Surface defect visual inspection device for metal product processing

Abstract

The invention discloses a surface defect visual inspection device for metal product processing, and relates to the technical field of visual inspection appliances. The function of orderly arranging metal products is achieved through cooperation of the first inductor and the second inductor; the allowable fluctuation range of the running speed of the conveying belt is judged through the analysis module, so that the system can strictly guarantee the image definition and the detection processing time while pursuing high efficiency, it is ensured that each product can be detected under the qualified condition, and image blurring, missing detection and false detection caused by blind pursuing of productivity are avoided; when the speed deviates from the range, the system not only can trigger an alarm, but also can accurately diagnose a specific reason and give a specific correction direction, so that the defects of difficulty in troubleshooting and long downtime when the traditional equipment breaks down or the detection quality is reduced are avoided; the minimum stable speed is introduced and calculated, and the stick-slip phenomenon generated when the conveying belt runs at a low speed is avoided.

Description

Technical Field

[0001] This invention relates to the field of visual inspection equipment technology, and in particular to a visual inspection device for surface defects in metal product processing. Background Technology

[0002] In the metal products processing industry, the surface quality of products plays a crucial role in their performance, reliability, and market competitiveness. Defects on the surface of metal products, such as scratches, cracks, pores, and inclusions, not only affect the appearance of the product but may also cause safety hazards during subsequent use, leading to premature product failure and, in severe cases, even threatening the lives and property of users. For example, in the aerospace field, tiny cracks on the surface of metal parts may rapidly propagate under high stress and high fatigue environments, causing catastrophic accidents; in automobile manufacturing, surface defects in the body steel panels can affect the coating effect and corrosion resistance, reducing the quality and service life of the automobile.

[0003] In the metal product processing, surface defect detection is a crucial step in ensuring product quality. Traditional detection methods have many drawbacks, significantly impacting efficiency and accuracy. Traditional methods rely heavily on manual operation, requiring workers to carefully observe the surface of metal products with the naked eye to determine the presence of defects such as scratches, cracks, and pinholes. However, this method is not only labor-intensive and time-consuming, but the results are also susceptible to factors such as worker experience, eyesight, and work condition, easily leading to missed or false detections. For example, after prolonged work, worker visual fatigue can reduce sensitivity to subtle defects, allowing substandard products to enter subsequent production stages. Furthermore, manual material handling... However, due to a lack of precise control, it is difficult to maintain a consistent material spacing. When the material spacing is too small, the vision camera is easily interfered with by adjacent materials during the shooting process, resulting in blurred images and affecting the clarity and accuracy of the detection. On the other hand, if the material spacing is too large, it will increase the detection time and reduce the overall detection efficiency. At the same time, the existing detection devices also have shortcomings in terms of light source. The clarity of the vision camera is highly dependent on the stability and uniformity of the light source. Changes in external light, such as fluctuations in the intensity of natural light and flickering of lights in the workshop, will have an adverse effect on the detection results. Under unstable lighting conditions, the images captured by the camera may have problems such as uneven brightness and shadows, making it difficult to accurately identify surface defects.

[0004] Therefore, the above-mentioned problems need to be addressed and improved. Summary of the Invention

[0005] The purpose of this invention is to address the shortcomings of existing technologies by proposing a visual inspection device for surface defects in metal product processing.

[0006] To achieve the above objectives, the present invention adopts the following technical solution: a surface defect visual inspection device for metal product processing, comprising a first conveyor belt, an adjustment mechanism installed on the first conveyor belt, and an inspection box installed at the rear end of the first conveyor belt. A third conveyor belt and an inspection mechanism are installed inside the inspection box. The inspection mechanism is located at the upper end of the third conveyor belt. A second conveyor belt is installed at the rear end of the inspection box. A material distribution mechanism is installed on the second conveyor belt, and a first discharge port is installed at the rear end of the second conveyor belt.

[0007] The testing chamber is equipped with testing components, including an analysis module;

[0008] The analysis module receives the material and conveying parameters acquired during the conveying process and performs data preprocessing. Based on the preprocessed data, it analyzes whether the spacing between adjacent materials needs to be adjusted. If so, it generates a spacing adjustment signal and transmits the signal to the adjustment module. It analyzes whether the adjustment process will affect the detection accuracy and determines the range of fluctuation in the conveyor belt's running speed. If the running speed is outside the range of fluctuation, it issues an alarm to notify the staff.

