. The third camera 31 is vertically fixed to the camera fixing plate 36, and the ring light source assembly 32 is mounted on the light source fixing plate 35. The front-to-back position of the third camera 31 and the ring light source assembly 32, perpendicular to the conveying direction of the feeding conveyor belt 2, can be adjusted via the adjustment table 33. Furthermore, the vertical height of the third camera 31 and the ring light source assembly 32 is also adjustable.
[0037] The light source of the ring light source assembly 32 is a planar light source. There is a through hole in the middle of the ring light source assembly 32, and there is also a through hole in the middle of the light source fixing plate 35. The ring light source assembly 32 is used to provide supplementary lighting for the bottom of the transformer 16. The third camera 31 is a high-speed camera that can quickly capture images of the bottom surface of the transformer 16.
[0038] See Figure 4 The adjustment platform 33 consists of a base 331, a slide 332, a wedge block 333, and a knob 334. The base 331 has a groove in the middle forming a slide track. The bottom of the slide 332 protrudes downwards to form a sliding part 3321. The two sides of the sliding part 3321 respectively engage with the inner wall of the slide track and the inclined surface of the wedge block 333. The rod of the knob 334 is threaded to the base 331 and inserts into the slide track, abutting against the wedge block 333. By rotating the knob 334, pressure is applied to the wedge block 333, which in turn presses against the slide 332. Under the action of the inclined surface, the slide 332 is pressed downwards, fixing it to the base 331 and preventing it from sliding. When the position of the slide 332 needs to be adjusted, simply rotate the knob 334 to remove the squeezing force applied to the slide 332 by the wedge block 333, and then slide the slide 332.
[0039] Two guide rods (not shown in the figure) are connected to one side of the wedge block 333. The guide rods are inserted and connected to the base 331. Under the action of the guide rods, the wedge block 333 can only move relative to the width direction of the slide.
[0040] like Figure 5 , Figure 6 As shown, the pin vision inspection mechanism 4 mainly includes an adjustment platform 33, a stand 34, a camera mounting plate 36, a light source mounting plate 35, a first light source assembly 41, and a first camera 42. The stand 34 is vertically fixed on the adjustment platform 33, and its front and rear positions can be adjusted via the adjustment platform 33. The light source mounting plate 35 and the camera mounting plate 36 are respectively connected to the slide rails on the stand 34 by sliders. The light source mounting plate 35 is located above the camera mounting plate 36, the first camera 42 is vertically fixed on the camera mounting plate 36, and the first light source assembly 41 is mounted on the light source mounting plate 35.
[0041] See Figure 7 The first light source assembly 41 consists of a light source plate 411 and two light source emitting blocks 412. The two light source emitting blocks 412 are located on both sides of the upper part of the light source plate 411, and a clearance groove 401 is formed on the light source plate 411 between the two light source emitting blocks 412. The two light source emitting blocks 412 contain light sources, and their outer shells are made of a light-proof material. A slit 4121 is located on opposite sides of the two light source emitting blocks 412, extending along the length of the clearance groove 401. The height of the slit 4121 is sufficient to concentrate the light emitted from it onto the two rows of pins on both sides of the transformer 16 located within the clearance groove 401, without illuminating the entire sides of the transformer 16, thus preventing the reflection of the tape on the surface of the transformer 16 from affecting the clarity of the image captured by the first camera 42.
[0042] A rectangular clearance hole is provided between the light source plate 411 and the light source fixing plate 35 so that the first camera 42 below can clearly capture the two rows of pins on both sides of the transformer 16 above.
[0043] like Figure 5 , Figure 8 As shown, the first positioning module 6 mainly consists of a first support frame 61 and a support plate 62. The support plate 62 is horizontally fixed to the top of the first support frame 61 by bolts. A groove is formed near the front end of the support plate 62. The size of the groove is adapted to the size of the transformer 16, and the groove is shallow so as to expose as much of the outer surface of the transformer 16 as possible. The support plate 62 is used to lift and position the transformer 16, supporting the transformer 16 within the clearance groove 401.
[0044] A clearance area is formed by recessing the plate 62 on both sides of the groove. When the transformer 16 is placed in the groove, the two rows of pins on both sides of the transformer 16 can fall within the clearance area so that the first camera 42 below can capture the two rows of pins on both sides of the transformer 16.
[0045] A sensor 63 is also provided on the tray 62 to detect whether there is a transformer 16 on the tray 62.
