Automobile part surface quality visual inspection system

Abstract

The invention discloses an automobile part surface quality visual inspection system which comprises a step frame, a lifting mechanism is fixedly installed at the bottom in the step frame, a second U-shaped frame is rotatably installed on the upper surface of the lifting mechanism, and a bearing frame is fixedly installed between the two ends in the second U-shaped frame. And a second conveyor is installed between the outer surface of the bearing frame and the second U-shaped frame in a transmission mode, a first U-shaped frame is fixedly installed on the upper surface of the top of the ladder frame, and clamping turnover mechanisms are fixedly installed at the two ends of the first U-shaped frame correspondingly. Through the design of the clamping turn-over mechanism and the lifting mechanism, the height and angle of the second conveyor are adjusted by using the lifting action of an X-shaped hinge rod on the mounting plate, so that the second conveyor can adapt to the specification of a to-be-detected accessory, and the accessory is automatically clamped, turned over and transferred through a double-shaft motor and clamping teeth; and full-coverage automatic detection of the upper and lower surfaces of the automobile parts is realized.

Description

Technical Field

[0001] This invention relates to the field of automotive parts quality inspection technology, specifically to a visual inspection system for the surface quality of automotive parts. Background Technology

[0002] The surface quality of automotive parts directly affects the assembly precision, service life, and appearance of a vehicle. This is especially true for critical components such as engine blocks, stamped body parts, and injection-molded interior parts. Defects such as scratches, dents, bumps, cracks, and missing materials on their surfaces not only reduce the structural strength and reliability of the parts but can also lead to assembly failures and even compromise vehicle safety. Therefore, surface quality inspection is an indispensable core process in automotive parts manufacturing.

[0003] For example, the national authorized patent announcement number CN218787815U discloses an automotive parts testing device, belonging to the field of automotive parts testing technology. It includes a testing platform, a support plate fixedly connected to the upper surface of the testing platform, and a lifting plate slidably connected inside the support plate. One end of the lifting plate has a rotating shaft, and the lower end of the rotating shaft is fixedly connected to a rotating plate. The rotating plate has symmetrically formed first grooves inside, and a slider is slidably connected inside the first grooves. A horizontal plate is fixedly connected to the upper surface of the slider, and a spring is provided on one side of the horizontal plate. An inverted L-shaped plate is fixedly connected to the upper surface of the rotating plate, and a spacing measuring instrument is fixedly connected to the lower surface of the inverted L-shaped plate. A testing component is provided on the upper surface of the slider, and a testing roller is rotatably connected to the lower surface of the slider. This device avoids the need for workers to repeatedly test the hole diameter of automotive parts using calipers, thus saving time and labor, improving the testing efficiency of automotive parts, reducing testing errors, and improving the quality of automotive parts.

[0004] However, the aforementioned automotive parts inspection devices focus primarily on measuring the aperture size and local parameters of the parts, without specifically targeting surface defects such as scratches, dents, and cracks. Furthermore, their inspection dimensions are limited, failing to achieve full-coverage visual inspection of the entire surface of the parts. Additionally, the positioning and transport of parts during inspection require manual adjustment, resulting in low automation and making it difficult to adapt to the continuous inspection needs of high-speed mass production lines. Their inspection structure lacks effective anti-interference and supplementary lighting design, easily leading to data deviations when external light fluctuates. Moreover, the adaptation and adjustment for different specifications and shapes of automotive parts are cumbersome, resulting in poor versatility and an inability to meet diverse surface quality inspection scenarios. Summary of the Invention

[0005] The purpose of this invention is to provide a visual inspection system for the surface quality of automotive parts, in order to solve the problems mentioned in the background art, such as the inability of the inspection equipment to achieve full-surface full-coverage inspection of parts, low degree of automation and poor adaptability to mass production requirements, weak supplementary lighting and anti-interference capabilities, insufficient detection accuracy, poor versatility and cumbersome adaptation and adjustment.

[0006] To achieve the above objectives, the present invention provides the following technical solution: A visual inspection system for the surface quality of automotive parts includes: a stepped frame, a lifting mechanism fixedly installed at the bottom of the stepped frame, a second U-shaped frame rotatably installed on the upper surface of the lifting mechanism, a bearing frame fixedly installed between the two ends of the second U-shaped frame, and a second conveyor drivingly installed between the outer surface of the bearing frame and the second U-shaped frame. The stepped frame has a first U-shaped frame fixedly installed on its top surface. A support frame is fixedly installed between the two ends of the first U-shaped frame. A first conveyor is driven between the outer surface of the support frame and the first U-shaped frame. The first conveyor is located above the second conveyor and is perpendicular to it. Both ends of the first U-shaped frame are fixedly installed with clamping and flipping mechanisms, so that the clamping and flipping mechanisms can clamp the inspected automotive parts on the first conveyor and then place them on the upper surface of the second conveyor by flipping them.