[0009] Preferably, the analysis module performs the following steps to analyze the spacing between adjacent materials:

[0010] M1: Based on the maximum lateral width KD of the material wl Detection of safety redundancy width KD aq Conveyor belt speed V cs Total time T for single material testing jc And the effective field of view (KD) of a single shot by the camera sy Determine the minimum safe distance D min and the maximum reasonable spacing D max And set the fluctuation range FW2;

[0011] M2: When D sj Within the FW2 range, the spacing is determined to be acceptable; otherwise, the spacing is determined to be abnormal, a spacing adjustment signal is generated, and the spacing adjustment signal is transmitted to the adjustment module.

[0012] Preferably, the analysis module performs the following steps to analyze abnormal running speed:

[0013] N1: Considering image acquisition clarity, system capacity, detection time and spacing, determine the fluctuation range FW3 of the conveyor belt speed. If the conveyor belt speed V cs Within the FW3 range, it is determined that it will not affect the detection accuracy;

[0014] N2: If the conveyor belt speed V cs Not within the scope of FW3, for V csTo obtain the specific value of V, if V cs If the value exceeds the upper limit of range FW3, the judgment speed is too fast; if the upper limit is... If the detection time is deemed insufficient, an alarm will sound via the buzzer module of the detection component, and a "Detection cycle time exceeded" alarm will be displayed on the detection box's screen, prompting staff to optimize the algorithm and reduce the Ttime. jc Or reassess the minimum safe distance D min If the upper limit is If the image is deemed blurry, the buzzer module of the detection component will sound an alarm, and the display screen of the detection box will show an alarm stating "Image acquisition conditions not met," prompting the staff to extend the T... bg Improve the lighting or use a higher-performance camera;

[0015] N3: If V cs If the value is less than the lower limit of range FW3, the determination speed is too slow; if the lower limit is... If the decision is made, it indicates that the current speed cannot complete the production task. An alarm will sound via the buzzer module of the detection component, and a "Production Capacity Not Meeting Standard" warning will be displayed on the detection box's screen, prompting staff to check the feeding system for smooth operation. If the lower limit is V... min If the system is deemed unable to operate stably at such a low speed, the detection component will issue a buzzer warning and display a "Running speed below stable limit" alarm on the detection box's display screen, indicating to staff that there may be a mechanical or control-related malfunction risk.

[0016] Preferably, the adjustment mechanism includes a first sensor installed on both sides of the first conveyor belt, a second sensor installed at the rear end of the first sensor, and an L-shaped baffle between the first and second sensors. A DC motor is installed between the first and second sensors, and a bidirectional lead screw is installed at the output end of the DC motor via a coupling. A first geared motor for driving the first conveyor belt is installed on one side of the first conveyor belt. Preferably, two moving blocks are threaded onto the bidirectional lead screw. A connecting rod is hinged to one end of each moving block. The two connecting rods are hinged together at their centers, and a sliding plate is hinged to the other end of each connecting rod. The two sliding plates are slidably connected to the baffle, and a pressure sensor is installed at one end of the baffle.

[0017] Preferably, the detection mechanism includes a light shield installed inside the detection box, a first camera and a fill light are installed on the top of the light shield, the fill light is located directly below the first camera, and four second cameras and two fill lights are installed at equal intervals on the inner wall of the light shield.

[0018] Preferably, the material distribution mechanism includes a mounting plate installed on one side of the second conveyor belt and a second discharge port installed on the other end of the second conveyor belt. An electric push rod is mounted on the mounting plate, and a push plate is mounted on the output end of the electric push rod.

[0019] Preferably, two guide rods are fixed to one side of the push plate, the other end of the guide rods passes through the mounting plate, and a compression spring is installed between the mounting plate and the push plate. The compression spring is sleeved on the outside of the guide rods, and a second reduction motor for driving the second conveyor belt is installed on one side of the second conveyor belt.

[0020] Compared with the prior art, the beneficial effects of the present invention are:

[0021] 1. The combination of the first and second sensors facilitates real-time monitoring of the spacing between metal products, controlling the opening and closing of the adjustment mechanism, thereby enabling the orderly arrangement of metal products. Furthermore, the combination of a DC motor and a bidirectional lead screw facilitates the driving of the moving block to move the connecting rod, improving the accuracy of the baffle spacing adjustment and preventing damage to the inspected parts caused by the baffles. The combination of multiple cameras, supplementary lights, and supplementary apertures avoids interference from external light, enabling comprehensive and accurate detection of surface defects in metal products. Finally, the combination of an electric push rod and a push plate smoothly pushes defective metal products to the second discharge port, achieving rapid material separation. Ultimately, this solves the problems of inconsistent material spacing leading to inconsistent detection time and the visual camera's clarity being affected by light sources in existing devices with manual material feeding.