[0046] like Figure 9 , Figure 10 As shown, the first PPU transplanting mechanism 5 consists of a mounting frame 51, a vertical plate 52, a follower plate 53, a connecting plate 54, a drive motor 57, a cam 55, and two gripping components 56. The vertical plate 52 is vertically fixed to the mounting frame 51. A horizontally fixed slide rail is provided on the lower side of the front of the vertical plate 52, and two sliders are slidably connected to the slide rail. The follower plate 53 is fixedly connected to the upper ends of the two slide rails, which are slidably connected to the two sliders. The lower ends of the two slide rails are connected through the connecting plate 54, and the two gripping components 56 are respectively installed at both ends of the connecting plate 54. The drive motor 57 is installed on the back of the vertical plate 52, and the output end of the drive motor 57 passes through the vertical plate 52 and is connected to the cam 55. The cam 55 is located on the front of the vertical plate 52, between the two vertically arranged slide rails.
[0047] The spacing between the two gripping components 56 is adapted to the spacing between the feeding conveyor belt 2 and the first positioning module 6. When the drive motor 57 drives the cam 55 to rotate, the cam 55 acts on the two slide rails and the follower plate 53, causing the two gripping components 56 to move along an arc-shaped trajectory. One gripping component 56 picks up the transformer 16 on the feeding conveyor belt 2 and transfers it to the first positioning module 6. The other gripping component 56 picks up the transformer 16 located on the first positioning module 6 and transfers it to one of the positioning fixtures 17 of the first rotating fixture.
[0048] In order to adapt to the structure of each positioning module, one of the two gripping components 56 in the first PPU transplanting mechanism 5 uses adsorption to grip the transformer 16, and the other uses a finger cylinder 146 to clamp the transformer 16.
[0049] During the process of transferring transformer 16 from the feeding conveyor belt 2 to the first positioning module 6, it will pass directly above the bottom visual inspection mechanism 3, and the third camera 31 will quickly capture images of the bottom of transformer 16. After transformer 16 is placed on the tray 62, the first camera 42 will capture images of the two rows of pins on both sides of transformer 16. The images will be uploaded to the system, which will automatically process and analyze the images to identify whether there is wear on the bottom surface of transformer 16, whether the spacing and row spacing of the two rows of pins on both sides meet the requirements, etc. At the same time, the bottom surface of transformer 16 has a QR code, which the third camera 31 will simultaneously recognize to enter the information of transformer 16 into the system and bind the inspection information with the QR code of transformer 16 for easy traceability later.
[0050] like Figure 1 As shown, the first rotating jig 8 is located between the first positioning module 6 and the second positioning module 9. The second positioning module 9 is located between the first rotating jig 8 and the third positioning module 12, the third positioning module 12 is located between the second positioning module 9 and the second rotating jig 13, and the third PPU transplanting mechanism is located on one side of the aforementioned third positioning module 12.
[0051] like Figure 11 As shown, the first rotary fixture table 8 consists of a motor mounting base 81, a rotary motor 82, an indexing plate 83, and four positioning fixtures 17. The rotary motor 82 is vertically mounted on the motor mounting base 81, and the indexing plate 83 is located above the motor mounting base 81 and connected to the output shaft of the rotary motor 82. The indexing plate 83 is cross-shaped, and the four positioning fixtures 17 are located at the four ends of the indexing plate 83 and are evenly distributed around the center of rotation.
[0052] At the bottom of the indexing plate 83, a sensor 19 is provided below each positioning fixture 17, and a photoelectric sensor 18 is provided on the motor mounting base 81 to detect whether the indexing plate 83 has rotated into place.
[0053] See Figure 12 The positioning fixture 17 has an upward-protruding support portion 171 in the middle, which is used to lift the transformer 16 to a certain height and prevent the pins on both sides from contacting the upper surface of the positioning fixture 17. The four corners of the support portion 171 have upward-protruding positioning portions 172, and a positioning area is formed between the four positioning portions 172 for placing the transformer 16 and positioning the transformer 16.
[0054] The distance between the first positioning module 6 and one of the positioning fixtures 17 is adapted to the distance between the two gripping components 56 in the first PPU transfer mechanism 5. After the bottom surface and the pins on both sides of the transformer 16 are photographed, the first PPU transfer mechanism 5 will clamp the transformer 16 and transfer it to the corresponding positioning fixture 17.
[0055] like Figure 1 As shown, the top surface visual inspection mechanism 7 is located on one side of the first rotating fixture table 8. Then, the rotary motor 82 controls the indexing plate 83 to rotate 90°, and the positioning fixture 17 carrying the transformer 16 rotates and moves to directly below the second camera of the top surface visual inspection mechanism 7 so as to take a picture of the top surface of the transformer 16.