[0007] Preferably, the upper surfaces of the first U-shaped frame and the second U-shaped frame are fixedly installed with U-shaped cylinders and are perpendicular to the first conveyor and the second conveyor, respectively. Three sets of cameras are fixedly installed in the two sets of U-shaped cylinders at equal intervals, and a light tube is fixedly installed in the gap between each pair of cameras.

[0008] Preferably, both ends of the two sets of U-shaped tubes are fixedly connected to sunshade curtains.

[0009] Preferably, the clamping and flipping mechanism includes two sets of semicircular plates. The two sets of semicircular plates are fixedly installed on both sides of the first U-shaped frame, and a T-shaped arm is rotatably installed at one end of each set of semicircular plates. A guide rail block is fixedly installed on the upper surface of the T-shaped arm and slidably installed on the outer surface of the guide rail. The guide rail is fixedly installed on both sides of the semicircular plate in a semi-circular shape, and the guide rail is horizontally opposite to and overlaps with the two sides of the tail end of the first conveyor.

[0010] Preferably, a connecting plate is rotatably installed inside the guide rail block. One end of the outer surface of the connecting plate is fixedly installed with clamping teeth, and the other end of the outer surface of the connecting plate is rotatably connected to the piston rod of the first electric push rod. The first electric push rod is rotatably installed at one end of the T-shaped arm, so that the two sets of the first electric push rods can drive the connecting plate to move the two sets of clamping teeth inward synchronously through the pushing of the piston rod to achieve clamping of the automotive parts.

[0011] Preferably, the outer surface of the T-shaped arm has an annular cavity, and the outer annular surface of the annular cavity is provided with protruding teeth that engage with the inner teeth of the timing belt and are fitted onto the outer surface. The other end of the timing belt is fitted onto the outer surface of the timing pulley. The timing pulley is fixedly installed on the outer surface of the output shaft of the dual-axis motor. The dual-axis motor is fixedly installed in the support frame and the output shafts on both sides are rotated through the support frame and the first U-shaped frame in sequence.

[0012] Preferably, the lifting mechanism includes two sets of X-shaped hinge rods and a set of mounting plates. The two sets of X-shaped hinge rods are arranged horizontally opposite each other, with one end of each rod rotatably connected to the inner bottom of the step frame, and the upper ends on the same side rotatably connected to one end of the lower surface of the mounting plate. Rollers are rotatably mounted on the upper and lower ends of the other side of the two sets of X-shaped hinge rods, and the rollers on the upper and lower ends of the other side are respectively rollingly engaged with the inside of the first U-shaped cylinder and the second U-shaped cylinder. The first U-shaped cylinder is fixedly installed on one end of the upper surface of the mounting plate, and the second U-shaped cylinder is fixedly installed on one end of the inner bottom of the step frame.

[0013] Preferably, a support rod is fixedly installed between the inner members of the two sets of X-shaped hinge rods. One end of the support rod is rotatably connected to the piston rod of the second electric push rod, which is rotatably installed at one end of the other set of support rods. The support rod is fixedly installed between the outer members of the two sets of X-shaped hinge rods.

[0014] Preferably, two sets of L-shaped frames are fixedly installed on one end of the upper surface of the mounting plate, and a second U-shaped frame is rotatably installed between the two sets of L-shaped frames, so that it can be rotated to press its bottom against the upper surface of the mounting plate.

[0015] Preferably, a window is provided at one end of the upper surface of the mounting plate, and a connecting plate is fixedly installed on the lower surface of the window. A third electric push rod is rotatably installed at one end of the connecting plate, and the piston rod of the third electric push rod is rotatably installed on the lower surface of the second U-shaped frame through the window.

[0016] Compared with the prior art, the beneficial effects of the present invention are: 1. Through the coordinated operation of the first conveyor, the second conveyor and the clamping and flipping mechanism, the automatic continuous inspection of the upper and lower surfaces of automotive parts is realized, eliminating the need for manual assistance in flipping and transfer, greatly improving inspection efficiency and adapting to the needs of modern high-speed mass production lines.

[0017] 2. Through the combination design of multi-angle cameras, supplementary lighting tubes and sunshades at both ends inside the U-shaped tube, external light interference is effectively isolated, ensuring the clarity of image acquisition, significantly improving the accuracy of surface defect identification, and reducing the probability of missed detection and false detection.

