Industrial automatic real-time visual inspection device

Abstract

The invention provides an industrial automatic real-time visual inspection device, and relates to the technical field of visual inspection, the industrial automatic real-time visual inspection device comprises a quick release mechanism, the quick release mechanism comprises a clamping rod, a limiting plate is arranged at one end of the clamping rod, a reinforcing ring is arranged at one end of the limiting plate, and a supporting bearing plate is arranged at one end, away from the limiting plate, of the reinforcing ring; a pressure sensor is arranged on one side of the supporting bearing plate; according to the invention, the quick-release mechanism is additionally arranged on the visual inspection device, so that insertion and installation are realized, and the maintenance and remodeling time is greatly shortened; a dual connection mode is matched with a pressure sensor, connection stability is enhanced, precision reduction and equipment damage caused by improper installation are effectively avoided, a lifting and adjusting mechanism is integrated, flexible and stable multi-degree-of-freedom vision is provided, a complex detection station can be quickly and accurately aligned, and the system has a self-checking function and is convenient to use. The system can actively give an alarm when the quick release mechanism is loosened or the posture is abnormal, thereby preventing batch defective products, and remarkably improving the reliability and intelligent level of the detection system.

Description

Technical Field

[0001] This invention relates to the field of visual inspection technology, and more particularly to a real-time visual inspection device for industrial automation. Background Technology

[0002] Industrial automation vision inspection devices are widely used in product quality inspection, dimensional measurement, and defect identification.

[0003] In existing technologies, real-time vision inspection devices for industrial automation typically use bolt fixing or simple snap-fit ​​connections. The installation and disassembly process is cumbersome and time-consuming. They lack integrated sensors to monitor the connection status in real time, which can easily lead to poor stability due to improper installation. Furthermore, the components cannot automatically reset after disassembly, increasing the complexity of operation. In addition, the field of view is limited, and most of the adjustment relies on manual adjustment, which is inflexible. Mechanical parts are prone to wear, the drive system is complex, and jamming or displacement is likely to occur after long-term use, affecting the reliability of inspection.

[0004] Furthermore, existing monitoring systems are prone to blurring or distortion during image acquisition, rely on simple sensors, and cannot dynamically adjust according to production line speed, resulting in inaccurate detection timing. In terms of image processing, they mostly use a single central processor and traditional algorithms, which result in slow processing speed, difficulty in real-time identification of complex defects, low system integration, inability to effectively interface with upper-level manufacturing execution systems, forming data silos, reliance on manually set thresholds, poor adaptive learning capabilities, and complex maintenance and configuration, which not only increases the cost of use but also easily leads to a waste of time. Summary of the Invention

[0005] The purpose of this invention is to overcome the shortcomings of the existing technology and provide a real-time visual inspection device for industrial automation.

[0006] To achieve the above objectives, the present invention adopts the following technical solution: a real-time visual inspection device for industrial automation, comprising a quick-release mechanism, the quick-release mechanism comprising a locking rod, a limit plate at one end of the locking rod, a reinforcing ring at one end of the limit plate, a support plate at the end of the reinforcing ring away from the limit plate, a pressure sensor on one side of the support plate, a support column at the end of the pressure sensor away from the support plate, a limit buckle at the end of the support column near the support plate, a spring one at the end of the support plate away from the pressure sensor, a connecting rod at the end of the spring one away from the support plate, an extension rod on one side of the support plate, a limit block at the end of the extension rod away from the support plate, a spring two at the end of the limit block away from the extension rod, an adjusting support plate at the end of the spring two away from the limit block, a lifting mechanism at the end of the connecting rod away from the spring one, and a rotating mechanism at the end of the locking rod away from the limit plate.

[0007] In a preferred embodiment, the lifting mechanism includes a protective frame, a pull rod at one end of the protective frame, an anti-detachment plate at the end of the pull rod near the protective frame, a gear at the side of the pull rod away from the anti-detachment plate, a rotating shaft at the end of the gear away from the pull rod, and a motor at the end of the rotating shaft away from the gear.