[0022] 2. By analyzing the allowable fluctuation range of the conveyor belt speed, the system can strictly guarantee image clarity and detection processing time while pursuing high efficiency. This ensures that every product can be inspected under qualified conditions, avoiding image blurring, missed detections, and false detections caused by blindly pursuing production capacity. When the speed deviates from this range, the system can not only trigger an alarm but also accurately diagnose the specific cause and provide specific correction directions. This avoids the drawbacks of traditional equipment, such as difficult troubleshooting and long downtime when malfunctions or decreased detection quality occur. The introduction and calculation of the minimum stable speed avoids the "stick-slip" phenomenon that occurs when the conveyor belt runs at low speed. This phenomenon not only leads to inaccurate material positioning and affects the spacing control accuracy but also accelerates the wear of transmission components. Attached Figure Description

[0023] The accompanying drawings, which are included to provide a further understanding of the invention and form part of this application, illustrate exemplary embodiments of the invention and, together with their description, serve to explain the invention and do not constitute an undue limitation thereof. In the drawings:

[0024] Figure 1 This is a schematic diagram of the overall appearance of the device proposed in this invention;

[0025] Figure 2 This is a rear view schematic diagram of the overall appearance of the device proposed in this invention;

[0026] Figure 3 This is a top view schematic diagram of the first conveyor belt structure proposed in this invention;

[0027] Figure 4 This is a schematic diagram of the detection mechanism structure proposed in this invention;

[0028] Figure 5 The present invention proposes Figure 1 Enlarged schematic diagram of the structure at part A in the middle;

[0029] Figure 6 The present invention proposes Figure 3 Enlarged schematic diagram of the structure at part A in the middle;

[0030] Figure 7 This is a flowchart of the system proposed in this invention.

[0031] In the diagram, the following components are listed: 1. First conveyor belt; 2. Detection box; 3. Second conveyor belt; 4. Third conveyor belt; 5. First discharge port; 6. First sensor; 7. Second sensor; 8. First geared motor; 9. DC motor; 10. Bidirectional lead screw; 11. Moving block; 12. Connecting rod; 13. Baffle; 14. Slide plate; 15. Pressure sensor; 16. Light shield; 17. First camera; 18. Aperture ring; 19. Second camera; 20. Fill light; 21. Mounting plate; 22. Electric actuator; 23. Push plate; 24. Compression spring; 25. Second discharge port; 26. Second geared motor. Detailed Implementation

[0032] The technical solutions of the present invention will be clearly and completely described below with reference to the accompanying drawings of the embodiments of the present invention. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments.

