A visual defect detection system and method

Abstract

This invention discloses a visual defect detection system and method, including a conveying mechanism, a pair of first detection mechanisms, a pair of second detection mechanisms, an auxiliary mechanism, and a marking mechanism. The pair of first detection mechanisms are mounted on the conveying mechanism and respectively located on the upper and lower sides of a metal foil. The pair of second detection mechanisms are also located on the upper and lower sides of the metal foil. Each second detection mechanism includes a second support and a second illumination lamp. The second support is mounted on the conveying mechanism and has an infrared camera mounted on it. The second illumination lamp is also mounted on the second support. This invention features a dual detection structure to avoid missed or false detections of surface defects on the metal foil, thereby ensuring the robustness of the visual inspection system. Simultaneously, it significantly improves the sensitivity of machine vision inspection in defect feedback, enabling workers to quickly and accurately determine the type of surface defects on the metal foil to meet subsequent high-standard industrial production requirements.

Description

Technical Field

[0001] This invention belongs to the field of visual defect detection technology, specifically relating to a visual defect detection system and detection method. Background Technology

[0002] Metal foil is an extremely thin sheet material made from ductile metals (such as aluminum, copper, gold, and silver) through rolling or forging processes. Its thickness typically ranges from micrometers to millimeters. Metal foil possesses properties such as moisture resistance, airtightness, light blocking, and abrasion resistance, and is commonly used in packaging, hot stamping, and industrial materials, making it an indispensable material in modern industry.

[0003] After processing, metal foil requires visual defect inspection to ensure surface quality. Current methods primarily rely on manual inspection or simple machine vision. Manual inspection is subjective and prone to error, failing to meet the demands of high-precision, high-efficiency production. While machine vision inspection effectively addresses these issues, it typically employs only a single vision unit. A single unit cannot comprehensively capture all surface defects, potentially leading to missed or false detections, thus reducing the robustness of the system. Furthermore, existing machine vision inspection methods are inadequate in defect feedback, failing to provide real-time marking based on defect characteristics. This hinders the rapid and accurate identification of surface defect types by operators, ultimately failing to meet the demands of high-standard industrial production.

[0004] Therefore, in order to address the aforementioned technical problems, it is necessary to provide a visual defect detection system and detection method.

[0005] The information disclosed in this background section is intended only to enhance the understanding of the overall background of the invention and should not be construed as an admission or in any way implying that the information constitutes prior art known to those skilled in the art. Summary of the Invention

[0006] The purpose of this invention is to provide a visual defect detection system and method that can solve the problems of low robustness and poor sensitivity of defect feedback in machine vision detection.

[0007] To achieve the above objectives, a specific embodiment of the present invention provides the following technical solution:

[0008] A visual defect detection system includes a conveying mechanism, a pair of first detection mechanisms, a pair of second detection mechanisms, an auxiliary mechanism, and a marking mechanism. The pair of first detection mechanisms are mounted on the conveying mechanism and respectively located on the upper and lower sides of a metal foil. The pair of second detection mechanisms are respectively located on the upper and lower sides of the metal foil. Each second detection mechanism includes a second bracket and a second illumination lamp. The second bracket is mounted on the conveying mechanism and has an infrared camera mounted on it. The second illumination lamp is mounted on the second bracket. When the first detection mechanism detects a defect on the surface of the metal foil, it triggers the second detection mechanism to perform a second inspection of the metal foil surface. The auxiliary mechanism includes an air pipe, a connecting rod, an air pump, and a heating wire. The air pipe is connected to the second bracket via the connecting rod and is located on the upper side of the metal foil. The bottom of the air pipe has multiple evenly distributed air holes. The air pump is mounted on the air pipe, with its outlet located inside the air pipe. The heating wire is installed inside the air pipe. The marking mechanism is mounted on the second bracket and connected to the auxiliary mechanism. When the second detection mechanism detects a defect on the surface of the metal foil, the marking mechanism is used to mark the surface of the metal foil.

[0009] In one or more embodiments of the present invention, the conveying mechanism includes a base, a winding roller, and a plurality of guide rollers. The winding roller is mounted on the base for conveying metal foil. The plurality of guide rollers are mounted on the base, and the metal foil is conveyed around the plurality of guide rollers.

[0010] In one or more embodiments of the present invention, the first detection mechanism includes a first bracket and a first illumination lamp. The first bracket is mounted on the base, and a CMOS camera is mounted on the first bracket. The first illumination lamp is mounted on the base and is disposed on one side of the first bracket.

[0011] In one or more embodiments of the present invention, the length of the air tube is greater than the width of the metal foil, the air hole is inclined at the bottom of the air tube, and the inclination angle of the air hole is 15°-45°.