[0008] In a preferred embodiment, the rotating mechanism includes a second motor, a connecting plate at one end of the second motor, a rotating connecting shaft at the end of the connecting plate away from the second motor, a connecting plate at the end of the rotating connecting shaft away from the connecting plate, a connecting shaft at the end of the connecting plate away from the rotating connecting shaft, a connecting ball at the end of the connecting shaft away from the connecting plate, a connecting shaft two at the end of the connecting ball away from the connecting plate, a connecting plate two at the end of the connecting shaft two away from the connecting ball, a rotating connecting shaft two at the end of the connecting plate two away from the connecting shaft two, and a third motor at the end of the rotating connecting shaft two away from the connecting plate two.

[0009] In a preferred embodiment, extension rods are provided on both sides of the support plate, and the extension rods are symmetrically distributed about the support column. Two springs are provided at the end of the limiting block away from the extension rods, and the springs are arranged in a linear equidistant array.

[0010] In a preferred embodiment, the support column is provided with twelve limiting buckles at one end near the support bearing plate, and the limiting buckles are arranged in a circular equidistant array; the support bearing plate is provided with twelve pressure sensors at one side, and the pressure sensors are arranged in a circular equidistant array.

[0011] In a preferred embodiment, a rotating mechanism is provided at one end of the quick-release mechanism, a camera is provided at the end of the rotating mechanism away from the quick-release mechanism, and a lifting mechanism is provided at the end of the quick-release mechanism away from the rotating mechanism.

[0012] In a preferred embodiment, a monitoring system is also included, which includes an image acquisition module, a trigger control module, an image processing module, a result output module, and a main control computer module.

[0013] The image acquisition module consists of a high frame rate, global shutter industrial camera and a matching customized optical light source, ensuring the capture of clear, distortion-free images during motion;

[0014] The trigger control module employs a high-precision rotary encoder working in conjunction with a programmable logic controller (PLC). The encoder is mounted on the production line drive shaft, providing continuous position feedback. The PLC runs a predictive algorithm to dynamically calculate and issue precise trigger signals based on the real-time linear velocity and the fixed distance between the camera and the rejection point.

[0015] The image processing module adopts an innovative heterogeneous parallel architecture of central processing unit, graphics processing unit and field programmable gate array;

[0016] The result output module is used to provide simple switching signals to drive rejection cylinders, alarm lights, etc., and send the inspection report to the upper manufacturing execution system via industrial Ethernet;

[0017] The main control computer runs integrated testing software and provides a user-friendly graphical interface for setting up testing processes, managing product formulas, monitoring system status, and visually displaying test results and historical data.

[0018] In one preferred embodiment, the field-programmable gate array (FPGA) is responsible for the low-level, fixed image preprocessing tasks, and its parallel pipeline characteristics enable microsecond-level image enhancement and region of interest extraction.

[0019] The graphics processor is equipped with a pre-trained and online optimized lightweight deep learning model, which is responsible for quickly semantic segmentation or classification of defects in images and identifying defects.

[0020] The central processing unit runs complex traditional measurement algorithms to perform pixel-level quantitative analysis on the defective areas identified by the graphics processor, ensuring the accuracy of the results.

[0021] In one preferred embodiment, the image acquisition module includes a visual inspection device, a control unit, a data processing unit, and a communication unit;

[0022] The visual inspection device is responsible for acquiring image information in complex industrial environments;

[0023] The control unit uses a high-performance programmable logic controller to collect data from the pressure sensor in real time, monitor the installation stability and attitude of the device, and precisely control the motor start-stop, direction and speed according to the instructions from the upper level, thereby driving the lifting mechanism and the rotating mechanism.

[0024] The data processing unit, through an integrated image processing library and AI algorithms, enables real-time statistics of production line output, warehouse cargo location and status identification, and comprehensive monitoring of the operational status of the production logistics process.

[0025] The communication unit is responsible for uploading the analysis results of the data processing unit and the device's own status data to the host monitoring computer and manufacturing execution system in real time, while receiving control commands from the upper-level system.