[0056] The structure of the top visual inspection mechanism 7 is similar to that of the bottom visual inspection mechanism 3, except that the ring light source assembly 32 of the top visual inspection mechanism 7 is located directly below the second camera. The second camera can capture the top surface of the positioning fixture 17 below through the through hole in the middle of the ring light source assembly 32. The ring light source assembly 32 is used to provide supplementary lighting for the top surface of the transformer 16.
[0057] After the top surface of the transformer 16 is photographed, the drive motor 57 will control the indexing plate 83 to continue rotating 90°, and the positioning fixture 17 carrying the transformer 16 will reach a position close to the second positioning module 9. Then, the transformer 16 will be picked up and transferred to the second positioning module 9 by the second PPU transfer mechanism 11.
[0058] The structure of the second PPU transplanting mechanism 11 is similar to that of the first PPU transplanting mechanism 5, except that the second PPU transplanting mechanism 11 has four gripping components 56, which correspond to the first rotating fixture 8, the second positioning module 9, the third positioning module 12 and the second rotating fixture 13, and the spacing between them is also consistent.
[0059] like Figure 14 As shown, the second positioning module 9 consists of a second support frame 91, a base plate 92, a rotary motor 82, and a positioning fixture 17. The base plate 92 is located above the second support frame 91 and is connected to the output shaft of the rotary motor 82, which is vertically mounted on the second support frame 91. The positioning fixture 17 is fixedly mounted on the base plate 92 with screws. This positioning fixture 17 is used to position the transformer 16. The rotation of the positioning fixture 17 can be controlled by the rotary motor 82 to adjust the angle of the transformer 16.
[0060] A sensing plate 19 is provided on one side of the base plate 92. Correspondingly, a photoelectric sensor 18 is installed on the second support frame 91. The sensing area of the photoelectric sensor 18 is located on the rotation path of the sensing plate 19.
[0061] See Figure 13 There are four side vision inspection mechanisms 10 in total, but generally at least two should be provided. The four side vision inspection mechanisms 10 are distributed along the diagonal of the transformer 16 on the second positioning module 9. That is to say, one side vision inspection mechanism 10 can generally capture images of two sides of the transformer 16 and the rounded corner surface between the two sides simultaneously. The four side vision inspection mechanisms 10 can capture images of the entire side of the transformer 16 simultaneously.
[0062] The side-view inspection mechanism 10 includes a ring light source assembly and a camera, which is horizontally positioned with the ring light source located in front of the camera's field of view. The camera and ring light source assembly can be moved horizontally to adjust the camera's focus. The camera can capture images of the side of the transformer 16 product through a through-hole in the center of the ring light source assembly.
[0063] After the four side-view inspection mechanisms 10 have completed the inspection of the entire side of the transformer 16, the rotary motor 82 controls the product to rotate. During the rotation, the four cameras continue to capture images of the sides of the transformer 16, thus forming a continuous image of the entire side of the transformer 16 within the system to prevent any missed areas and ensure a more comprehensive view. Simultaneously, it self-checks for any issues with the previously captured images. The photoelectric sensor 18 and the sensing plate 19 work together to detect the product's rotation angle and whether the product has rotated to the correct position.
[0064] After the side view is taken, the second PPU transfer mechanism 11 will pick up the transformer 16 from the second positioning module 9 and transfer it to the third positioning module 12. The third positioning module 12 serves as a transition to prevent the transformer 16 from accumulating on the second rotating fixture table 13.
[0065] See Figure 15 The third positioning module 12 includes a third support frame 121, and a positioning fixture 17 is provided on the top of the third support frame 121 for positioning the transformer 16 so that the second PPU transplanting mechanism 11 can clamp the transformer 16.
[0066] The structure of the second rotary fixture 13 is the same as that of the first rotary fixture 8. The second rotary fixture 13 also has four positioning fixtures 17 distributed around the rotation center. Because the cycle time of the previous process is relatively fast, the four gripping components 56 of the second PPU transfer mechanism 11 can simultaneously grip the transformers 16 on the corresponding modules, so the cycle time is also relatively fast; while the unloading transfer mechanism 14 can only grip one transformer 16 at a time, so the second rotary fixture 13 can act as a buffer to reduce the cycle time.
[0067] Once the transformer 16, which has completed all inspections, is in position on the second rotating fixture table 13, the unloading and transfer mechanism 14 will pick up the transformer 16 and transfer it to the unloading conveyor belt 15 to complete the unloading.