[0018] 3. Through the X-shaped articulated lifting structure of the lifting mechanism and the rotatable design of the second U-shaped frame, the height and angle of the second conveyor can be flexibly adjusted, allowing it to adapt to the testing needs of automotive parts of different specifications and sizes, improving the equipment's versatility and reducing the equipment investment cost for enterprises to test multiple specifications of parts. Attached Figure Description

[0019] Figure 1 This is a top view of the overall structure of the present invention; Figure 2 This is a schematic diagram of the overall structure of the present invention from a bottom view; Figure 3 This is a schematic diagram of the overall side structure of the present invention; Figure 4 This is a schematic diagram of the structure of the semi-circular plate and guide rail of the present invention; Figure 5 This is a schematic diagram of the clamping and flipping mechanism of the present invention; Figure 6 This is a schematic diagram of the X-shaped hinge rod and mounting plate of the present invention; Figure 7 This is a schematic diagram of the lifting mechanism of the present invention.

[0020] In the diagram: 1. Ladder frame; 101. First U-shaped frame; 102. Second U-shaped frame; 103. First conveyor; 104. Second conveyor; 105. U-shaped cylinder; 106. Sunshade curtain; 107. Camera; 108. Light tube; 109. Support frame; 2. Clamping and flipping mechanism; 201. Semicircular plate; 202. Annular cavity; 203. Guide rail; 204. T-shaped arm; 205. First electric push rod; 206. 1. Guide rail block; 207. Connecting disc; 208. Clamping tooth; 209. Dual-axis motor; 210. Synchronous pulley; 3. Lifting mechanism; 301. X-shaped hinge rod; 302. Connecting plate; 303. First U-shaped cylinder; 304. Second U-shaped cylinder; 305. Roller; 306. Second electric push rod; 307. Third electric push rod; 308. L-shaped frame; 309. Mounting plate; 310. Window; 311. Support rod. Detailed Implementation

[0021] 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.

[0022] Please see Figures 1-7 This embodiment provides the following technical solution: like Figures 1-3As shown, a visual inspection system for the surface quality of automotive parts includes: a stepped frame 1, a lifting mechanism 3 fixedly installed at the bottom of the stepped frame 1, a second U-shaped frame 102 rotatably installed on the upper surface of the lifting mechanism 3, a bearing frame 109 fixedly installed between the two ends of the second U-shaped frame 102, and a second conveyor 104 drivingly installed between the outer surface of the bearing frame 109 and the second U-shaped frame 102. The first U-shaped frame 101 is fixedly installed on the top surface of the stepped frame 1. A bearing frame 109 is fixedly installed between the two ends of the first U-shaped frame 101. A first conveyor 103 is driven between the outer surface of the bearing frame 109 and the first U-shaped frame 101. The first conveyor 103 is located above the second conveyor 104 and is perpendicular to it. Both ends of the first U-shaped frame 101 are fixedly installed with clamping and flipping mechanisms 2, so that the clamping and flipping mechanisms 2 can clamp the inspected car parts on the first conveyor 103 and then place them on the upper surface of the second conveyor 104 by flipping them.

[0023] The upper surfaces of the first U-shaped frame 101 and the second U-shaped frame 102 are each fixedly equipped with a U-shaped cylinder 105, which is perpendicular to the first conveyor 103 and the second conveyor 104 respectively. Three sets of cameras 107 are fixedly installed in the two sets of U-shaped cylinders 105 at equal intervals, and a light tube 108 is fixedly installed in the gap between each pair of cameras 107.

[0024] Both ends of the two sets of U-shaped tubes 105 are fixedly connected to sunshade curtains 106.

[0025] Through the design of the stepped frame 1, the first conveyor 103, the second conveyor 104, the U-shaped cylinder 105, the sunshade 106, the camera 107, the light tube 108, the clamping and flipping mechanism 2, and the lifting mechanism 3, during operation, the height of the second U-shaped frame 102 is first adjusted by the lifting mechanism 3 so that the second conveyor 104 is adapted to the specifications and dimensions of the automotive parts to be inspected with the first conveyor 103 on the first U-shaped frame 101. Then, the automotive parts to be inspected are transported to the first conveyor 103, and the first conveyor 103 drives the parts. The component moves at a constant speed to the area below the U-shaped cylinder 105, which is perpendicular to it. At this time, the three sets of cameras 107 inside the U-shaped cylinder 105, under the supplementary lighting of the lamp tube 108, perform all-round visual imaging inspection of the upper surface of the component. The sunshades 106 at both ends of the U-shaped cylinder 105 can effectively isolate external light interference, ensuring image clarity and inspection accuracy. After the upper surface of the component is inspected, the first conveyor 103 transports it to the end position. At this time, the clamping and flipping mechanism 2 at both ends of the first U-shaped frame 101 is activated and accurately clamps the component. After inspection, the automotive parts are flipped over and then placed stably on the upper surface of the second conveyor 104 below. The second conveyor 104 moves the parts at a constant speed to the underside of the U-shaped cylinder 105, which is perpendicular to it. The camera 107 and lamp 108 inside the U-shaped cylinder 105 simultaneously complete a full-range visual inspection of the lower surface of the parts. The entire inspection process requires no manual intervention. Through the integrated support design of the stepped frame 1, the vertical layout of the first conveyor 103 and the second conveyor 104 is achieved. With the automatic flipping and transfer of the clamping and flipping mechanism 2 and the height adjustment function of the lifting mechanism 3, not only is full-coverage automated inspection of the upper and lower surfaces of automotive parts achieved, solving the problem of large blind spots in traditional equipment, but also significantly improving the continuity and efficiency of the inspection process, adapting to the needs of high-speed mass production. At the same time, the combination design of the sunshade 106 and the lamp 108 ensures the stability of the inspection accuracy, and the adjustment function of the lifting mechanism 3 improves the adaptability of the equipment to parts of different specifications, reducing the equipment investment cost and debugging time for enterprises.