[0033] Example 1: See Figures 1 to 6The present invention discloses a surface defect visual inspection device for metal product processing, comprising a first conveyor belt 1, which works in conjunction with a second conveyor belt 3 to move the inspection pieces, and the first and second conveyor belts 1 and 3 rotate at the same speed; an adjustment mechanism is installed on the first conveyor belt 1 to adjust the distance between two adjacent inspection pieces, preventing uninspected and inspected pieces from accumulating due to insufficient distance; an inspection box 2 is installed at the rear end of the first conveyor belt 1, which works in conjunction with a light shield 16 to create a relatively dark environment; a third conveyor belt 4 and an inspection mechanism are installed inside the inspection box 2, and the rotation speed of the third conveyor belt 4 is less than that of the first and second conveyor belts 1 and 3. The belt rotates at 3 speeds to improve image clarity during inspection. The inspection mechanism is located on the upper end of the third conveyor belt 4. A second conveyor belt 3 is installed at the rear end of the inspection box 2. A material separating mechanism is installed on the second conveyor belt 3 to separate qualified and unqualified parts. Qualified parts are discharged through the first discharge port 5, and unqualified parts are discharged through the second discharge port 25. The first discharge port 5 is installed at the rear end of the second conveyor belt 3. The adjustment mechanism includes first sensors 6 installed on both sides of the first conveyor belt 1, second sensors 7 installed at the rear end of the first sensors 6, and an L-shaped baffle 13 located between the first sensors 6 and the second sensors 7. The first sensors 6 and the second sensors 7 facilitate the detection of whether an inspection piece has passed through, and work in conjunction with the baffle 13. When the first sensor 6 at the front end and the second sensor 7 at the rear end detect the passage of a detection element, the baffles 13 on both sides move inward to block subsequent detection elements from moving forward. If some detection elements are too close, the baffles 13 can also clamp them. A DC motor 9 is installed between the first sensor 6 and the second sensor 7. The DC motor 9 facilitates the connection to and drive of the bidirectional lead screw 10. The output end of the DC motor 9 is connected to the bidirectional lead screw 10 via a coupling. When the bidirectional lead screw 10 rotates, it drives two moving blocks 11 to move inward. At the same time, the two connecting rods 12, with the center as the hinge point, cooperate with the sliding connection of the slide plate 14 and the baffle 13 to drive the baffle 13 to move inward. And the first conveyor... A first geared motor 8 for driving the first conveyor belt 1 is installed on one side of the belt 1. Two moving blocks 11 are threadedly connected to the bidirectional lead screw 10. A connecting rod 12 is hinged to one end of the moving block 11. The two connecting rods 12 are hinged to each other at their center, and a sliding plate 14 is hinged to the other end of the two connecting rods 12. The two sliding plates 14 are slidably connected to the baffle 13. A pressure sensor 15 is installed on one end of the baffle 13. The baffle 13 facilitates blocking the movement of the detection piece or clamping adjacent detection pieces that are close to each other. The pressure sensor 15 facilitates sensing that the baffle 13 has clamped the detection piece. The pressure sensor 15 transmits a signal to the DC motor 9, and the DC motor 9 immediately stops running to prevent the baffle 13 from continuing to clamp the detection piece and leaving defects on the surface of the detection piece.

[0034] In this invention, the detection mechanism includes a light shield 16 installed inside the detection box 2. A first camera 17 and a supplementary aperture 18 are mounted on the top of the light shield 16. The first camera 17 and the second camera 19 facilitate all-round photography of the test piece from all sides and above to compare and detect whether the test piece is qualified. The supplementary aperture 18 is located directly below the first camera 17, and four second cameras 19 and two supplementary lights 20 are equidistantly installed on the inner wall of the light shield 16. The supplementary aperture 18 facilitates the use of the supplementary lights 20 to enhance the light source around the first camera 17 and the second camera 19, thereby improving the clarity of the photos taken by the cameras. The material distribution mechanism includes a mounting plate 21 installed on one side of the second conveyor belt 3 and a second discharge plate installed on the other end of the second conveyor belt 3. The second discharge port 25 is connected to the mounting plate 21 for easy fixing of the electric push rod 22 and the guide rod. The electric push rod 22 is mounted on the mounting plate 21, which facilitates the movement of the push plate 23 and simultaneously stretches the compression spring 24. The push plate 23 is mounted on the output end of the electric push rod 22. Two guide rods are fixed to one side of the push plate 23, and the other end of the guide rods passes through the mounting plate 21. A compression spring 24 is installed between the mounting plate 21 and the push plate 23. The compression spring 24 helps to slow down the movement speed of the push plate 23 and avoids secondary damage caused by the collision between the detection piece and the second discharge port 25 due to high speed. The compression spring 24 is sleeved on the outside of the guide rod, and a second geared motor 26 for driving the second conveyor belt 3 is installed on one side of the second conveyor belt 3.

[0035] In this invention, the first sensor 6 and the second sensor 7 are optoNCDT5500 laser sensors, the geared motor is SR45-1500W, and the first camera 17 and the second camera 19 are MV-SUA1000C.