[0026] Compared with the prior art, the advantages and positive effects of the present invention are as follows:

[0027] 1. This invention adds a quick-release mechanism to the visual inspection device, which allows operators to simply insert the device to complete the installation, replacing the cumbersome process of traditional bolt fixing. This greatly shortens the maintenance and replacement time. Furthermore, the use of a dual connection method in conjunction with a pressure sensor further improves the stability of the overall device connection, fundamentally avoiding the decrease in detection accuracy and equipment damage caused by improper installation.

[0028] 2. At the same time, by adding a lifting mechanism and an adjustment mechanism to the device, the device is provided with a flexible and stable multi-degree-of-freedom vision, which can quickly and accurately align with complex inspection stations;

[0029] 3. The system not only detects products, but also detects itself. It can actively alarm when the quick-release mechanism is loose or the posture is abnormal, preventing the generation of batch defective product data and improving the reliability and intelligence level of the entire detection system. Attached Figure Description

[0030] Figure 1 This invention provides a schematic diagram of the installation structure of a real-time visual inspection device for industrial automation.

[0031] Figure 2 This invention provides a structural schematic diagram of a real-time visual inspection device for industrial automation.

[0032] Figure 3 This invention provides a schematic diagram of the rotating mechanism structure of a real-time visual inspection device for industrial automation.

[0033] Figure 4 This invention provides a cross-sectional view of the lifting mechanism of a real-time visual inspection device for industrial automation.

[0034] Figure 5 This invention provides a schematic diagram of the vertical cross-section of the lifting mechanism of a real-time visual inspection device for industrial automation.

[0035] Figure 6 This invention provides a schematic diagram of the upper cross-sectional structure of the quick-release mechanism of a real-time visual inspection device for industrial automation.

[0036] Figure 7 This invention provides a schematic diagram of a quick-release mechanism thin-cut structure for a real-time visual inspection device for industrial automation.

[0037] Figure 8 This invention presents a cross-sectional schematic diagram of the quick-release mechanism of a real-time visual inspection device for industrial automation.

[0038] Figure 9 This invention presents a module diagram of a real-time visual inspection device for industrial automation.

[0039] Figure 10 The present invention provides a flowchart of a real-time visual inspection device for industrial automation.

[0040] Legend:

[0041] 1. Quick-release mechanism; 11. Clip rod; 12. Limiting plate; 13. Reinforcing ring; 14. Limiting buckle; 15. Support column; 16. Support receiving plate; 161. Adjustable receiving plate; 17. Spring one; 18. Connecting rod; 19. Pressure sensor; 101. Extension rod; 102. Limiting block; 103. Spring two;

[0042] 2. Lifting mechanism; 21. Protective frame; 22. Tie rod; 23. Anti-detachment plate; 24. Gear; 25. Rotating shaft; 26. Motor 1;

[0043] 3. Rotating mechanism; 31. Motor II; 32. Connecting plate; 33. Rotating connecting shaft I; 34. Connecting plate I; 35. Connecting shaft I; 36. Connecting ball; 37. Connecting shaft II; 38. Connecting plate II; 39. Rotating connecting shaft II; 301. Motor III;

[0044] 4. Camera. Detailed Implementation

[0045] The technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.