[0026] like Figures 4-5 As shown, the clamping and flipping mechanism 2 includes two sets of semi-circular plates 201. The two sets of semi-circular plates 201 are fixedly installed on both sides of the first U-shaped frame 101, and a T-shaped arm 204 is rotatably installed on one end of each of the two sets of semi-circular plates 201. A guide rail block 206 is fixedly installed on the upper surface of the T-shaped arm 204 and slidably installed on the outer surface of the guide rail 203. The guide rail 203 is fixedly installed on both sides of the semi-circular plate 201 and is in a semi-circular shape. The guide rail 203 is horizontally opposite to and overlaps with the two sides of the tail end of the first conveyor 103.

[0027] A connecting plate 207 is rotatably mounted inside the guide block 206. A clamping tooth 208 is fixedly mounted on one end of the outer surface of the connecting plate 207. The other end of the outer surface of the connecting plate 207 is rotatably connected to the piston rod of the first electric push rod 205. The first electric push rod 205 is rotatably mounted on one end of the T-shaped arm 204. This allows the two sets of first electric push rods 205 to drive the connecting plate 207 to move the two sets of clamping teeth 208 inward synchronously through the pushing of the piston rod, thereby clamping the automotive parts.

[0028] The outer surface of the T-shaped arm 204 has an annular cavity 202. The outer annular surface of the annular cavity 202 has protruding teeth that mesh with the inner teeth of the timing belt and are fitted onto the outer surface. The other end of the timing belt is fitted onto the outer surface of the timing pulley 210. The timing pulley 210 is fixedly installed on the outer surface of the output shaft of the dual-axis motor 209. The dual-axis motor 209 is fixedly installed inside the support frame 109 and allows the output shafts on both sides to rotate through the support frame 109 and the first U-shaped frame 101 in sequence.

[0029] Through the design of the semi-circular plate 201, annular cavity 202, guide rail 203, T-shaped arm 204, first electric push rod 205, guide rail block 206, connecting plate 207, clamping teeth 208, dual-axis motor 209, and synchronous pulley 210, the first conveyor 103 can uniformly transport the inspected parts to the end position, and then start the dual-axis motor 209 to drive the synchronous pulley 210 on the output shaft to rotate. The synchronous pulley 210 drives the T-shaped arm 204 through the synchronous belt. The outer surface annular cavity 202 rotates. Since the outer annular surface protrusions of the annular cavity 202 mesh with the inner teeth of the synchronous belt, stable power transmission can be achieved, thereby driving the T-shaped arm 204 to rotate around one end of the semicircular plate 201. At the same time, the guide block 206 on the upper surface of the T-shaped arm 204 will slide smoothly along the semi-annular guide rails 203 on both sides of the semicircular plate 201. The guide rails 203 are horizontally aligned with the two sides of the tail end of the first conveyor 103, ensuring that the T-shaped arm 204 moves accurately to the accessory. Once the clamping position is in place, the piston rod of the first electric push rod 205 pushes, driving the connecting plate 207 inside the guide rail block 206 to rotate. This, in turn, causes the clamping teeth 208 at one end of the connecting plate 207 to retract inward simultaneously, achieving a stable clamping of the automotive parts. After clamping is completed, the dual-axis motor 209 reverses to drive the T-shaped arm 204 to flip again along the guide rail 203, smoothly transferring the parts to the upper surface of the second conveyor 104 below. At this time, the parts are with their lower surface facing up. Subsequently, the piston rod of the first electric push rod 205 retracts, the clamping teeth 208 release the parts, and the dual-axis motor 209 reverses again to drive the T-shaped arm 204 to reset, preparing for the next clamping and flipping operation. This achieves full-coverage automated inspection of the upper and lower surfaces of the automotive parts, solving the problem of large blind spots in traditional equipment inspection, and significantly improving inspection efficiency, adapting to the needs of high-speed mass production. At the same time, the combination design of the sunshade 106 and the lamp tube 108 ensures the stability of inspection accuracy.