[0036] Working Principle: In the use of this invention, the device is first powered on, and a photograph is taken by the detection mechanism to compare whether the clarity meets the standard. Then, the detection piece is placed on the first conveyor belt 1. The first reduction motor 8 drives the first conveyor belt 1 to rotate, moving the detection piece forward. When the detection piece passes the first sensor 6, the first sensor 6 transmits a signal to the second sensor 7. If the second sensor 7 also detects a detection piece passing by at this time, it indicates that the distance between adjacent detection pieces is too small. At this time, the second sensor 7 transmits a signal to the DC motor 9. The DC motor 9... Upon startup, the bidirectional lead screw 10 is driven to rotate. The two moving blocks 11 on the bidirectional lead screw 10 move inwards. As the moving blocks 11 move inwards, the connecting rod 12 is compressed, reducing its intersection angle. At this time, one end of the connecting rod 12 moves inwards, causing the baffle 13 to move inwards via the slide plate 14, blocking subsequent detection components from advancing. Some detection components that are too close may also be clamped by the baffle 13. When the pressure sensor 15 senses that the pressure of the baffle 13 on the detection component reaches the set value, it transmits a signal to the DC motor 9, causing the DC motor 9 to stop operating, preventing the baffle 13 from overshooting. The damaged inspection piece is clamped; after the spacing is adjusted by the adjustment mechanism, the inspection piece enters the inspection box 2. The third conveyor belt 4 inside the inspection box 2 operates at a slower speed to improve the clarity of the photos during inspection. Inside the light shield 16, the first camera 17, with the assistance of the supplementary aperture 18, takes pictures of the inspection piece from above. At the same time, four second cameras 19 and two supplementary lights 20 on the inner wall of the light shield 16 work together to take pictures of the inspection piece from all sides, avoiding interference from external light and comprehensively and accurately detecting defects on the surface of the inspection piece. After the inspection is completed, the inspection... The parts are conveyed onto the second conveyor belt 3. If a defect is detected in the part, the electric push rod 22 is activated, pushing the push plate 23 to smoothly push the defective part to the second discharge port 25 for discharge. If the part is qualified, it continues to move with the second conveyor belt 3 and is discharged from the first discharge port 5. During the movement of the push plate 23, the guide rod ensures the stability of the push plate 23, and the compression spring 24 slows down the movement speed of the push plate 23 to avoid the part colliding with the second discharge port 25 and causing secondary damage. Finally, the qualified and unqualified parts are placed separately and the power is disconnected.

[0037] Example 2: See Figure 7 The detection box 2 is equipped with a detection component, which includes an analysis module and an adjustment module;

[0038] The analysis module receives the material and conveying parameters acquired during the conveying process and performs data preprocessing. Based on the preprocessed data, it analyzes whether the spacing between adjacent materials needs to be adjusted. If so, it generates a spacing adjustment signal and transmits the signal to the adjustment module. It analyzes whether the adjustment process will affect the detection accuracy and determines the range of fluctuation in the conveyor belt's running speed. If the running speed is outside the range of fluctuation, it issues an alarm to notify the staff.

[0039] Maximum lateral width KD of the material wl Detection of safety redundancy width KD aq Conveyor belt speed V cs Total time T for single material testing jc And the effective field of view (KD) of a single shot by the camera sy The data is acquired and preprocessed for multiple corresponding items acquired per unit time.

[0040] Preprocessing: The collected data are sorted according to the collection time. For the corresponding item a1 data collected at the same time, the mean A1 and standard deviation B are calculated. The fluctuation range FW1 = [A1-3B, A1+3B] of the collected data for the corresponding item is set based on the calculated mean A1 and standard deviation B. The collected data for the corresponding item is compared with the fluctuation range FW1. Data for the corresponding item that is not within the fluctuation range is marked as outliers, and the number of outliers a2 is recorded. If a2 > 30% * a1, the collected data is determined to be abnormal, and the data is re-detected. If a2 ≤ 30% * a1, the outliers are removed. The mean A2 of the remaining detected data for the corresponding item after removing outliers is calculated, and the calculated mean A2 is used as the detected data for the corresponding item at the corresponding time.

[0041] Minimum safety distance Maximum reasonable spacing D max =V cs ×T e Maximum allowable material interval time JC mb This represents the hourly target inspection quantity corresponding to the equipment's production capacity target; during the inspection process, the actual spacing is D. sj When D sj In FW2=[D min D max If the spacing is within the specified range, the spacing is deemed acceptable; otherwise, the spacing is deemed abnormal, a spacing adjustment signal is generated, and the spacing adjustment signal is transmitted to the adjustment module.