[0012] In one or more embodiments of the present invention, the marking mechanism includes a guide rail, an outer cylinder, an inner cylinder, multiple storage tanks, a conveying component, multiple air supply pipes, a connecting pipe, a top cover, and a driving mechanism. The guide rail is mounted on the side wall of the second support. The outer cylinder is located on one side of the second support and can move relative to the infrared camera via the guide rail. The inner cylinder is rotatably connected inside the outer cylinder. The storage tanks are installed inside the inner cylinder. The conveying component is installed inside the inner cylinder, and the multiple storage tanks surround the conveying component. The multiple air supply pipes are fixedly connected to the side wall of the conveying component and correspond to the multiple storage tanks respectively. The conveying component communicates with the storage tanks via the air supply pipes, and a third control valve is installed on the air supply pipes. The connecting pipe is connected to the bottom of the outer cylinder, and the conveying component is connected to the air supply pipe via the connecting pipe. A fourth control valve is installed on the connecting pipe. The top cover is located at the opening of the outer cylinder, and a support ring is connected to the top cover, the support ring contacting the multiple storage tanks. The drive mechanism is installed on the side wall of the outer cylinder and is used to drive the inner cylinder to rotate.

[0013] In one or more embodiments of the present invention, the storage tank includes an outer tank, an inner tank, a coating material, an extrusion plate, and an exhaust pipe. The outer tank is fixedly connected to the bottom wall of the inner cylinder, and the bottom of the outer tank is provided with a plurality of circumferentially evenly distributed injection holes. The bottom of the inner cylinder is provided with through holes that match the injection holes. The inner tank is disposed inside the outer tank, and an air passage is formed between the outer wall of the inner tank and the inner wall of the outer tank. An exhaust pipe is connected to the inner tank, one end of which passes through the outer tank and the inner cylinder. A first control valve is installed on the exhaust pipe, and the plurality of injection holes surround the exhaust pipe. The coating material is disposed inside the exhaust pipe. The extrusion plate is slidably disposed inside the inner tank and in contact with the coating material. A pair of guide rods are also provided inside the inner tank, and the extrusion plate is slidably disposed between the pair of guide rods. The exhaust pipe is connected to the inner tank, and the interior of the inner tank is connected to the air passage through the exhaust pipe. A second control valve is installed on the exhaust pipe.

[0014] In one or more embodiments of the present invention, the conveying component is provided with interconnected channels and a diffusion cavity, and the diffusion cavity is connected to the interior of the inner tank through the gas supply pipe.

[0015] In one or more embodiments of the present invention, a branch pipe is installed on the side wall of the gas supply pipe, the branch pipe is disposed in the gas passage, and a fifth control valve is installed on the branch pipe.

[0016] In one or more embodiments of the present invention, the drive mechanism includes a motor, a gear, and a protective cover. The motor is mounted on the outer cylinder sidewall. The gear is connected to the output end of the motor, and a gear ring is provided on the inner cylinder sidewall, through which the gear meshes with the gear ring. The protective cover covers the gear and is connected to the outer cylinder sidewall.

[0017] A method for detecting visual defects includes the following steps:

[0018] S1. The metal foil is released through the winding roller and conveyed around multiple guide rollers;

[0019] The S2 CMOS camera, in conjunction with the first illumination lamp, is used to perform the first inspection of the surface of the metal foil.

[0020] S3. If the CMOS camera does not detect defect data, the second detection mechanism, auxiliary mechanism, and marking mechanism are in a silent state. If the CMOS camera detects defect data, the second detection mechanism and auxiliary mechanism are triggered, and the conveying speed of the metal foil decreases. The infrared camera on the second bracket performs a second inspection on the area on the metal foil where defect data has been detected. The air pump operates and delivers gas to the air pipe. The gas is heated by the heating wire in the air pipe and then discharged through the air hole. Due to the inclined setting of the air hole, some of the heated gas will flow along the surface of the metal foil. When the heated gas flows under the infrared camera, the infrared camera can capture the flow of gas particles and determine whether there are defects on the surface of the metal foil by the stability of the gas particle flow.

[0021] S4. If the infrared camera captures unstable gas particle flow, it indicates that there is a defect on the surface of the metal foil, which triggers the marking mechanism. At the same time, based on the unstable state of the gas particle flow captured by the infrared camera, the type of surface defect is determined, and the coating to be used for marking is determined.

[0022] S5. Open the third control valve on the gas supply pipe to be sprayed with paint, the first control valve on the discharge pipe, and the fourth control valve on the connecting pipe. Some of the hot gas in the gas pipe enters the connecting channel and diffusion chamber through the connecting pipe, and then enters the inner tank through the gas supply pipe. As the gas in the inner tank increases, the gas pressure increases. The extrusion plate extrudes the paint under the action of the gas, causing the paint to be discharged through the discharge pipe. The guide rail moves the discharge pipe, and the drive mechanism adjusts the position of the discharge pipe so that the paint can be sprayed onto the defective areas of the metal foil. Open the fifth control valve on the branch pipe. Some of the gas in the gas supply pipe enters the gas channel through the branch pipe and flows in the gas channel. Since the gas carries heat, it can heat the side wall of the inner tank, thereby heating the paint and preventing the paint from solidifying. This allows the extrusion plate to better extrude the paint, facilitating the discharge of the paint. The gas in the gas channel is discharged through the injection hole and through hole to form an annular air curtain outside the discharge pipe, preventing splashing when the paint is sprayed out and ensuring the marking effect.