[0030] like Figures 6-7 As shown, the lifting mechanism 3 includes two sets of X-shaped hinge rods 301 and a set of mounting plates 309. The two sets of X-shaped hinge rods 301 are arranged horizontally opposite each other. One end of each rod is rotatably connected to the inner bottom of the step frame 1, and the upper end of each rod on the same side is rotatably connected to one end of the lower surface of the mounting plate 309. Rollers 305 are rotatably mounted on the upper and lower ends of the other side of the two sets of X-shaped hinge rods 301. The rollers 305 on the upper and lower ends of the other side are respectively rollingly engaged with the inside of the first U-shaped cylinder 303 and the second U-shaped cylinder 304. The first U-shaped cylinder 303 is fixedly installed on one end of the upper surface of the mounting plate 309, and the second U-shaped cylinder 304 is fixedly installed on one end of the inner bottom of the step frame 1.

[0031] A support rod 311 is fixedly installed between the inner members of the two sets of X-shaped hinge rods 301. One end of the support rod 311 is rotatably connected to the piston rod of the second electric push rod 306. The second electric push rod 306 is rotatably installed at one end of the other set of support rods 311. The support rod 311 is fixedly installed between the outer members of the two sets of X-shaped hinge rods 301.

[0032] Two sets of L-shaped brackets 308 are fixedly installed on one end of the upper surface of the mounting plate 309. The second U-shaped bracket 102 is rotatably installed between the two sets of L-shaped brackets 308, and can be rotated to press the bottom against the upper surface of the mounting plate 309.

[0033] A window 310 is provided at one end of the upper surface of the mounting plate 309, and a connecting plate 302 is fixedly installed on the lower surface of the window 310. A third electric push rod 307 is rotatably installed at one end of the connecting plate 302, and the piston rod of the third electric push rod 307 is rotatably installed on the lower surface of the second U-shaped frame 102 through the window 310.

[0034] Through the design of the X-shaped hinge rod 301, connecting plate 302, first U-shaped cylinder 303, second U-shaped cylinder 304, roller 305, second electric push rod 306, third electric push rod 307, L-shaped frame 308, and support rod 311, before inspecting the automotive parts, the height and angle of the second U-shaped frame 102 are adjusted by the lifting mechanism 3 to adapt to the specifications and dimensions of the automotive parts to be inspected. Specifically, the two sets of horizontally opposite X-shaped hinge rods 301 in the lifting mechanism 3 provide core lifting support, with one end rotatably connected to... At the bottom of the stepped frame 1, the upper end on the same side is rotatably connected to one end of the lower surface of the mounting plate 309. When the height of the mounting plate 309 needs to be adjusted, the second electric push rod 306 is activated, and its piston rod extends and retracts, driving the support rod 311 between the inner and outer rods of the two sets of X-shaped hinge rods 301 to move relative to each other, thereby driving the X-shaped hinge rods 301 to open and close. At this time, the rollers 305 at the upper and lower ends of the other side of the X-shaped hinge rods 301 roll smoothly inside the first U-shaped cylinder 303 and the second U-shaped cylinder 304 respectively. 03 is fixed to the upper surface of the mounting plate 309, and the second U-shaped cylinder 304 is fixed to the bottom of the step frame 1, ensuring the stability and precision of the opening, closing, lifting and lowering of the X-shaped hinge rod 301, realizing flexible adjustment of the height of the mounting plate 309, and thus driving the second U-shaped frame 102 above to lift and lower synchronously, so that the second conveyor 104 on it and the first conveyor 103 on the first U-shaped frame 101 maintain a suitable distance and height to match the size of the automotive parts. When it is necessary to finely adjust the angle of the second U-shaped frame 102 to adapt to the inspection of special specification parts, During testing, the two sets of L-shaped frames 308 on the upper surface of the mounting plate 309 provide stable rotational support for the second U-shaped frame 102. The piston rod of the third electric push rod 307, which is rotatably mounted on the connecting plate 302, extends and retracts through the window 310, driving the second U-shaped frame 102 to rotate around the L-shaped frame 308. This allows the bottom of the second U-shaped frame 102 to selectively press against the upper surface of the mounting plate 309, achieving precise micro-adjustment of the angle. Once the height and angle are adjusted, the automotive parts to be tested can be transported to the first conveyor 103 for surface testing.