[0042] After receiving the spacing adjustment signal, the adjustment module distinguishes between excessively large and excessively small spacing. If the spacing is too large, it sends a reverse rotation signal to the DC motor 9, driving the bidirectional lead screw 10 to move the moving block 11 outward. The connecting rod 12 unfolds, causing the baffle 13 to return to its initial position, removing the obstruction to subsequent materials and accelerating the material conveying rhythm. It also sends a speed-up signal to the first reduction motor 8, increasing the running speed of the first conveyor belt 1 without affecting detection accuracy, thus reducing the time interval between materials and consequently shortening the actual spacing. If the spacing continues to exceed the maximum reasonable spacing, it sends a warning signal to the equipment control system, triggering an audible and visual alert or linking the feeding device to alert the system. Replenish materials or adjust the feeding frequency; if the spacing is too small, send a drive signal to the DC motor 9 to control the bidirectional lead screw 10 to rotate in the forward direction, driving the moving blocks 11 on both sides to move inward, and through the connecting rod 12 to link the slide plate 14, causing the L-shaped baffle 13 to retract towards the center of the conveyor belt, clamping or blocking subsequent materials, and receive the signal from the pressure sensor 15 on the baffle 13 in real time. When the pressure reaches the preset safety threshold, immediately send a stop signal to the DC motor 9 to avoid excessive clamping and damage to the materials, temporarily reduce the running speed of the first conveyor belt 1 (by controlling the first reduction motor), reserve buffer time for spacing adjustment, and prevent materials from continuously accumulating;

[0043] Considering image acquisition sharpness, to obtain the maximum allowable blur amount mh, the conveyor belt running speed must meet the following requirements: T bg The image exposure time; considering the matching of detection time and spacing, the conveyor belt speed must meet the following requirements: Considering system capacity, the conveyor belt operating speed must meet the following requirements: Taking all three factors into account, the conveyor belt speed V cs exist Within the specified range, it is determined that the detection accuracy will not be affected, and the minimum stable speed is [not specified]. Where n min D is the minimum stable speed of the motor. k Where is the diameter of the conveyor belt drive roller, and cd is the transmission ratio of the reduction mechanism;

[0044] If the conveyor belt runs at speed V cs Not within the scope of FW3, for V cs To obtain the specific value of V, if V cs If the value exceeds the upper limit of range FW3, the judgment speed is too fast; if the upper limit is... If the decision is made, it indicates insufficient detection processing time, triggering a "detection cycle time exceeded" alarm and prompting staff to optimize the algorithm to reduce Ttime. jc Or reassess the minimum safe distance D min If the upper limit is If the decision is made, the image is determined to be blurry, and an alarm "Image acquisition conditions not met" is issued, prompting staff to extend the T... bgImprove the lighting or use a higher-performance camera;

[0045] If V cs If the value is less than the lower limit of range FW3, the determination speed is too slow; if the lower limit is... If the decision is made, it indicates that the current speed cannot complete the production task, and an "unsatisfactory capacity" alarm is issued, prompting staff to check whether the feeding system is functioning smoothly; if the lower limit is V min If the system is deemed unable to operate stably at such a low speed, an alarm will be issued indicating that the operating speed is below the stability limit, prompting staff to be aware of potential mechanical or control malfunctions.

[0046] The above description is only a preferred embodiment of the present invention, but the scope of protection of the present invention is not limited thereto. Any equivalent substitutions or modifications made by those skilled in the art within the scope of the technology disclosed in the present invention, based on the technical solution and inventive concept of the present invention, should be covered within the scope of protection of the present invention.

Claims

1. A visual inspection device for surface defects in metal product processing, comprising a first conveyor belt (1), characterized in that: An adjustment mechanism is installed on the first conveyor belt (1), and a detection box (2) is installed at the rear end of the first conveyor belt (1). A third conveyor belt (4) and a detection mechanism are installed inside the detection box (2). The detection mechanism is located at the upper end of the third conveyor belt (4). A second conveyor belt (3) is installed at the rear end of the detection box (2). A material distribution mechanism is installed on the second conveyor belt (3), and a first discharge port (5) is installed at the rear end of the second conveyor belt (3). The detection box (2) is equipped with a detection component, which includes an analysis module; The analysis module receives the material and conveying parameters acquired during the conveying process and performs data preprocessing. Based on the preprocessed data, it analyzes whether the spacing between adjacent materials needs to be adjusted. If so, it generates a spacing adjustment signal and transmits the signal to the adjustment module. It analyzes whether the adjustment process will affect the detection accuracy and determines the range of fluctuation in the conveyor belt's running speed. If the running speed is outside the range of fluctuation, it issues an alarm to notify the staff.

