Multidirectional automatic detection equipment and method for automobile lamp

Abstract

The invention discloses a multi-azimuth automatic detection device and method for an automobile lamp, and belongs to the technical field of automobile part detection. The equipment comprises an equipment main cabinet, a workpiece positioning module, a forward constraint mechanism and a multi-degree-of-freedom detection mechanism, and all the components are in communication connection with a control system; the workpiece positioning module realizes accurate positioning through a profiling supporting table and a backward locking mechanism, the forward restraining mechanism adopts a lever structure to restrain a workpiece from the front, and the multi-degree-of-freedom detection mechanism is distributed around a detection station and can acquire image data from different directions; according to the detection method, detection is completed through a full-automatic process of workpiece positioning, bidirectional fixing, multidirectional detection, data processing and reset workpiece taking, and the detection mechanisms can act synchronously or sequentially; the device can adapt to different types of vehicle lamps, realizes dead-corner-free detection, improves the detection precision and efficiency, and meets the flexible production requirements.

Description

Technical Field

[0001] This invention belongs to the field of automotive parts testing technology, and specifically relates to a multi-directional automatic testing device and method for automotive lights. Background Technology

[0002] As a key component of automobiles, headlights not only serve the function of illumination but are also important signaling devices. Their performance and appearance quality are directly related to driving safety and brand image.

[0003] In the field of automated inspection in the automotive manufacturing industry, there have been many explorations of automated inspection technology for vehicle lights, but these existing technical solutions still have obvious limitations and are difficult to meet the needs of modern flexible and high-speed production.

[0004] For example, a visual inspection device for surface defects of a car headlight cover uses a fixed ring light source and multiple industrial cameras arranged around the workpiece to acquire images of the headlight from different angles. The advantage of this solution is that the structure is relatively simple, but its inspection station is fixed and the position and viewing angle of the cameras cannot be dynamically adjusted.

[0005] For modern car headlights with complex shapes, especially those with deep cavities or highly reflective curved surfaces, a fixed camera angle is very likely to create blind spots, leading to missed detections.

[0006] In addition, the fixture of the equipment is a rigid structure designed for a single car light model, which lacks versatility. When switching between different car light models, the entire fixture needs to be replaced and all cameras need to be recalibrated, which seriously affects production efficiency.

[0007] For example, a robot-based vehicle headlight detection system uses a six-axis robot with a vision sensor at its end effector. The robot's flexible movement enables multi-angle detection of vehicle headlights, which to some extent solves the problem of blind spots in detection.

[0008] However, the detection process is sequential, and the robot needs to move to each predetermined point to take pictures. The entire detection cycle is long, making it difficult to apply to full inspection of high-speed production lines.

[0009] Meanwhile, a single robot cannot achieve simultaneous detection in multiple directions such as up, down, left, and right, resulting in a bottleneck in system efficiency. Furthermore, this paper does not propose an effective solution for the high stability and stress-free clamping problem of irregularly shaped vehicle lights during the detection process. The workpiece may experience slight movements during robot movement, affecting the detection accuracy.

[0010] In summary, existing automatic vehicle headlight detection equipment has the following main shortcomings:

[0011] 1. Positioning and clamping mechanisms are mostly specialized fixtures, which cannot be quickly adapted to mixed production lines with multiple varieties and small batches, resulting in long changeover times and high costs.

[0012] 2. Fixed multi-camera systems have blind spots, while single-robot sequential detection schemes are flexible but inefficient. Neither can achieve blind-spot-free, high-efficiency full-coverage detection of complex curved vehicle lights.

[0013] 3. For irregularly shaped workpieces, there is a lack of effective multi-directional collaborative constraint mechanisms, which may lead to poor repeatability of test results due to small displacements during the inspection process.

[0014] 4. Insufficient coordination among functional modules, or long and slow detection paths, failing to form an efficient and stable closed-loop detection process.

[0015] Therefore, there is an urgent need in this field for a new type of automatic detection equipment and method for automotive lights that can combine high flexibility, high efficiency, high precision, and full coverage detection to overcome the above-mentioned shortcomings. Summary of the Invention

[0016] To address the shortcomings of existing technologies, the present invention aims to propose a novel testing equipment solution. Specifically, the present invention aims to solve the core problems of existing technologies, such as poor equipment flexibility, incomplete testing coverage, unreliable fixation of irregularly shaped workpieces, and low system integration. To achieve the above objectives, the present invention provides a multi-directional automatic testing device for automotive lights. This device, through its unique mechanical structure and control system, achieves efficient, accurate, and comprehensive automated testing of automotive lights.