[0035] Specifically, this embodiment also provides a method for optimizing the detection coverage of a visual inspection system for the surface quality of automotive parts. The method employs a surface detection coverage optimization equation to evaluate and adjust the detection posture in real time. The equation is as follows: ; in, And the system is being improved. The target value is no less than 0.95, and the lifting mechanism and clamping and flipping mechanism are adjusted in a coordinated manner. The parameters are defined as follows: Effective detection coverage, dimensionless; n: The total number of cameras involved in the detection; The theoretical field of view coverage of the i-th camera is obtained from the camera model and calibration. The angle between the optical axis of the i-th camera and the normal to the surface of the accessory is calculated from the camera mounting angle and the orientation of the accessory. The actual distance from the i-th camera to the surface of the accessory is measured by a distance sensor or encoder; The optimal detection distance calibrated by the system; system calibration value. The adjustable distance range from the camera to the accessory surface is limited by the system's mechanical structure; σ: Standard deviation of surface curvature or texture undulation of the accessory, preset according to accessory type or estimated on the first scan; α: The field of view of the camera, an inherent parameter of the camera; : Total surface area of ​​the accessory to be inspected, either input by the user or obtained through 3D scanning.

[0036] The derivation of the equation is as follows: The detection coverage optimization equation of this invention is derived based on the following principle: 1. Basic coverage definition: Effective detection coverage Defined as the sum of the effective coverage areas of all cameras and the total area of ​​the surface to be tested of the accessories. The ratio of .

[0037] 2. Camera Effective Coverage Area Modeling: The effective coverage area of ​​each camera is affected by three factors: Theoretical field of view Determined by camera resolution and field of view; Attitude-distance influence factor The angle between the camera's optical axis and the normal to the accessory's surface. This will result in a smaller projected area, following the cosine law; the distance from the camera to the surface of the accessory. Deviating from the optimal distance When image clarity decreases and detection effectiveness is reduced, a Gaussian attenuation model is adopted. Surface undulation impact factor: Surface curvature or texture undulations in components can cause some areas to be at the edge of the field of view or out of focus. A Gaussian attenuation model is used, where σ is the standard deviation of surface undulation. Indicates distance The approximate value of the field radius at that location.

[0038] 3. Comprehensive modeling: Multiply the above factors to obtain the effective coverage area of ​​each camera, sum them up and divide by the total area to obtain the overall effective coverage rate of the system.

[0039] Example: Taking the inspection of a rectangular flat component (500mm × 300mm) as an example: 1. Determine the parameters: =150000 mm²; The system has a total of n=6 cameras, and the theoretical field of view coverage of each camera is... =30000mm 2 ; Set the optimal detection distance =400mm, adjustable range =300mm, =500mm; The camera's field of view α = 60° = 1.047 rad; Surface undulation standard deviation σ = 2 mm; Assuming all current cameras =0, =400mm; 2. Calculation : ; 3. Calculate the exponential decay term: ; 4. Calculation : ; because A value >1 indicates that the current detection coverage is sufficient, and the system can be adjusted appropriately to save energy or increase detection speed. If If the value is less than 0.95, the system will automatically adjust the lifting mechanism or the clamping and flipping mechanism until the coverage requirement is met.

[0040] Technical effects of the solution 1. Quantitative assessment of coverage integrity: Effective detection coverage is calculated in real time using mathematical equations to ensure no visual blind spots.

[0041] 2. Adaptive adjustment: The system can adjust according to... The lifting mechanism and clamping flipping mechanism are automatically adjusted to achieve dynamic optimization.

[0042] 3. Improve detection accuracy and stability: By considering factors such as posture, distance, and surface undulations, optimize imaging conditions to reduce missed detections and false detections.

[0043] 4. Enhanced versatility: The formula can be adapted to accessories of different sizes, shapes and surface features, realizing multiple uses of one machine and reducing the equipment investment cost for enterprises.

[0044] Working principle and process: 1. System Initialization: Input the component type or obtain the component dimensions, surface undulation parameter σ, and total area through laser scanning. .

[0045] 2. Parameter Acquisition: Read the current camera pose parameters. ,distance wait.

[0046] 3. Coverage Calculation: Calculate the current coverage using the surface detection coverage optimization equation. .

[0047] 4. Judgment and Adjustment: like ≥0.95, proceed to the testing process; like If the value is less than 0.95, activate the lifting mechanism to adjust the height and angle of the second conveyor, or fine-tune the posture of the parts using the clamping and flipping mechanism, and recalculate. , until the threshold is met.

[0048] 5. Perform inspection: Visual inspection of the upper and lower surfaces is carried out on the first and second conveyors respectively.

[0049] 6. Real-time monitoring: Continuous monitoring during the testing process. If the coverage decreases due to vibration or component displacement, the system parameters will be dynamically fine-tuned.

[0050] 7. Output Results: After the detection is complete, the output will be... As one of the indicators for evaluating the quality of the inspection, it is saved together with the defect image.