[0023] S6. After marking is completed, control the gas to prevent it from entering the inner tank, while allowing the gas to flow continuously in the air passage. At this time, the gas in the annular air curtain can dry the marked area, preventing the paint in the marked area from flowing or being wiped off later.

[0024] S7. After drying, the metal foil resumes its conveying speed and continues to be inspected for surface defects.

[0025] Compared with existing technologies, the visual defect detection system and method of the present invention have a dual detection structure to avoid missed or false detections of surface defects in metal foil, thereby ensuring the robustness of the visual inspection system. At the same time, it can also greatly improve the sensitivity of machine vision inspection in defect feedback, making it easier for operators to quickly and accurately determine the type of surface defects in metal foil to meet the high standards of subsequent industrial production. Attached Figure Description

[0026] To more clearly illustrate the technical solutions in the embodiments of the present invention or the prior art, the drawings used in the description of the embodiments or the prior art will be briefly introduced below. Obviously, the drawings described below are only some embodiments recorded in the present invention. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0027] Figure 1 This is a first-angle perspective view of a visual defect detection system according to an embodiment of the present invention;

[0028] Figure 2 This is a front view of a visual defect detection system according to an embodiment of the present invention;

[0029] Figure 3 This is a cross-sectional view of the marking mechanism in one embodiment of the present invention;

[0030] Figure 4 for Figure 3 Schematic diagram of the structure at point A in the middle;

[0031] Figure 5 for Figure 3 Schematic diagram of the structure at point B;

[0032] Figure 6 for Figure 3 Schematic diagram of the structure at point C;

[0033] Figure 7 This is a perspective view of the marking mechanism in one embodiment of the present invention;

[0034] Figure 8 This is a schematic diagram of the marking mechanism in one embodiment of the present invention;

[0035] Figure 9 for Figure 8 Schematic diagram of the structure at point D;

[0036] Figure 10 This is a perspective view of a storage tank according to one embodiment of the present invention;

[0037] Figure 11 This is a cross-sectional view of the storage tank in one embodiment of the present invention;

[0038] Figure 12 This is a perspective view of the upper cover in one embodiment of the present invention;

[0039] Figure 13 This is a second-angle perspective view of a visual defect detection system according to an embodiment of the present invention.

[0040] Explanation of key figure labels:

[0041] 1-Conveying mechanism, 101-Base, 102-Winding roller, 103-Guide roller, 2-First detection mechanism, 201-First support, 202-First lighting lamp, 3-Second detection mechanism, 301-Second support, 302-Second lighting lamp, 4-Auxiliary mechanism, 401-Air pipe, 4011-Air hole, 402-Connecting rod, 403-Air pump, 404-Heating wire, 5-Marking mechanism, 501-Guide rail, 502-Outer cylinder, 503-Inner cylinder, 504-Storage tank, 5 041-Outer tank, 5042-Inner tank, 5043-Discharge pipe, 5044-Coating, 5045-Guide rod, 5046-Extrusion plate, 5047-Air outlet pipe, 5048-Spray hole, 505-Conveying component, 5051-Connecting channel, 5052-Diffusion chamber, 506-Air supply pipe, 5061-Branch pipe, 507-Connecting pipe, 508-Top cover, 5081-Support ring, 509-Drive mechanism, 5091-Motor, 5092-Gear, 5093-Protective cover. Detailed Implementation

[0042] To enable those skilled in the art to better understand the technical solutions in this disclosure, the technical solutions in the embodiments of this disclosure will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of this disclosure, and not all embodiments. Based on the embodiments in this disclosure, all other embodiments obtained by those skilled in the art without creative effort should fall within the scope of protection of this disclosure.

[0043] like Figures 1 to 13As shown, a visual defect detection system according to an embodiment of the present invention includes a conveying mechanism 1, a pair of first detection mechanisms 2, a pair of second detection mechanisms 3, an auxiliary mechanism 4, and a marking mechanism 5. The pair of first detection mechanisms 2 are mounted on the conveying mechanism 1 and are respectively located on the upper and lower sides of a metal foil. The first detection mechanisms 2 are used to perform a first detection on the metal foil. The pair of second detection mechanisms 3 are respectively located on the upper and lower sides of the metal foil. Each second detection mechanism 3 includes a second support 301 and a second illumination lamp 302. The second support 301 is mounted on the conveying mechanism 1, and an infrared camera is mounted on the second support 301. The second illumination lamp 302 is mounted on the second support 301. When the first detection mechanism 2 detects a defect on the surface of the metal foil, it triggers the second detection mechanism 3 to perform a second detection on the surface of the metal foil. The auxiliary mechanism 4 includes an air pipe 401, a connecting rod 402, an air pump 403, and a heating wire 404. The air pipe 401 is connected to the second support 301 via the connecting rod 402. The air pipe 401 is located on the upper side of the metal foil, and its bottom has multiple evenly distributed air holes 4011. The air pump 403 is mounted on the air pipe 401, with its outlet located inside the air pipe 401. The heating wire 404 is also mounted inside the air pipe 401. The auxiliary mechanism 4 assists the second detection mechanism 3 in performing a second inspection of the metal foil. The marking mechanism 5 is mounted on the second support 301 and connected to the auxiliary mechanism 4. When the second detection mechanism 3 detects a defect on the surface of the metal foil, the marking mechanism 5 marks the surface of the metal foil.