[0017] To achieve the above-mentioned objectives, the technical solution adopted by this invention is described in detail below:

[0018] The multi-directional automatic detection equipment for automotive headlights described in this invention comprises a main unit cabinet, a workpiece positioning module, a forward constraint mechanism, and a multi-degree-of-freedom detection mechanism.

[0019] The main equipment cabinet serves as the basic support and control system carrier for the entire machine, and a testing station is located on its top.

[0020] The workpiece positioning module is fixed on the inspection station and is the key to the precise positioning of this equipment. It innovatively adopts a frame structure raised by the module support frame, and sets an upper positioning plate and a contour support platform from top to bottom. The top contour of the contour support platform strictly follows the irregular geometry of the bottom of a car headlight to form a complementary concave-convex structure, which ensures the initial positioning accuracy and stability of the workpiece when it is placed. At the same time, the rear locking mechanism integrated at the rear of the module can move forward actively to clamp the workpiece from the rear.

[0021] To overcome the risk of workpiece displacement during the inspection process, this invention designs a unique forward constraint mechanism. This mechanism operates based on the lever principle and has an L-shaped constraint arm at one end. It can switch between two states, lifting and lowering, under the drive of the driving device. When in the lowering state, the L-shaped constraint arm acts like a movable bolt, effectively blocking the workpiece from the front.

[0022] This mechanism is usually provided in multiple units, spanning above the workpiece positioning module. Through coordinated action with the rear locking mechanism, it applies clamping force to the workpiece from both the front and rear directions, thereby achieving a firm constraint on the four sides of the irregular workpiece and ensuring the uniformity and stability of the detection benchmark.

[0023] To achieve comprehensive inspection without blind spots, this equipment is equipped with multiple multi-degree-of-freedom inspection mechanisms around the inspection station. Each inspection mechanism is an independent motion and inspection unit, consisting of a linear drive mechanism, a multi-degree-of-freedom posture adjustment bracket, and an image acquisition device at the end.

[0024] The linear drive mechanism is responsible for enabling the detection unit to move over a wide range on a macroscopic scale, while the multi-degree-of-freedom attitude adjustment bracket is used to finely adjust the posture and angle of the image acquisition device on a microscopic scale, so that it can accurately focus on each part to be tested on the complex curved surface of the headlight.

[0025] These testing mechanisms can be divided into upper, lower, and side testing mechanisms based on their spatial location. Under the unified coordination of the system controller, they can either operate synchronously to improve testing efficiency or be executed sequentially according to a predetermined order to avoid interference between mechanisms.

[0026] All of the above components are connected to the central control system in the main equipment cabinet, forming a highly integrated intelligent detection system. This control system is responsible for coordinating mechanical sequence actions, processing image data, analyzing detection results and generating reports, and finally displaying the results on the screen on the main equipment cabinet.

[0027] By implementing the technical solution proposed in this invention, the following significant beneficial effects can be achieved compared to the prior art:

[0028] 1. Based on the combination of contour support and adjustable constraint mechanism, it can quickly adapt to different models of car lights, greatly reducing production changeover time and meeting the needs of flexible production.

[0029] 2. Through the collaborative work of multi-degree-of-freedom and multi-directional detection mechanisms, a comprehensive scan of all surfaces of the vehicle headlights without blind spots is achieved, effectively avoiding missed detections. At the same time, the stable clamping scheme eliminates workpiece micro-movements, ensuring the repeatability and high precision of the detection data.

[0030] 3. From workpiece loading, automatic fixing, multi-directional detection to result output, the entire process is fully automated, reducing manual intervention. This not only improves production efficiency but also provides strong support for process optimization and quality traceability through integrated data analysis and processing capabilities.

[0031] In summary, this invention effectively fills the gaps in the prior art and provides the automotive lighting manufacturing industry with a highly flexible, efficient, and precise all-round automated testing solution. Attached Figure Description

[0032] Figure 1 This is a schematic diagram of the overall three-dimensional structure of the multi-directional automatic detection device for automotive headlights described in this invention;

[0033] Figure 2 This is a schematic diagram of the main structure of the present invention;

[0034] Figure 3 This is a detailed structural diagram of the workpiece positioning module described in this invention;

[0035] Figure 4 This is a detailed structural diagram of the forward constraint mechanism described in this invention;

[0036] Figure 5 This is a detailed structural schematic diagram of the multi-degree-of-freedom detection mechanism described in this invention;

[0037] Figure 6 This is a flowchart of the detection method of the present invention;

[0038] In the figure, 1. workpiece positioning module, 101. module support frame, 102. upper positioning plate, 103. contour support platform, 104. rear locking mechanism, 2. forward constraint mechanism, 201. adjusting bolt, 202. L-shaped constraint arm, 3. multi-degree-of-freedom detection mechanism, 301. multi-degree-of-freedom posture adjustment bracket, 302. linear drive mechanism, 303. image acquisition device, 4. workpiece to be tested, 5. equipment main cabinet. Detailed Implementation

[0039] To enhance understanding of the present invention, the invention will be further described in detail below with reference to embodiments and accompanying drawings. These embodiments are only for explaining the invention and do not constitute a limitation on the scope of protection of the invention.