[0068] like Figure 16 As shown, the material feeding and transplanting mechanism 14 mainly consists of a truss 141, a horizontal moving module 142, a sliding plate 143, a slide block 144, a lifting cylinder 145, a finger cylinder 146, and two grippers 147. The horizontal moving module 142 is horizontally fixedly mounted on the truss 141, and the horizontal moving module 142 uses a motor-screw control to move the sliding plate 143 horizontally. The sliding plate 143 is mounted on the horizontal moving module 142. A vertically arranged slide rail is provided on the sliding plate 143. The slide block 144 is slidably connected to the slide rail via a slider. The lifting cylinder 145 is vertically fixedly mounted on the sliding plate 143, and the output end of the lifting cylinder 145 is connected to the slide block 144 to control the vertical sliding of the slide block 144.
[0069] The finger cylinder 146 is vertically fixed to the lower side of the slide 144 via an angle plate. Two grippers 147 are connected to the output end of the finger cylinder 146 respectively. The finger cylinder 146 controls the two grippers 147 to open or close to grip the transformer 16.
[0070] See Figure 17 On the sliding plate 143, a buffer 149 is provided on each side of the lifting cylinder 145. When the lifting cylinder 145 controls the sliding block 144 to move upward, the sliding block 144 will collide with the buffer 149, which will buffer the sliding block 144 and reduce the impact force. A connector 148 is provided on the outside of the finger cylinder 146, which extends downward between the two grippers 147. A buffer 149 is installed at the lower end of the connector 148, located between the two grippers 147 and at a certain distance from the lower end face of the grippers 147. After the finger cylinder 146 controls the two grippers 147 to open, the lifting cylinder 145 controls the grippers 147 to move downward, and the transformer 16 will gradually reach between the two grippers 147. At this time, the transformer 16 will gradually contact the buffer 149, which will buffer the impact and prevent the transformer 16 from being damaged. Then the finger cylinder 146 controls the jaws 147 to close, clamping the transformer 16.
[0071] During unloading, the horizontal movement module 142 controls the finger cylinder 146 to move directly above the positioning fixture 17 carrying the transformer 16 on the second rotating fixture table 13. Then, the lifting cylinder 145 controls the finger cylinder 146 to move downward, and the finger cylinder 146 controls the two grippers 147 to close, clamping the two sides of the transformer 16. Next, the horizontal movement module 142 controls the movement, with the movement direction perpendicular to the conveying direction of the unloading conveyor belt 15, finally transferring the transformer 16 onto the unloading conveyor belt 15. The unloading conveyor belt 15 will then continue to convey the transformer 16 to the subsequent production line.
[0072] The above technical solutions only embody the preferred technical solutions of the present invention. Any modifications that may be made by those skilled in the art to certain parts thereof embody the principles of the present invention and fall within the protection scope of the present invention.
Claims
1. A fully automatic visual inspection machine for transformers, used to inspect the appearance and pins on both sides of a transformer (16), characterized in that, include: The feeding conveyor belt (2) and the unloading conveyor belt (15) are respectively connected to the production line of the transformer (16) so as to convey the feeding and unloading of the transformer (16); Pin visual inspection mechanism (4), the pin visual inspection mechanism (4) includes a first light source assembly (41) and a first camera (42) capable of taking pictures of the pins of transformer (16) through the first light source assembly (41). The first light source assembly (41) has a clearance groove (401). Each side of the inner wall of the clearance groove (401) has a slit (4121) that facilitates the passage of light and enables the light to converge on the pins on both sides of transformer (16). The first positioning module (6) is used to support the transformer (16) in the relief groove (401) and make the pin height on both sides of the transformer (16) match the height of the slit (4121). A first rotating fixture table (8) has a plurality of positioning fixtures (17) that can rotate around a center, the positioning fixtures (17) being used to position the transformer (16); The first PPU transfer mechanism (5) is used to transfer the transformer (16) on the feeding conveyor belt (2) to the first positioning module (6) and to transfer the transformer (16) on the first positioning module (6) to one of the positioning fixtures (17); The bottom surface visual inspection mechanism (3) is used to capture images of the bottom surface of the transformer (16) during the process of the transformer (16) being transferred from the feeding conveyor belt (2) to the first positioning module (6); The top surface visual inspection mechanism (7) is used to photograph the top surface of the transformer (16) located on the positioning fixture (17); The second positioning module (9) is used to position the transformer (16) and control the rotation of the transformer (16); At least two side vision detection mechanisms (10) are diagonally distributed relative to the transformer (16) placed on the second positioning module (9); The second PPU transfer mechanism (11) is used to transfer the transformer (16) from the positioning fixture (17) to the second positioning module (9) and to remove the transformer (16) located on the second positioning module (9) to complete the unloading.