[0044] The metal foil is conveyed by the conveying mechanism 1. When the metal foil passes through the first detection mechanism 2, the pair of first detection mechanisms 2 can respectively perform defect detection on the top and bottom surfaces of the metal foil to improve the efficiency of surface defect detection. When the first detection mechanism 2 detects a defect on the surface of the metal foil, it triggers the second detection mechanism 3 to perform a second detection on the surface of the metal foil.

[0045] During the second inspection of the metal foil by the second inspection unit 3, the air pump 403 operates and supplies gas to the air pipe 401. The gas is heated by the heating wire 404 within the air pipe 401 and then discharged through the air hole 4011. Due to the inclined arrangement of the air hole 4011, some of the heated gas flows along the surface of the metal foil. When the heated gas flows below the infrared camera, the infrared camera can capture the flow of gas particles and determine whether there are defects on the surface of the metal foil by analyzing the stability of the gas particle flow.

[0046] When the infrared camera captures unstable gas particle flow, it indicates a defect on the surface of the metal foil, thus triggering the marking mechanism 5. Simultaneously, based on the unstable state of the gas particle flow captured by the infrared camera, the type of surface defect is determined, and the appropriate marking is determined.

[0047] In this embodiment, the length of the air tube 401 is greater than the width of the metal foil, so that the gas discharged from the air hole 4011 can fully cover the metal foil, avoiding dead corners, and facilitating the infrared camera to perform a second inspection of the surface of the metal foil in conjunction with the heated gas.

[0048] Furthermore, the vent 4011 is inclined at the bottom of the air pipe 401, with an inclination angle of 15°-45°. Preferably, the inclination angle of the vent 4011 is 30°. Part of the gas discharged through the vent 4011 flows with the bonded metal foil. Because the gas carries heat and there is a temperature difference with the external environment, the infrared camera can capture the flow of gas particles and use the stability of the gas particle flow to indicate whether there are defects on the surface of the metal foil.

[0049] Meanwhile, if there is dust on the surface of the metal foil, the dust can be blown away by the gas, thus avoiding the influence of dust on the second inspection and improving the detection accuracy of the infrared camera.

[0050] like Figures 1 to 2 As shown, the conveying mechanism 1 includes a base 101, a winding roller 102, and a plurality of guide rollers 103. The winding roller 102 is mounted on the base 101 and is used to convey metal foil. The plurality of guide rollers 103 are mounted on the base 101, and the metal foil is conveyed around the plurality of guide rollers 103. The winding roller 102 is used to release the metal foil and is released around the plurality of guide rollers 103.

[0051] like Figure 13 As shown, the first detection mechanism 2 includes a first support 201 and a first illumination lamp 202. The first support 201 is mounted on the base 101, and a CMOS camera is mounted on the first support 201. The first illumination lamp 202 is mounted on the base 101 and is located on one side of the first support 201. Under the action of the first illumination lamp 202, the CMOS camera can perform a first detection on the surface of the metal foil.

[0052] The CMOS camera has a resolution of 2K and a sampling frequency of 30FPS. The first illumination lamp 202 is a linear LED lamp, and it uses forward illumination on both the top and bottom surfaces of the metal foil.

[0053] In this example, the marking mechanism 5 is only installed on the upper side of the metal foil. For marking defects on the lower surface of the metal foil, existing labeling methods can be used, such as the labeling device disclosed in patent publication number CN115829950A.

[0054] like Figures 1 to 13As shown, the marking mechanism 5 includes a guide rail 501, an outer cylinder 502, an inner cylinder 503, multiple storage tanks 504, a conveying component 505, multiple air supply pipes 506, a connecting pipe 507, a top cover 508, and a drive mechanism 509. Compared with commercially available labeling devices, the marking mechanism 5 in this application can mark according to different types of surface defects, with more detailed markings, and also facilitates subsequent label removal.

[0055] The guide rail 501 is mounted on the side wall of the second bracket 301. The outer cylinder 502 is located on one side of the second bracket 301 and can move relative to the infrared camera via the guide rail 501. The inner cylinder 503 is rotatably connected inside the outer cylinder 502 and is used to accommodate multiple storage tanks 504.

[0056] In addition, storage tanks 504 are installed inside the inner cylinder 503. The number of storage tanks 504 is set as needed; in this application, there are six storage tanks 504. A conveying component 505 is installed inside the inner cylinder 503, with multiple storage tanks 504 surrounding it. Multiple air supply pipes 506 are fixedly connected to the side wall of the conveying component 505 and correspond to the multiple storage tanks 504 respectively. The conveying component 505 is connected to the storage tanks 504 through the air supply pipes 506, and a third control valve is installed on the air supply pipes 506. A connecting pipe 507 is connected to the bottom of the outer cylinder 502. The conveying component 505 is connected to the air pipe 401 through the connecting pipe 507, and a fourth control valve is installed on the connecting pipe 507. When the fourth and third control valves are open, some of the hot air in the air pipe 401 enters the conveying component 505 through the connecting pipe 507, and then enters the storage tanks 504 through the air supply pipes 506.