[0051] Based on the above technical solution, the working steps of this solution are summarized as follows: During operation, the second electric push rod 306 first drives the support rods 311 between the inner and outer rods of the two sets of horizontally arranged X-shaped hinge rods 301 to move relative to each other, causing the X-shaped hinge rods 301 to open and close. At this time, the rollers 305 at the upper and lower ends of one side of the X-shaped hinge rod 301 roll smoothly inside the first U-shaped cylinder 303 and the second U-shaped cylinder 304, respectively, thereby adjusting the height of the mounting plate 309, which in turn drives the second U-shaped frame 102 above to rise and fall synchronously, so that the second conveyor 104 on it and the first conveyor 103 on the first U-shaped frame 101 maintain a suitable distance and height to match the size of the automotive parts. When it is necessary to fine-tune the second U-shaped frame 102... When the angle is adapted to the inspection of special specification parts, the two sets of L-shaped frames 308 on the upper surface of the mounting plate 309 provide stable rotational support for the second U-shaped frame 102. The piston rod of the third electric push rod 307 rotatably mounted on the connecting plate 302 extends and retracts through the window 310, driving the second U-shaped frame 102 to rotate around the L-shaped frame 308, so that the bottom of the second U-shaped frame 102 can selectively press against the upper surface of the mounting plate 309, realizing precise fine-tuning of the angle. After the height and angle are adjusted, the automotive parts to be inspected can be transported to the first conveyor 103. The first conveyor 103 drives the parts to move at a uniform speed to the underside of the U-shaped cylinder 105 that is perpendicular to it. At this time, the three sets of cameras 107 arranged at equal intervals inside the U-shaped cylinder 105 are positioned between every two sets of cameras 107. Under the supplementary lighting of the lamps 108 within the spacing, the upper surface of the accessory is subjected to all-round visual imaging inspection. The sunshade curtains 106 fixedly connected to both ends of the U-shaped cylinder 105 effectively isolate external light interference, ensuring image clarity and inspection accuracy. After the upper surface of the accessory is inspected, the first conveyor 103 transports it to the end position, and then starts the dual-axis motor 209 and drives the synchronous wheel 210 on the output shaft to rotate. The synchronous wheel 210 drives the outer surface annular cavity 202 of the T-shaped arm 204 to rotate through the synchronous belt. Since the outer annular surface convex teeth of the annular cavity 202 are engaged with the inner teeth of the synchronous belt, the power can be stably transmitted, thereby driving the T-shaped arm 204 to rotate around one end of the semicircular plate 201. At the same time, the guide block 206 on the upper surface of the T-shaped arm 204 will rotate along the semicircular plate 201. The semi-circular guide rails 203 on both sides slide smoothly, and the guide rails 203 are horizontally aligned with the two sides of the tail end of the first conveyor 103, ensuring that the T-arm 204 moves accurately to the part clamping position. After it is in position, the piston rod of the first electric push rod 205 pushes, driving the connecting plate 207 inside the guide rail block 206 to rotate, thereby driving the clamping teeth 208 at one end of the connecting plate 207 to move inward synchronously, realizing the stable clamping of the automotive part. After clamping is completed, the dual-axis motor 209 reverses to drive the T-arm 204 to flip again along the guide rail 203, smoothly transferring the part to the upper surface of the second conveyor 104 below. At this time, the part is with its lower surface facing up. The second conveyor 104 can then drive the part to move at a constant speed to the lower part of the U-shaped cylinder 105 that is perpendicular to it.The camera 107 and the light tube 108 inside the U-shaped cylinder 105 simultaneously complete omnidirectional visual imaging inspection of the lower surface of the component. The entire process achieves fully automated inspection of the upper and lower surfaces of automotive components, with all structures working together without manual intervention.

[0052] In summary: By using the lifting action of the X-shaped hinge rod 301 to lift the mounting plate 309, the height and angle of the second conveyor 104 can be adjusted to adapt to the specifications of the parts to be inspected, thereby improving the equipment's adaptability to parts of different specifications. Furthermore, the automatic clamping, flipping, and transfer of parts by the dual-axis motor 209 and the clamping teeth 208 achieves full-coverage automated inspection of the upper and lower surfaces of automotive parts, solving the problem of large blind spots in traditional equipment, and significantly improving the continuity and efficiency of the inspection process, thus meeting the needs of high-speed mass production.

[0053] All parts not described in this invention are the same as or can be implemented using existing technology. Although embodiments of the invention have been shown and described, it will be understood by those skilled in the art that various changes, modifications, substitutions, and variations can be made to these embodiments without departing from the principles and spirit of the invention, the scope of which is defined by the appended claims and their equivalents.