[0040] In the description of this invention, it should be understood that the terms front, back, up, down, left, right, etc., indicate the orientation or positional relationship based on the orientation or positional relationship shown in the accompanying drawings. They are only for the convenience of describing this invention and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation. Therefore, they should not be construed as limiting this invention.

[0041] Workpiece positioning module 1, module support frame 101, upper positioning plate 102, contour support platform 103, rear locking mechanism 104, forward constraint mechanism 2, adjusting bolt 201, L-shaped constraint arm 202, multi-degree-of-freedom detection mechanism 3, multi-degree-of-freedom posture adjustment bracket 301, linear drive mechanism 302, image acquisition device 303, workpiece to be tested 4, equipment main cabinet 5.

[0042] like Figure 1 , 2 As shown in Figures 3, 4, and 5, this embodiment details the specific structure of the multi-directional automatic detection device for automotive headlights described in this invention.

[0043] The main equipment cabinet 5 is a box-type structure. Its internal space is used to install and accommodate the core components of the control system, such as industrial computers, PLCs, power modules, motion control cards, etc. Its outer surface integrates operation buttons, emergency stop switches, and displays for displaying detection data and equipment status, forming a complete human-machine interface.

[0044] The top of the main equipment cabinet 5 is precision machined to form a flat testing station, providing a stable installation foundation for all the upper mechanisms.

[0045] The workpiece positioning module 1 is fixed to the inspection station by the module support frame 101 at its bottom.

[0046] The contour support platform 103 is fastened to the module support frame 101 by bolts.

[0047] The contour support platform 103 is a replaceable design. By replacing the contour support platform with different contours, it can be quickly adapted to different models of car lights, thereby realizing flexible production of the equipment. As a preferred embodiment, the car lights of the present invention are particularly applicable to, but not limited to, car taillights, because car taillights usually have more complex curved surfaces and installation structures.

[0048] The upper positioning plate 102 is supported above the contour support platform 103 by a column, and has holes and grooves that match the positioning pins or specific contours of the upper part of the headlight.

[0049] When the operator places the headlight on the module, the bottom contour of the headlight first fits against the complementary surface of the contour support 103 to achieve primary positioning. At the same time, the positioning pin or specific structure on the upper part of the headlight is embedded in the corresponding holes and grooves of the upper positioning plate 102 to achieve auxiliary positioning and angular constraint, together completing the initial and precise positioning.

[0050] The rear locking mechanism 104 is installed at the rear end of the module. It can use a pneumatic or electric push cylinder as a power source and is equipped with a flexible clamping head at the end. After receiving a control signal, the push cylinder extends and the clamping head smoothly presses against the rear of the headlight, completing the final step of positioning.

[0051] The forward constraint mechanism 2 is movably mounted on the main equipment cabinet 5 via its own mounting base and is located directly above the workpiece positioning module 1. Its core is a lever structure, and the fulcrum of the lever is an adjustable hinge.

[0052] The L-shaped constraint arm 202 is fixed to one end of the lever. The length of its vertical section is precisely calculated to ensure that it can effectively block the front of the headlights when it is lowered. The other end of the lever is connected to a drive device. By extending and retracting the drive device, the L-shaped constraint arm 202 can be switched between the raised and lowered states.

[0053] The adjusting bolt 201 is screwed into the threaded hole on the lever body, and its end abuts against a fixed base. By rotating the adjusting bolt 201, the initial angle of the lever and its final position after falling can be finely adjusted, thereby precisely controlling the constraint force applied by the L-shaped constraint arm 202 to the vehicle light, avoiding damage to the product due to excessive tightness or instability due to excessive looseness.

[0054] The multi-degree-of-freedom detection mechanism 3 is provided in multiple ways, specifically including an upper detection mechanism located directly above the workpiece positioning module 1, a lower detection mechanism located directly below it, and side detection mechanisms distributed on the left and right sides.