[0057] Preferably, the connecting pipe 507 is a telescopic flexible hose, which will not be affected by the movement of the outer cylinder 502.

[0058] Specifically, the upper cover 508 is installed at the opening of the outer cylinder 502, and a support ring 5081 is connected to the upper cover 508. The support ring 5081 is in contact with multiple storage tanks 504 and is used to seal the opening of the outer cylinder 502 and to fix the storage tanks 504.

[0059] In addition, the drive mechanism 509 is installed on the side wall of the outer cylinder 502 to drive the inner cylinder 503 to rotate, thereby adjusting the position of the storage tank 504.

[0060] like Figures 1 to 13 As shown, the storage tank 504 includes an outer tank 5041, an inner tank 5042, a coating material 5044, an extrusion plate 5046, and an exhaust pipe 5047. The outer tank 5041 is fixedly connected to the bottom wall of the inner cylinder 503. The bottom of the outer tank 5041 is provided with a plurality of circumferentially evenly distributed spray holes 5048, and the bottom of the inner cylinder 503 is provided with through holes that match the spray holes 5048.

[0061] The inner tank 5042 is located inside the outer tank 5041. An air passage is formed between the outer wall of the inner tank 5042 and the inner wall of the outer tank 5041. A discharge pipe 5043 is connected to the inner tank 5042. One end of the discharge pipe 5043 passes through the outer tank 5041 and the inner cylinder 503. A first control valve is installed on the discharge pipe 5043. Multiple spray holes 5048 surround the discharge pipe 5043. The paint 5044 is located inside the discharge pipe 5043.

[0062] In addition, the extrusion plate 5046 is slidably disposed within the inner tank 5042 and in contact with the coating 5044. A pair of guide rods 5045 are also provided inside the inner tank 5042, and the extrusion plate 5046 is slidably disposed between the pair of guide rods 5045. An exhaust pipe 5047 is connected to the inner tank 5042, and the interior of the inner tank 5042 is connected to an air passage via the exhaust pipe 5047. A second control valve is installed on the exhaust pipe 5047.

[0063] When the fourth control valve on the connecting pipe 507 is opened, some of the hot gas in the gas pipe 401 enters the conveying component 505 through the connecting pipe 507, and then enters the inner tank 5042 through the gas delivery pipe 506. As the gas in the inner tank 5042 increases, the gas pressure increases, and the extrusion plate 5046 extrudes the coating 5044 under the action of the gas, causing the coating 5044 to be discharged through the discharge pipe 5043, thereby marking the defective areas of the metal foil.

[0064] If the gas flows within the air passage, its heat can heat the side wall of the inner tank 5042, thereby heating the coating 5044 and preventing it from solidifying, especially in winter. This allows the extrusion plate 5046 to better compress the coating 5044, facilitating its discharge. The gas in the air passage exits through the injection hole 5048 and the through-hole, forming an annular air curtain outside the discharge pipe 5043. This annular air curtain prevents the coating 5044 from splashing when sprayed through the discharge pipe 5043, ensuring a good marking effect. It also facilitates subsequent drying of the coating 5044 on the metal foil, preventing its flow.

[0065] In this embodiment, the surface defect types of the metal foil include particles, pinholes, blemishes, pits, and foreign matter. For example, if the surface defect is a particle, the coating 5044 is green; if the surface defect is a pinhole, the coating 5044 is red; if the surface defect is a blemish, the coating 5044 is yellow; if the surface defect is a pit, the coating 5044 is blue; and if the surface defect is a foreign matter, the coating 5044 is purple.

[0066] Preferably, the coating 5044 can be paint, which can be removed using paint remover when removing the markings later.

[0067] like Figures 3 to 6As shown, the conveying component 505 has an interconnected connecting channel 5051 and a diffusion chamber 5052. The diffusion chamber 5052 is connected to the interior of the inner tank 5042 via a gas supply pipe 506. When the fourth control valve on the connecting pipe 507 is opened, some gas in the gas pipe 401 enters the connecting channel 5051 and the diffusion chamber 5052 through the connecting pipe 507. If the third control valve on the gas supply pipe 506 is opened, gas can enter the inner tank 5042 through the gas supply pipe 506.

[0068] The gas supply pipe 506 has a branch pipe 5061 installed on its side wall. The branch pipe 5061 is located inside the gas passage and a fifth control valve is installed on the branch pipe 5061. When the fifth control valve is opened, some of the gas in the gas supply pipe 506 enters the gas passage through the branch pipe 5061, allowing the gas to flow within the gas passage. At the same time, when the gas in the gas passage is discharged through the injection hole 5048 and the through hole, it can also be used to form an annular air curtain outside the discharge pipe 5043.