[0046] Example 1

[0047] like Figure 2 - Figure 8As shown, the present invention provides a technical solution: a real-time visual inspection device for industrial automation, including a quick-release mechanism 1. The quick-release mechanism 1 includes a locking rod 11, a limiting plate 12 at one end of the locking rod 11, a reinforcing ring 13 at one end of the limiting plate 12, and a supporting plate 16 at the end of the reinforcing ring 13 away from the limiting plate 12. The reinforcing ring 13 and the supporting plate 16 are threadedly connected. Twelve pressure sensors 19 are arranged in a circular equidistant array on one side of the supporting plate 16. One end of each pressure sensor 19 is locked into a locking groove opened inside the supporting plate 16, and the locking rod 11 contacts the sensing post of the pressure sensor 19. A supporting post 15 is arranged at the end of the pressure sensor 19 away from the supporting plate 16. Twelve limiting buckles 14 are arranged at the end of the supporting post 15 near the supporting plate 16. The circular equidistant array has a snap-fit ​​groove at the end of the snap-fit ​​rod 11 near the limit buckle 14 for snap-fitting and fixing. A spring 17 is provided at the end of the support plate 16 away from the pressure sensor 19. A connecting rod 18 is provided at the end of the spring 17 away from the support plate 16. Extension rods 101 are provided on both sides of the support plate 16. The extension rods 101 are symmetrically distributed about the support column 15. A limit block 102 is provided at the end of the extension rod 101 away from the support plate 16. Two springs 103 are provided at the end of the limit block 102 away from the extension rod 101. The springs 103 are arranged in a linear equidistant array. An adjusting support plate 161 is provided at the end of the springs 103 away from the limit block 102. The end of the connecting rod 18 away from the spring 17 is connected to the lifting mechanism 2. The end of the snap-fit ​​rod 11 away from the limit plate 12 is connected to the rotating mechanism 3.

[0048] In this embodiment, the quick-release mechanism 1 uses a limit buckle 14 and a locking rod 11. The upper and lower ends of the vision inspection device are quickly connected and separated by the locking groove. A pressure sensor 19 is installed inside the support plate 16. During the clamping process between the support plate 16 and the adjusting plate 161 by rotating the reinforcing ring 13, the pressure signal sensed by the pressure sensor 19 is used to analyze the current locking effect between the locking rod 11 and the limit buckle 14, determining whether the installation is in place. For disassembly, the connection between the reinforcing ring 13 and the support plate 16 is first released, and the support plate 16 and the adjusting plate 161 are slid downwards to release the limit buckle 14 from the locking rod 11, thus disassembling the vision inspection device. After disassembly, the support plate 16 and the adjusting plate 161 are reset by the spring return torque. The overall installation process is simple and easy to operate, greatly saving time for equipment replacement and maintenance. Furthermore, through dual fixing and status signal detection, the device's stability is ensured while achieving automated process control.

[0049] Example 2

[0050] like Figure 1 - Figure 5 As shown, based on the real-time visual inspection device for industrial automation proposed in Embodiment 1, the lifting mechanism 2 includes a protective frame 21. A pull rod 22 is provided at one end of the protective frame 21. An anti-detachment plate 23 is provided at the end of the pull rod 22 near the protective frame 21. A gear 24 is provided on the side of the pull rod 22 away from the anti-detachment plate 23. The pull rod 22 meshes with the gear 24. A rotating shaft 25 is provided at the end of the gear 24 away from the pull rod 22. A motor 26 is provided at the end of the rotating shaft 25 away from the gear 24. The rotating mechanism 3 includes a second motor 31. A connecting plate 32 is provided at one end of the second motor 31. A rotating connecting shaft 33 is provided at the end of the connecting plate 32 away from the second motor 31. A connecting plate 34 is provided at one end away from the connecting plate 32. A connecting shaft 35 is provided at one end of the connecting plate 34 away from the rotating connecting shaft 33. A connecting ball 36 is provided at one end of the connecting shaft 35 away from the connecting plate 34. A connecting shaft 37 is provided on one side of the connecting ball 36 away from the connecting plate 34. A connecting plate 38 is provided at one end of the connecting shaft 37 away from the connecting ball 36. A rotating connecting shaft 39 is provided at one end of the connecting plate 38 away from the connecting shaft 37. A motor 301 is provided at one end of the rotating connecting shaft 39 away from the connecting plate 38. A camera 4 is provided at one end of the connecting shaft 35 away from the connecting ball 36. One side of the protective frame 21 is connected to the production line.

[0051] In this embodiment, the lifting mechanism 2 controls the gear 24 to rotate via motor 26. When the gear 24 rotates, the latched pull rod 22 moves up and down, thereby moving the vision inspection device up and down and achieving stable adjustment of the height of the camera 4. The rotating mechanism 3 adjusts the up and down angle of the camera 4 via motor 31 and adjusts the left and right angle of the camera 4 via motor 301, which greatly improves the overall field of view and enhances the adaptability and efficiency of industrial automation inspection.