2. The fully automatic visual inspection machine for transformers according to claim 1, characterized in that, The pin visual inspection mechanism (4) further includes an adjustment platform (33) that can adjust the front and rear positions, a stand (34) vertically set on the adjustment platform (33), a light source fixing plate (35) and a camera fixing plate (36) that can slide up and down relative to the stand (34). The light source fixing plate (35) is located above the camera fixing plate (36). The first light source assembly (41) and the first camera (42) are respectively mounted on the light source fixing plate (35) and the camera fixing plate (36). The light source fixing plate (35) has a clearance hole in the middle.
3. The fully automatic visual inspection machine for transformers according to claim 2, characterized in that, The first light source assembly (41) includes a light source plate (411) and two light source emitting blocks (412) respectively disposed on both sides of the light source plate (411). The clearance groove (401) is formed between the two light source emitting blocks (412). The slits (4121) are located on opposite sides of the two light source emitting blocks (412). The clearance hole is located in the middle of the light source plate (411).
4. The fully automatic visual inspection machine for transformers according to claim 1, characterized in that, A baffle (21) is provided on each side of the upper part of the feeding conveyor belt (2), and a guide channel is formed between the two baffles (21). The width of the feeding end of the guide channel gradually decreases along the conveying direction.
5. The fully automatic visual inspection machine for transformers according to claim 4, characterized in that, The discharge end of the feeding conveyor belt (2) is provided with a stop plate (22) and a pressure plate (23). The stop plate (22) is transversely cut across the discharge end of the guide channel. The stop plate (22) is provided with a sensor for detecting the position of the transformer (16) and a magnet for attracting the transformer (16). The pressure plate (23) is fixed on one of the baffles (21), and one side of the pressure plate (23) extends directly above the discharge end of the guide channel. There is an appropriate distance between the pressure plate (23) and the stop plate (22) so as to grab the transformer (16).
6. The fully automatic visual inspection machine for transformers according to claim 1, characterized in that, The first positioning module (6) includes a first support frame (61) and a tray (62) fixed on the first support frame (61). The tray (62) is horizontally arranged and has a groove for positioning the transformer (16). The two sides of the groove are recessed inward along the width direction of the tray (62) so as to expose the two rows of pins on both sides of the transformer (16) to the field of view of the first camera (42).
7. The fully automatic visual inspection machine for transformers according to claim 1, characterized in that, The first rotary fixture table (8) includes an indexing plate (83), a rotary motor (82) for driving the indexing plate (83) to rotate, a motor mounting base (81) for mounting the rotary motor (82), and four positioning fixtures (17) respectively distributed around the rotation center of the indexing plate (83). The positioning fixture (17) has a support part (171) protruding upward in the middle, and the support part (171) has a positioning part (172) for positioning the two ends of the transformer (16) on the upward protrusion.
8. The fully automatic visual inspection machine for transformers according to claim 1, characterized in that, The second positioning module (9) includes a stand (34), a base plate (92) located above the stand (34), a rotary motor (82) for driving the base plate (92) to rotate, and a positioning fixture (17) mounted on the base plate (92). The rotary motor (82) is vertically fixed on the stand (34). A sensing plate (19) is provided on one side of the base plate (92), and a photoelectric sensor (18) that cooperates with the sensing plate (19) is provided on the stand (34).
9. The fully automatic visual inspection machine for transformers according to claim 1, characterized in that, The vision inspection machine also includes a third positioning module (12) that serves as a transition and a second rotary fixture table (13), as well as a material transfer mechanism (14) for transferring the transformer (16) from the second rotary fixture table to the material transfer conveyor belt (15).
10. The fully automatic visual inspection machine for transformers according to claim 9, characterized in that, The material feeding and transplanting mechanism (14) includes a truss (141), a horizontal moving module (142) mounted on the truss (141), a sliding plate (143) mounted on the horizontal moving module (142), a slide seat (144) that can slide up and down relative to the sliding plate (143), a lifting cylinder (145) that drives the slide seat (144) to move up and down, a finger cylinder (146) mounted on the slide seat (144), and two grippers (147) respectively mounted on the finger cylinder (146). A buffer (149) is provided on the sliding plate (143), and the buffer (149) is located above the slide seat (144). A connector (148) is provided on the outside of the finger cylinder (146), and the lower end of the connector (148) extends between the two grippers (147). The lower end of the connector (148) is provided with a buffer (149).