[0069] like Figures 8 to 9 As shown, the drive mechanism 509 includes a motor 5091, a gear 5092, and a protective cover 5093. The motor 5091 is mounted on the side wall of the outer cylinder 502. The gear 5092 is connected to the output end of the motor 5091. A gear ring is provided on the side wall of the inner cylinder 503, and the gear 5092 passes through the side wall of the outer cylinder 502 and meshes with the gear ring. The protective cover 5093 covers the gear 5092 and is connected to the side wall of the outer cylinder 502. The protective cover 5093 protects the gear 5092.

[0070] When the motor 5091 is running, the motor 5091 causes the gear 5092 to rotate. Since the gear 5092 meshes with the gear ring, the gear 5092 can rotate the inner cylinder 503 to adjust the position of the discharge pipe 5043 so that the coating 5044 can be sprayed more effectively onto the defective areas of the metal foil.

[0071] A visual defect detection system also includes a processing system and a human-computer interaction system. The processing system receives, processes, and provides feedback on data transmitted from a CMOS camera and an infrared camera. The human-computer interaction system monitors the entire process of visual defect detection of metal foil and makes processing decisions: if the second detection agency 3 has no defect detection data, it sends abnormal data to the human-computer interaction system, indicating that the first detection agency 2 has made a false detection, requiring timely intervention and adjustment by staff. If the second detection agency 3 has defect detection data, it triggers the marking mechanism 5. Simultaneously, staff can also stop the continued transport of the metal foil through the human-computer interaction system to inspect the marked area.

[0072] A method for detecting visual defects includes the following steps:

[0073] S1. The metal foil is released through the winding roller 102 and conveyed around multiple guide rollers 103;

[0074] S2, the CMOS camera, in conjunction with the first illumination lamp 202, is used to perform the first inspection of the surface of the metal foil;

[0075] S3. If the CMOS camera does not detect defect data, the second detection mechanism 3, the auxiliary mechanism 4, and the marking mechanism 5 are in a silent state. If the CMOS camera detects defect data, the second detection mechanism 3 and the auxiliary mechanism 4 are triggered, and the conveying speed of the metal foil decreases. The infrared camera on the second bracket 301 can perform a second detection on the area on the metal foil where defect data has been detected. During the second detection, the air pump 403 runs and delivers gas to the air pipe 401. The gas is heated by the heating wire 404 in the air pipe 401 and then discharged through the air hole 4011. Since the air hole 4011 is tilted, some of the heated gas will flow along the surface of the metal foil. When the heated gas flows under the infrared camera, the infrared camera can capture the flow of gas particles and determine whether there are defects on the surface of the metal foil by the stability of the gas particle flow.

[0076] S4. If the infrared camera captures unstable gas particle flow, it indicates that there is a defect on the surface of the metal foil, which triggers the marking mechanism 5. At the same time, based on the unstable state of the gas particle flow captured by the infrared camera, the type of surface defect is determined, and the paint 5044 to be used for marking is determined. For example, if the surface defect is a particle, the paint 5044 is green; if the surface defect is a pinhole, the paint 5044 is red; if the surface defect is a blemish, the paint 5044 is yellow; if the surface defect is a pit, the paint 5044 is blue; if the surface defect is a foreign object, the paint 5044 is purple.

[0077] S5. Open the third control valve on the air supply pipe 506 and the first control valve on the discharge pipe 5043, as well as the fourth control valve on the connecting pipe 507, to which the paint 5044 needs to be sprayed. Some of the hot air in the air pipe 401 enters the connecting channel 5051 and the diffuser chamber 5052 through the connecting pipe 507, and then enters the inner tank 5042 through the air supply pipe 506. As the gas in the inner tank 5042 increases, the air pressure increases, and the extrusion plate 5046 extrudes the paint 5044 under the action of the gas, causing the paint 5044 to be discharged through the discharge pipe 5043. The guide rail 501 then moves the discharge pipe 5043, and the drive mechanism 509 adjusts the position of the discharge pipe 5043, allowing the paint 5044 to be sprayed... It can spray onto defective areas of metal foil; when the fifth control valve on the branch pipe 5061 is opened, some gas in the gas supply pipe 506 enters the air passage through the branch pipe 5061 and flows in the air passage. Since the gas carries heat, it can heat the side wall of the inner tank 5042, and thus heat the coating 5044 to prevent the coating 5044 from solidifying, especially in winter. This allows the extrusion plate 5046 to better extrude the coating 5044, facilitating the discharge of the coating 5044. The gas in the air passage is discharged through the spray hole 5048 and the through hole to form an annular air curtain outside the discharge pipe 5043, preventing the coating 5044 from splashing when it is sprayed through the discharge pipe 5043, and ensuring the marking effect.

[0078] S6. After marking is completed, control the gas to prevent it from entering the inner tank 5042, while allowing the gas to flow continuously in the air passage. At this time, the gas in the annular air curtain can dry the marking area, preventing the paint 5044 in the marking area from flowing or being wiped off later, thus ensuring the marking effect.

[0079] S7. After drying, the metal foil resumes its conveying speed and continues to be inspected for surface defects.