[0052] Example 3

[0053] like Figure 9 - Figure 10 As shown, the monitoring system includes an image acquisition module, a trigger control module, an image processing module, a result output module, and a main control computer module;

[0054] The image acquisition module consists of a high frame rate, global shutter industrial camera and a matching customized optical light source, ensuring the capture of clear, distortion-free images during motion;

[0055] The image acquisition module includes a visual inspection device, a control unit, a data processing unit, and a communication unit.

[0056] The visual inspection device is responsible for acquiring image information in complex industrial environments;

[0057] The control unit uses a high-performance programmable logic controller to collect data from the pressure sensor 19 in real time, monitor the installation stability and attitude of the device, and precisely control the motor start-stop, direction and speed according to the instructions from the upper level, thereby driving the lifting mechanism 2 and the rotating mechanism 3.

[0058] The data processing unit, through an integrated image processing library and AI algorithms, enables real-time statistics of production line output, warehouse cargo location and status identification, and comprehensive monitoring of the operational status of the production logistics process.

[0059] The communication unit is responsible for uploading the analysis results of the data processing unit and the status data of the device itself to the host monitoring computer and the manufacturing execution system in real time, and at the same time receiving control commands from the upper-level system.

[0060] The trigger control module employs a high-precision rotary encoder working in conjunction with a programmable logic controller (PLC). The encoder is mounted on the production line drive shaft, providing continuous position feedback. The PLC runs a predictive algorithm to dynamically calculate and issue precise trigger signals based on the real-time linear velocity and the fixed distance between the camera and the rejection point.

[0061] The image processing module adopts an innovative heterogeneous parallel architecture of central processing unit, graphics processing unit and field programmable gate array;

[0062] The field-programmable gate array (FPGA) is responsible for the low-level, fixed image preprocessing tasks, and utilizes its parallel pipeline characteristics to achieve microsecond-level image enhancement and region of interest extraction.

[0063] The graphics processor is equipped with a pre-trained and online optimized lightweight deep learning model, which is responsible for quickly semantic segmentation or classification of defects in images and identifying defects.

[0064] The central processing unit runs complex traditional measurement algorithms to perform pixel-level quantitative analysis on the defect areas identified by the graphics processor, ensuring the accuracy of the results;

[0065] The result output module is used to provide simple switching signals to drive rejection cylinders, alarm lights, etc., and send the inspection report to the upper manufacturing execution system via industrial Ethernet;

[0066] The main control computer runs integrated testing software and provides a user-friendly graphical interface for setting up testing processes, managing product formulas, monitoring system status, and visually displaying test results and historical data.

[0067] In this embodiment, when products move on the production line, the trigger control module uses the position signal fed back by the rotary encoder and the prediction algorithm to dynamically calculate the precise moment and send a trigger signal to the high frame rate, global shutter industrial camera to ensure that clear and distortion-free images are obtained during movement. Then, the image processing module processes the images using an innovative heterogeneous parallel architecture. The field-programmable gate array first performs microsecond-level image preprocessing and region of interest extraction, while the graphics processor uses a lightweight deep learning model to quickly identify and classify defects. The central processing unit then performs precise quantitative analysis of the defect areas. The data is then sent to the result output module, which drives the removal of actuators such as cylinders based on the judgment results and sends the inspection report to the upper system via industrial Ethernet. The main control computer module is responsible for overall coordination, setting inspection parameters, monitoring status, and visualizing results through a graphical interface.

[0068] In summary, by ensuring precise capture timing through trigger control and leveraging the advantages of parallel preprocessing of the field-programmable gate array (FPGA), AI inference of the graphics processing unit (GPU), and complex logic processing of the central processing unit (CPU) through a heterogeneous computing architecture, a highly efficient processing pipeline is formed. At the same time, by combining deep learning algorithms, the system is endowed with the intelligence to identify complex defects, meeting the real-time requirements of high-speed production. It has excellent flexibility and intelligence to meet the needs of flexible manufacturing. Through deep integration with the manufacturing execution system (MES), comprehensive digital monitoring and traceability of production quality are achieved, improving the quality control level and intelligent management capabilities of the automated production line.