[0055] Each testing organization includes:

[0056] The linear drive mechanism 302, which serves as a macroscopic movement unit, may be, for example, a precision ball screw slide or synchronous belt module driven by a servo motor.

[0057] The multi-degree-of-freedom attitude adjustment bracket 301 is installed at the movable end of the slide, such as a three-degree-of-freedom parallel mechanism or a robotic arm with multiple joints.

[0058] And an image acquisition device 303 fixed to the end of the attitude adjustment bracket. The image acquisition device 303 is preferably a high-resolution industrial CCD or CMOS camera, which can be equipped with lenses of different focal lengths and auxiliary light sources according to the detection requirements.

[0059] The rear locking mechanism 104 of the workpiece positioning module 1, the driving device of the forward constraint mechanism 2, the linear driving mechanism 302 of the multi-degree-of-freedom detection mechanism 3, and the attitude adjustment bracket 301 are all connected to the control system in the main equipment cabinet 5 via cables and are subject to its unified scheduling.

[0060] refer to Figure 6As shown in claims 7, 8, 9, and 10, this embodiment details the detection method based on the above-described equipment.

[0061] Step S1: The operator places the car taillight, which is the workpiece to be tested 4, into the workpiece positioning module 1 through the front opening. The bottom of the taillight fits tightly with the outline of the contour support platform 103, and the upper structure is also engaged in the corresponding position of the upper positioning plate 102, thus completing the initial positioning.

[0062] Step S2: The control system issues a command to drive the drive device of the forward constraint mechanism 2, so that the lever drives the L-shaped constraint arm 202 from the raised state to the lowered state, just like several door bolts falling down, blocking the car taillights from the front.

[0063] Step S3: The control system activates the rear locking mechanism 104 of the workpiece positioning module 1. Its push cylinder extends smoothly and presses against the car taillight from the rear. At this time, the car taillight is constrained in the vertical direction by the contour support platform 103 and the upper positioning plate 102, constrained in the front-back direction by multiple forward constraint mechanisms 2, and pressed against the rear by the rear locking mechanism 104, thus achieving a firm fixation on all four sides and laying the foundation for high-precision detection.

[0064] Step S4: After confirming that the workpiece is securely fixed, the control system coordinates the command to activate all multi-degree-of-freedom detection mechanisms 3. Regarding the operation mode of this step, the present invention provides two preferred implementation schemes:

[0065] The first approach involves controlling all multi-degree-of-freedom detection mechanisms 3 to move synchronously. The upper, lower, left, and right detection mechanisms simultaneously drive their linear drive mechanisms 302 and posture adjustment brackets 301, causing their respective image acquisition units 303 to quickly move to preset detection positions close to the surfaces of the car taillights and simultaneously trigger image capture. This approach can minimize the detection cycle and improve overall efficiency.

[0066] The second approach involves controlling multiple multi-degree-of-freedom detection mechanisms 3 to perform actions sequentially in a predetermined order. For example, the control system can first control the upper detection mechanism to move and take a picture, then reset it after completion, and then control the left detection mechanism to move, and so on. This mode can effectively avoid motion interference that may occur between multiple large mechanisms in a limited space, and is especially suitable for scenarios with particularly compact structures or complex detection trajectories.

[0067] Step S5: The data collected by all image acquisition devices 303 is transmitted back to the control system in the main equipment cabinet 5 in real time. The system uses the built-in image processing algorithm to analyze the data and compare it with the standard template, and finally generates a test report containing a qualified or unqualified conclusion and detailed data.

[0068] Step S6: After the inspection is completed, the control system issues reset commands in sequence: First, it controls all multi-degree-of-freedom inspection mechanisms 3 to drive their image acquisition units 303 to move to a safe initial position; then, it controls the rearward locking mechanism 104 to retract and release the clamping on the workpiece; finally, it controls the forward constraint mechanism 2 to lift up; at this time, the operator can conveniently remove the inspected car taillight from the front of the equipment.

[0069] Throughout the process, the test results generated in step S5 will be displayed on the screen of the equipment host cabinet 5 in real time, allowing the operator to view them immediately and choose to save or print the report.

[0070] Implementation example:

[0071] Suppose that the equipment described in this invention is deployed at the final inspection station of a certain automobile taillight production line. When a left rear taillight of "XYZ model" arrives at the station with the conveyor belt, a robot or operator places it into the workpiece positioning module 1 that has been customized for this model.

[0072] The equipment operates fully automatically, completing the entire process of "fixing - multi-directional image acquisition - result judgment - reset" within 30 seconds.

[0073] The inspection report showed that there was a minor scratch on one side of the taillight, which the system judged as unqualified and recorded the result in the database.