[0080] Those skilled in the art will understand that embodiments of the present invention can be provided as methods, systems, or computer program products. Therefore, the present invention can take the form of a completely hardware embodiment, a completely software embodiment, or an embodiment combining software and hardware aspects. Furthermore, the present invention can take the form of a computer program product implemented on one or more computer-usable storage media containing computer-usable program code, including but not limited to disk storage, CD-ROM, optical storage, etc.

[0081] This invention is described with reference to flowchart illustrations and / or block diagrams of methods, apparatus (systems), and computer program products according to embodiments of the invention. It will be understood that each block of the flowchart illustrations and / or block diagrams, and combinations of blocks in the flowchart illustrations and / or block diagrams, can be implemented by computer program instructions. These computer program instructions can be provided to a processor of a general-purpose computer, special-purpose computer, embedded processor, or other programmable data processing apparatus to produce a machine, such that the instructions, which execute via the processor of the computer or other programmable data processing apparatus, generate instructions for implementing the flowchart illustrations and / or block diagrams. Figure 1 One or more processes and / or boxes Figure 1 A device that provides the functions specified in one or more boxes.

[0082] These computer program instructions may also be stored in a computer-readable storage medium that can direct a computer or other programmable data processing device to function in a particular manner, such that the instructions stored in the computer-readable storage medium produce an article of manufacture including instruction means, which are implemented in a process Figure 1 One or more processes and / or boxes Figure 1 The function specified in one or more boxes.

[0083] These computer program instructions may also be loaded onto a computer or other programmable data processing equipment to cause a series of operational steps to be performed on the computer or other programmable equipment to produce a computer-implemented process, thereby providing instructions that execute on the computer or other programmable equipment for implementing the process. Figure 1 One or more processes and / or boxes Figure 1 The steps of the function specified in one or more boxes.

[0084] It will be apparent to those skilled in the art that this disclosure is not limited to the details of the exemplary embodiments described above, and that this disclosure can be implemented in other specific forms without departing from its spirit or essential characteristics. Therefore, the embodiments should be considered in all respects as exemplary and non-limiting, and the scope of this disclosure is defined by the appended claims rather than the foregoing description. Thus, all variations falling within the meaning and scope of equivalents of the claims are intended to be included within this disclosure. No reference numerals in the claims should be construed as limiting the scope of the claims.

[0085] Furthermore, it should be understood that although this specification describes embodiments, not every embodiment contains only one independent technical solution. This narrative style is merely for clarity. Those skilled in the art should consider the specification as a whole, and the technical solutions in each embodiment can also be appropriately combined to form other embodiments that can be understood by those skilled in the art.

Claims

1. A visual defect detection system, characterized by, include: Conveying mechanism; A pair of first detection mechanisms are installed on the conveying mechanism and are respectively located on the upper and lower sides of the metal foil. A pair of second detection mechanisms are respectively located on the upper and lower sides of the metal foil. The second detection mechanism includes a second bracket and a second lighting lamp. The second bracket is mounted on the conveying mechanism. An infrared camera is mounted on the second bracket. The second lighting lamp is mounted on the second bracket. When the first detection mechanism detects a defect on the surface of the metal foil, the second detection mechanism is triggered and performs a second detection on the surface of the metal foil. The auxiliary mechanism includes an air pipe, a connecting rod, an air pump, and a heating wire. The air pipe is connected to the second bracket via the connecting rod. The air pipe is located on the upper side of the metal foil. The bottom of the air pipe has multiple evenly distributed air holes. The air pump is installed on the air pipe, and its outlet is located inside the air pipe. The heating wire is installed inside the air pipe. A marking mechanism is mounted on the second support and connected to the auxiliary mechanism. When the second detection mechanism detects a defect on the surface of the metal foil, the marking mechanism is used to mark the surface of the metal foil. The marking mechanism includes a guide rail, an outer cylinder, an inner cylinder, and multiple storage tanks. The guide rail is mounted on the side wall of the second support, the outer cylinder is located on one side of the second support, and the outer cylinder can move relative to the infrared camera through the guide rail. The inner cylinder is rotatably connected to the outer cylinder, and the storage tanks are installed inside the inner cylinder. The storage tanks include: The outer tank is fixedly connected to the bottom wall of the inner cylinder. The bottom of the outer tank is provided with a plurality of circumferentially evenly distributed injection holes, and the bottom of the inner cylinder is provided with through holes that match the injection holes. An inner tank is located inside the outer tank. An air passage is formed between the outer wall of the inner tank and the inner wall of the outer tank. A discharge pipe is connected to the inner tank. One end of the discharge pipe passes through the outer tank and the inner cylinder. A first control valve is installed on the discharge pipe. Multiple injection holes surround the discharge pipe. The coating material is disposed inside the discharge pipe; An extrusion plate is slidably disposed inside the inner tank and in contact with the coating material. A pair of guide rods are also provided inside the inner tank, and the extrusion plate is slidably disposed between the pair of guide rods. An air outlet pipe is connected to the inner tank, and the interior of the inner tank is connected to the air passage through the air outlet pipe. A second control valve is installed on the air outlet pipe.