[0069] Working principle:

[0070] like Figure 1 - Figure 9As shown, a rotating mechanism 3 is provided at one end of the quick-release mechanism 1, a camera 4 is provided at the end of the rotating mechanism 3 away from the quick-release mechanism 1, and a lifting mechanism 2 is provided at the end of the quick-release mechanism 1 away from the rotating mechanism 3. The quick-release mechanism 1 includes a locking rod 11, a limiting plate 12 is provided at one end of the locking rod 11, a reinforcing ring 13 is provided at one end of the limiting plate 12, and a supporting plate 16 is provided at the end of the reinforcing ring 13 away from the limiting plate 12. The reinforcing ring 13 and the supporting plate 16 are threadedly connected. Twelve pressure sensors 19 are provided on one side of the supporting plate 16. The pressure sensors 19 are arranged in a circular equidistant array. One end of the pressure sensor 19 is locked into a locking groove opened inside the supporting plate 16. The locking rod 11 is in contact with the sensing column of the pressure sensor 19. A support column 15 is provided at the end of the sensor 19 away from the support plate 16. Twelve limit buckles 14 are provided at the end of the support column 15 near the support plate 16, arranged in a circular, equidistant array. A locking rod 11 has a locking groove at the end near the limit buckle 14 for locking and fixing with the limit buckle 14. A spring 17 is provided at the end of the support plate 16 away from the pressure sensor 19. A connecting rod 18 is provided at the end of the spring 17 away from the support plate 16. Extension rods 101 are provided on both sides of the support plate 16, symmetrically distributed about the support column 15. A limit block 102 is provided at the end of the extension rod 101 away from the support plate 16, with two limit blocks 102 at the end of the limit block 102 away from the extension rod 101. Spring 103 is arranged in a linear, equidistant array. An adjusting support plate 161 is provided at the end of spring 103 furthest from the limiting block 102. A connecting rod 18 is connected to the lifting mechanism 2 at the end furthest from spring 17. A locking rod 11 is connected to the rotating mechanism 3 at the end furthest from the limiting plate 12. The lifting mechanism 2 includes a protective frame 21, with a pull rod 22 at one end. An anti-detachment plate 23 is provided at the end of the pull rod 22 near the protective frame 21. A gear 24 is provided on the side of the pull rod 22 furthest from the anti-detachment plate 23, engaging with the gear 24. A rotating shaft 25 is provided at the end of the gear 24 furthest from the pull rod 22, and a motor 26 is provided at the end of the rotating shaft 25 furthest from the gear 24. The rotating mechanism 3 includes a second motor 31, with an adjusting support plate 161 at one end... A connecting plate 32 is provided. A rotating connecting shaft 33 is provided at the end of the connecting plate 32 away from the motor 31. A connecting plate 34 is provided at the end of the rotating connecting shaft 33 away from the connecting plate 32. A connecting shaft 35 is provided at the end of the connecting plate 34 away from the rotating connecting shaft 33. A connecting ball 36 is provided at the end of the connecting shaft 35 away from the connecting plate 34. A connecting shaft 37 is provided at the side of the connecting ball 36 away from the connecting plate 34. A connecting plate 38 is provided at the end of the connecting shaft 37 away from the connecting ball 36. A rotating connecting shaft 39 is provided at the end of the connecting plate 38 away from the connecting shaft 37. A motor 301 is provided at the end of the rotating connecting shaft 39 away from the connecting plate 38. A camera 4 is provided at the end of the connecting shaft 35 away from the connecting ball 36.

[0071] The entire monitoring system uses a trigger control module to provide continuous position feedback through a high-precision rotary encoder. Its internal programmable logic controller runs a prediction algorithm to dynamically calculate and issue a precise trigger signal based on the real-time linear velocity and the fixed distance between the camera and the rejection point.