2. The surface defect visual inspection device for metal product processing according to claim 1, characterized in that: The analysis module performs the following steps to analyze the spacing between adjacent materials: M1: Based on the maximum lateral width KD of the material wl Detection of safety redundancy width KD aq Conveyor belt speed V cs Total time T for single material testing jc And the effective field of view (KD) of a single shot by the camera sy Determine the minimum safe distance D min and the maximum reasonable spacing D max And set the fluctuation range FW2; M2: When D sj Within the FW2 range, the spacing is deemed acceptable; Conversely, if the spacing is abnormal, a spacing adjustment signal is generated and transmitted to the adjustment module.

3. The surface defect visual inspection device for metal product processing according to claim 2, characterized in that: The analysis module performs the following steps to analyze abnormal running speed: N1: Considering image acquisition clarity, system capacity, detection time and spacing, determine the fluctuation range FW3 of the conveyor belt speed. If the conveyor belt speed V cs Within the FW3 range, it is determined that it will not affect the detection accuracy; N2: If the conveyor belt speed V cs Not within the scope of FW3, for V cs To obtain the specific value of V, if V cs If the value exceeds the upper limit of range FW3, the judgment speed is too fast; if the upper limit is... If the decision is made, it is determined that the detection processing time is insufficient. A buzzer warning is issued through the buzzer module of the detection component, and a "Detection cycle time exceeded" alarm is displayed on the screen of the detection box (2), prompting the staff to optimize the algorithm and reduce T. jc Or reassess the minimum safety clearance D min If the upper limit is If the image is determined to be blurry, a buzzer warning will be issued through the buzzer module of the detection component, and an alarm "Image acquisition conditions not met" will be displayed on the screen of the detection box (2), prompting the staff to extend the T... bg Improve the lighting or use a higher-performance camera; N3: If V cs If the value is less than the lower limit of range FW3, the determination speed is too slow; if the lower limit is... If the decision is made, it is determined that the current speed cannot complete the production task. A buzzer warning is issued through the buzzer module of the detection component, and a "Production capacity not up to standard" warning is displayed on the screen of the detection box (2), prompting the staff to check whether the feeding system is smooth; if the lower limit is V min If the system is found to be unable to operate stably at such a low speed, the system will issue a buzzer warning through the buzzer module of the detection component and display a "Running speed is below the stable limit" alarm on the display screen of the detection box (2), indicating to the staff that there may be a mechanical or control failure risk.

4. The surface defect visual inspection device for metal product processing according to claim 1, characterized in that: The adjustment mechanism includes a first sensor (6) installed on both sides of the first conveyor belt (1), a second sensor (7) installed at the rear end of the first sensor (6), and an L-shaped baffle (13) between the first sensor (6) and the second sensor (7). A DC motor (9) is installed between the first sensor (6) and the second sensor (7). A bidirectional lead screw (10) is installed at the output end of the DC motor (9) through a coupling. A first geared motor (8) for driving the first conveyor belt (1) is installed on one side of the first conveyor belt (1).

5. The surface defect visual inspection device for metal product processing according to claim 4, characterized in that: The bidirectional lead screw (10) is threaded with two moving blocks (11). One end of each moving block (11) is hinged to a connecting rod (12). The two connecting rods (12) are hinged to each other at their center. The other end of each connecting rod (12) is hinged to a sliding plate (14). The two sliding plates (14) are slidably connected to a baffle (13). A pressure sensor (15) is installed at one end of the baffle (13).

6. The surface defect visual inspection device for metal product processing according to claim 1, characterized in that: The detection mechanism includes a light shield (16) installed inside the detection box (2). A first camera (17) and a fill light (18) are installed on the top of the light shield (16). The fill light (18) is located directly below the first camera (17). Four second cameras (19) and two fill lights (20) are installed at equal intervals on the inner wall of the light shield (16).

7. The surface defect visual inspection device for metal product processing according to claim 1, characterized in that: The material distribution mechanism includes a mounting plate (21) installed on one side of the second conveyor belt (3) and a second discharge port (25) installed on the other end of the second conveyor belt (3). An electric push rod (22) is installed on the mounting plate (21), and a push plate (23) is installed at the output end of the electric push rod (22).

8. The surface defect visual inspection device for metal product processing according to claim 7, characterized in that: Two guide rods are fixed to one side of the push plate (23), and the other end of the guide rods passes through the mounting plate (21). A compression spring (24) is installed between the mounting plate (21) and the push plate (23). The compression spring (24) is sleeved on the outside of the guide rods. A second geared motor (26) for driving the second conveyor belt (3) is installed on one side of the second conveyor belt (3).

Images