2. A visual defect detection system according to claim 1, wherein The conveying mechanism includes: Base; A winding roller, mounted on the base, is used to convey metal foil. Multiple guide rollers are mounted on the base, and the metal foil is conveyed by passing around the multiple guide rollers.

3. A visual defect detection system according to claim 2, wherein The first testing institution includes: A first bracket is mounted on the base, and a CMOS camera is mounted on the first bracket; The first lighting lamp is mounted on the base and located on one side of the first bracket.

4. The visual defect detection system of claim 1, wherein The length of the air tube is greater than the width of the metal foil, and the air hole is inclined at the bottom of the air tube with an inclination angle of 15°-45°.

5. The visual defect detection system of claim 1, wherein The marking mechanism further includes: A conveyor is installed inside the inner cylinder, and multiple storage tanks surround the conveyor. Multiple gas supply pipes are fixedly connected to the side wall of the conveying component and correspond to multiple storage tanks respectively. The conveying component is connected to the storage tanks through the gas supply pipes, and a third control valve is installed on the gas supply pipes. A connecting pipe is rotatably connected to the bottom of the outer cylinder. The conveying component is connected to the air pipe through the connecting pipe. A fourth control valve is installed on the connecting pipe. A top cover is provided at the opening of the outer cylinder, and a support ring is connected to the top cover. The support ring is in contact with the plurality of storage tanks. A drive mechanism, installed on the side wall of the outer cylinder, is used to drive the inner cylinder to rotate.

6. A visual defect detection system according to claim 5, wherein The conveying component is provided with interconnected channels and a diffusion cavity, and the diffusion cavity is connected to the interior of the inner tank through the gas delivery pipe.

7. A visual defect detection system according to claim 5, wherein A branch pipe is installed on the side wall of the gas supply pipe, the branch pipe is located inside the gas passage, and a fifth control valve is installed on the branch pipe.

8. The visual defect detection system of claim 5, wherein, The drive mechanism includes: The motor is installed on the side wall of the outer cylinder; A gear is connected to the output end of the motor. A toothed ring is provided on the side wall of the inner cylinder. The gear passes through the side wall of the outer cylinder and meshes with the toothed ring. A protective cover is provided to house the gear and is connected to the side wall of the outer cylinder.

9. A method for detecting visual defects, applied to the system for detecting visual defects according to any one of claims 1 to 8, characterized in that, Includes the following steps: S1. The metal foil is released through the winding roller and conveyed around multiple guide rollers; The S2 CMOS camera, in conjunction with the first illumination lamp, is used to perform the first inspection of the surface of the metal foil. S3. If the CMOS camera does not detect defect data, the second detection mechanism, auxiliary mechanism, and marking mechanism are in a silent state. If the CMOS camera detects defect data, the second detection mechanism and auxiliary mechanism are triggered, and the conveying speed of the metal foil decreases. The infrared camera on the second bracket performs a second inspection on the area on the metal foil where defect data has been detected. The air pump operates and delivers gas to the air pipe. The gas is heated by the heating wire in the air pipe and then discharged through the air hole. Due to the inclined setting of the air hole, some of the heated gas will flow along the surface of the metal foil. When the heated gas flows under the infrared camera, the infrared camera can capture the flow of gas particles and determine whether there are defects on the surface of the metal foil by the stability of the gas particle flow. S4. If the infrared camera captures unstable gas particle flow, it indicates that there is a defect on the surface of the metal foil, which triggers the marking mechanism. At the same time, based on the unstable state of the gas particle flow captured by the infrared camera, the type of surface defect is determined, and the coating to be used for marking is determined. S5. Open the third control valve on the gas supply pipe to be sprayed with paint, the first control valve on the discharge pipe, and the fourth control valve on the connecting pipe. Some of the hot gas in the gas pipe enters the connecting channel and diffusion chamber through the connecting pipe, and then enters the inner tank through the gas supply pipe. As the gas in the inner tank increases, the gas pressure increases. The extrusion plate extrudes the paint under the action of the gas, causing the paint to be discharged through the discharge pipe. The guide rail moves the discharge pipe, and the drive mechanism adjusts the position of the discharge pipe so that the paint can be sprayed onto the defective areas of the metal foil. Open the fifth control valve on the branch pipe. Some of the gas in the gas supply pipe enters the gas channel through the branch pipe and flows in the gas channel. Since the gas carries heat, it can heat the side wall of the inner tank, thereby heating the paint and preventing the paint from solidifying. This allows the extrusion plate to better extrude the paint, facilitating the discharge of the paint. The gas in the gas channel is discharged through the injection hole and through hole to form an annular air curtain outside the discharge pipe, preventing splashing when the paint is sprayed out and ensuring the marking effect. S6. After marking is completed, control the gas to prevent it from entering the inner tank, while allowing the gas to flow continuously in the air passage. At this time, the gas in the annular air curtain can dry the marked area, preventing the paint in the marked area from flowing or being wiped off later. S7. After drying, the metal foil resumes its conveying speed and continues to be inspected for surface defects.

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