[0072] Then, the signal activates the image acquisition module, and the vision inspection device captures clear and distortion-free images. The control unit inside the image acquisition module collects data from the pressure sensor 19 in real time to monitor the installation stability and posture of the quick-release mechanism, and controls the movement of the lifting mechanism 2 and the rotating mechanism 3 according to the production line instructions. Then, the data processing unit performs preliminary real-time statistics and status identification on the collected image information, and realizes data uploading and instruction reception through the communication unit.

[0073] Then, the image is sent to the image processing module, which adopts a heterogeneous parallel architecture of central processing unit, graphics processing unit and field programmable gate array. First, the field programmable gate array performs low-level, fixed image preprocessing to achieve microsecond-level image enhancement and region of interest extraction. Then, the lightweight deep learning model on the graphics processing unit performs rapid semantic segmentation or classification recognition of defects in the image.

[0074] Finally, the central processing unit runs complex traditional measurement algorithms to perform pixel-level quantitative analysis on the defect areas identified by the graphics processor to ensure the accuracy of the results. Finally, the result output module receives the analysis results, provides switching signals to drive actuators such as rejection cylinders and alarm lights, and sends the inspection report to the upper manufacturing execution system via industrial Ethernet.

[0075] Throughout the process, the main control computer module runs integrated testing software, providing a graphical interface for setting up testing procedures, managing product formulations, monitoring system status, and visually displaying test results and historical data, thereby managing the entire system.

[0076] The above description is merely a preferred embodiment of the present invention and is not intended to limit the present invention in any other way. Any person skilled in the art may make changes or modifications to the above-disclosed technical content to create equivalent embodiments for application in other fields. However, any simple modifications, equivalent changes, and modifications made to the above embodiments based on the technical essence of the present invention without departing from the scope of the present invention shall still fall within the protection scope of the present invention.

Claims

1. A real-time visual inspection device for industrial automation, characterized in that, include: A quick-release mechanism (1) includes a locking rod (11), a limiting plate (12) at one end of the locking rod (11), a reinforcing ring (13) at one end of the limiting plate (12), a supporting plate (16) at the end of the reinforcing ring (13) away from the limiting plate (12), a pressure sensor (19) on one side of the supporting plate (16), a supporting column (15) at the end of the pressure sensor (19) away from the supporting plate (16), a limiting buckle (14) at the end of the supporting column (15) near the supporting plate (16), and a spring at the end of the supporting plate (16) away from the pressure sensor (19). 17), the spring one (17) is provided with a connecting rod (18) at the end away from the support plate (16), the support plate (16) is provided with an extension rod (101) on one side, the extension rod (101) is provided with a limit block (102) at the end away from the support plate (16), the limit block (102) is provided with a spring two (103) at the end away from the extension rod (101), the spring two (103) is provided with an adjusting support plate (161) at the end away from the limit block (102), the connecting rod (18) is connected to the lifting mechanism (2) at the end away from the spring one (17), and the snap-fit ​​rod (11) is connected to the rotating mechanism (3) at the end away from the limit plate (12).

2. The real-time visual inspection device for industrial automation according to claim 1, characterized in that: The lifting mechanism (2) includes a protective frame (21), a pull rod (22) is provided at one end of the protective frame (21), an anti-detachment plate (23) is provided at the end of the pull rod (22) near the protective frame (21), a gear (24) is provided on the side of the pull rod (22) away from the anti-detachment plate (23), a rotating shaft (25) is provided at the end of the gear (24) away from the pull rod (22), and a motor (26) is provided at the end of the rotating shaft (25) away from the gear (24).

3. The real-time visual inspection device for industrial automation according to claim 1, characterized in that: The rotating mechanism (3) includes a second motor (31), a connecting plate (32) is provided at one end of the second motor (31), a rotating connecting shaft (33) is provided at the end of the connecting plate (32) away from the second motor (31), a connecting plate (34) is provided at the end of the rotating connecting shaft (33) away from the connecting plate (32), a connecting shaft (35) is provided at the end of the connecting plate (34) away from the rotating connecting shaft (33), a connecting ball (36) is provided at the end of the connecting shaft (35) away from the connecting plate (34), a connecting shaft (37) is provided on the side of the connecting ball (36) away from the connecting plate (34), a connecting plate (38) is provided at the end of the connecting shaft (37) away from the connecting ball (36), a rotating connecting shaft (39) is provided at the end of the connecting plate (38) away from the connecting shaft (37), and a third motor (301) is provided at the end of the rotating connecting shaft (39) away from the connecting plate (38).