[0074] Meanwhile, since the next product to be inspected was the right rear taillight of "model ABC", the staff only needed to switch the preset program in the control system, and the equipment could be ready for the next inspection without replacing any hardware, fully demonstrating its high flexibility and high efficiency.

[0075] The above description is only a preferred embodiment of the present invention and is not intended to limit the present invention. Any modifications, equivalent substitutions, improvements, etc., made within the spirit and principles of the present invention should be included within the protection scope of the present invention.

Claims

1. A multi-directional automatic detection device for automotive lights, characterized in that, include: Equipment main cabinet, workpiece positioning module, forward constraint mechanism and multi-degree-of-freedom detection mechanism; The main equipment cabinet has a testing station on its top. The workpiece positioning module is set on the detection station and is configured to carry and position the workpiece to be tested. The forward constraint mechanism is movably mounted on the main equipment cabinet and located above the workpiece positioning module, and is configured to constrain the workpiece to be measured from the front. Multiple multi-degree-of-freedom detection mechanisms are provided and distributed around the detection station, and are configured to detect the workpiece to be tested from different directions. The workpiece positioning module, forward constraint mechanism, and multi-degree-of-freedom detection mechanism are all communicatively connected to the control system located in the main equipment cabinet.

2. The multi-directional automatic detection device for automotive lights according to claim 1, characterized in that, The workpiece positioning module includes: a module support frame, a contour support platform, an upper positioning plate, and a rear locking mechanism; The module support frame is fixed to the top of the equipment main cabinet; The contouring support platform is mounted on the module support frame, and its top profile matches the bottom shape of the workpiece to be tested. The upper positioning plate is disposed above the contour support platform, and it is provided with positioning holes or concave and convex structures that cooperate with the upper structure of the workpiece to be tested. The rearward locking mechanism is located behind the workpiece positioning module and is configured to press against the workpiece to be tested from the rear.

3. The multi-directional automatic detection device for automotive lights according to claim 2, characterized in that, The forward constraint mechanism is a lever structure, with an L-shaped constraint arm at one end and the other end connected to the drive device; The forward restraint mechanism has a raised state and a lowered state; When in the falling state, the L-shaped constraint arm blocks the workpiece to be tested from the front.

4. The multi-directional automatic detection device for automotive lights according to claim 3, characterized in that, The lever structure is equipped with an adjusting bolt, which is used to adjust the fulcrum position or constraint force of the lever.

5. The multi-directional automatic detection device for automotive lights according to claim 1, characterized in that, The multi-degree-of-freedom detection mechanism includes: a linear drive mechanism, a multi-degree-of-freedom attitude adjustment bracket, and an image acquisition device; The linear drive mechanism is mounted on the main equipment cabinet; The multi-degree-of-freedom attitude adjustment bracket is installed at the movable end of the linear drive mechanism; The image acquisition device is fixed to the end of the multi-degree-of-freedom attitude adjustment bracket.

6. The multi-directional automatic detection device for automotive lights according to claim 1, characterized in that, The plurality of multi-degree-of-freedom detection mechanisms include at least an upper detection mechanism located above the workpiece positioning module, a lower detection mechanism located below it, and a side detection mechanism located to the side.

7. A detection method based on the multi-directional automatic detection device for automotive headlights according to any one of claims 1 to 6, characterized in that, Includes the following steps: S1: Place the workpiece to be tested on the workpiece positioning module for initial positioning; S2: Control the forward constraint mechanism to constrain the workpiece from the front; S3: Control the rear locking mechanism of the workpiece positioning module to press the workpiece to be tested from the rear, so that the workpiece to be tested is firmly fixed. S4: Control the movement of multiple multi-degree-of-freedom detection mechanisms, so that the image acquisition devices on them move from different directions to preset positions close to the workpiece to be tested, and acquire image data; S5: Transmit the acquired image data to the control system for processing and analysis to generate detection results; S6: Control the multi-degree-of-freedom detection mechanism to reset, and then control the rear locking mechanism and the forward constraint mechanism to release the fixation of the workpiece to be tested.

8. The detection method according to claim 7, characterized in that, In step S4, the actions of multiple multi-degree-of-freedom detection mechanisms are controlled synchronously.

9. The detection method according to claim 7, characterized in that, In step S4, the actions of the multiple multi-degree-of-freedom detection mechanisms are controlled sequentially according to a predetermined order.

10. The detection method according to claim 7, characterized in that, In step S5, the detection results are displayed visually on a display screen installed on the equipment main unit cabinet.

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