4. The real-time visual inspection device for industrial automation according to claim 1, characterized in that: Both sides of the support plate (16) are provided with extension rods (101), the extension rods (101) are symmetrically distributed about the support column (15), and two springs (103) are provided at the end of the limiting block (102) away from the extension rods (101), the springs (103) are arranged in a linear equidistant array.

5. The real-time visual inspection device for industrial automation according to claim 1, characterized in that: The support column (15) is provided with twelve limiting buckles (14) near the end of the support plate (16), and the limiting buckles (14) are arranged in a circular equidistant array; the support plate (16) is provided with twelve pressure sensors (19) on one side, and the pressure sensors (19) are arranged in a circular equidistant array.

6. The real-time visual inspection device for industrial automation according to claim 1, characterized in that: The quick-release mechanism (1) is provided with a rotating mechanism (3) at one end, and a camera (4) is provided at the end of the rotating mechanism (3) away from the quick-release mechanism (1). The quick-release mechanism (1) is provided with a lifting mechanism (2) at the end away from the rotating mechanism (3).

7. A real-time visual inspection device for industrial automation according to any one of claims 1-6, characterized in that: It also includes a monitoring system, which comprises an image acquisition module, a trigger control module, an image processing module, a result output module, and a main control computer module; The image acquisition module consists of a high frame rate, global shutter industrial camera and a matching customized optical light source, ensuring the capture of clear, distortion-free images during motion; The trigger control module employs a high-precision rotary encoder working in conjunction with a programmable logic controller (PLC). The encoder is mounted on the production line drive shaft, providing continuous position feedback. The PLC runs a predictive algorithm to dynamically calculate and issue precise trigger signals based on the real-time linear velocity and the fixed distance between the camera and the rejection point. The image processing module adopts an innovative heterogeneous parallel architecture of central processing unit, graphics processing unit and field programmable gate array; The result output module is used to provide simple switching signals to drive rejection cylinders, alarm lights, etc., and send the inspection report to the upper manufacturing execution system via industrial Ethernet; The main control computer runs integrated testing software and provides a user-friendly graphical interface for setting up testing processes, managing product formulas, monitoring system status, and visually displaying test results and historical data.

8. The real-time visual inspection device for industrial automation according to claim 7, characterized in that: The field-programmable gate array is responsible for the low-level, fixed image preprocessing tasks, and its parallel pipeline characteristics enable microsecond-level image enhancement and region of interest extraction. The graphics processor is equipped with a pre-trained and online optimized lightweight deep learning model, which is responsible for quickly semantic segmentation or classification of defects in images and identifying defects. The central processing unit runs complex traditional measurement algorithms to perform pixel-level quantitative analysis on the defective areas identified by the graphics processor, ensuring the accuracy of the results.

9. The real-time visual inspection device for industrial automation according to claim 7, characterized in that: The image acquisition module includes a visual inspection device, a control unit, a data processing unit, and a communication unit; The visual inspection device is responsible for acquiring image information in complex industrial environments; The control unit uses a high-performance programmable logic controller to collect data from the pressure sensor (19) in real time, monitor the installation stability and attitude of the device, and precisely control the motor start-stop, direction and speed according to the instructions from the upper level, thereby driving the lifting mechanism (2) and the rotating mechanism (3). The data processing unit, through an integrated image processing library and AI algorithms, enables real-time statistics of production line output, warehouse cargo location and status identification, and comprehensive monitoring of the operational status of the production logistics process. The communication unit is responsible for uploading the analysis results of the data processing unit and the device's own status data to the host monitoring computer and manufacturing execution system in real time, while receiving control commands from the upper-level system.

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