Claims

1. A visual inspection system for the surface quality of automotive parts, characterized in that, include: A stepped frame (1) is provided, with a lifting mechanism (3) fixedly installed at the bottom inside the stepped frame (1). A second U-shaped frame (102) is rotatably installed on the upper surface of the lifting mechanism (3). A bearing frame (109) is fixedly installed between the two ends inside the second U-shaped frame (102). A second conveyor (104) is driven between the outer surface of the bearing frame (109) and the second U-shaped frame (102). The top surface of the stepped frame (1) is fixedly mounted with a first U-shaped frame (101). A bearing frame (109) is fixedly mounted between the two ends of the first U-shaped frame (101). A first conveyor (103) is driven between the outer surface of the bearing frame (109) and the first U-shaped frame (101). The first conveyor (103) is located at the upper end of the second conveyor (104) and is perpendicular to it. Both ends of the first U-shaped frame (101) are fixedly mounted with clamping and flipping mechanisms (2), so that the clamping and flipping mechanisms (2) can clamp the inspected car parts on the first conveyor (103) and then place them on the upper surface of the second conveyor (104) by flipping them.

2. The visual inspection system for the surface quality of automotive parts according to claim 1, characterized in that: The upper surfaces of the first U-shaped frame (101) and the second U-shaped frame (102) are fixedly equipped with U-shaped cylinders (105) and are perpendicular to the first conveyor (103) and the second conveyor (104) respectively. Three sets of cameras (107) are fixedly installed in the two sets of U-shaped cylinders (105) at equal intervals, and a lamp tube (108) is fixedly installed in the gap between each pair of cameras (107).

3. The visual inspection system for the surface quality of automotive parts according to claim 2, characterized in that: Both ends of the two sets of U-shaped tubes (105) are fixedly connected to sunshade curtains (106).

4. The visual inspection system for the surface quality of automotive parts according to claim 1, characterized in that: The clamping and flipping mechanism (2) includes two sets of semicircular plates (201). The two sets of semicircular plates (201) are fixedly installed on both sides of the first U-shaped frame (101). A T-shaped arm (204) is rotatably installed on one end of each set of semicircular plates (201). A guide block (206) is fixedly installed on the upper surface of the T-shaped arm (204) and slidably installed on the outer surface of the guide rail (203). The guide rail (203) is fixedly installed on both sides of the semicircular plate (201) and is semi-circular. The guide rail (203) is horizontally opposite to and overlaps with the tail end of the first conveyor (103).

5. The visual inspection system for the surface quality of automotive parts according to claim 4, characterized in that: A connecting plate (207) is rotatably installed inside the guide block (206). A clamping tooth (208) is fixedly installed on one end of the outer surface of the connecting plate (207). The other end of the outer surface of the connecting plate (207) is rotatably connected to the piston rod of the first electric push rod (205). The first electric push rod (205) is rotatably installed on one end of the T-shaped arm (204). This allows the two sets of first electric push rods (205) to drive the connecting plate (207) to move the two sets of clamping teeth (208) inward synchronously through the pushing of the piston rod, thereby clamping the automotive parts.

6. A visual inspection system for the surface quality of automotive parts according to claim 4 or 5, characterized in that: The outer surface of the T-shaped arm (204) is provided with an annular cavity (202). The outer annular surface of the annular cavity (202) is provided with protruding teeth that mesh with the inner teeth of the synchronous belt and are fitted onto the outer surface. The other end of the synchronous belt is fitted onto the outer surface of the synchronous pulley (210). The synchronous pulley (210) is fixedly installed on the outer surface of the output shaft of the dual-axis motor (209). The dual-axis motor (209) is fixedly installed in the support frame (109) and the output shafts on both sides are sequentially rotated through the support frame (109) and the first U-shaped frame (101).

7. The visual inspection system for the surface quality of automotive parts according to claim 1, characterized in that: The lifting mechanism (3) includes two sets of X-shaped hinge rods (301) and a set of mounting plates (309). The two sets of X-shaped hinge rods (301) are arranged horizontally opposite each other. One end of each rod is rotatably connected to the inner bottom of the step frame (1), and the upper end of each rod on the same side is rotatably connected to the lower surface of the mounting plate (309). Rollers (305) are rotatably installed on the upper and lower ends of the other side of the two sets of X-shaped hinge rods (301). The rollers (305) on the upper and lower ends of each roller are respectively rolled and fitted inside the first U-shaped cylinder (303) and the second U-shaped cylinder (304). The first U-shaped cylinder (303) is fixedly installed on the upper surface of the mounting plate (309), and the second U-shaped cylinder (304) is fixedly installed on the inner bottom of the step frame (1).

8. The visual inspection system for the surface quality of automotive parts according to claim 7, characterized in that: A support rod (311) is fixedly installed between the inner members of the two sets of X-shaped hinge rods (301). One end of the support rod (311) is rotatably connected to the piston rod of the second electric push rod (306). The second electric push rod (306) is rotatably installed at one end of the other set of support rods (311). The support rod (311) is fixedly installed between the outer members of the two sets of X-shaped hinge rods (301).

9. The visual inspection system for the surface quality of automotive parts according to claim 7, characterized in that: Two sets of L-shaped brackets (308) are fixedly installed on one end of the upper surface of the mounting plate (309). The second U-shaped bracket (102) is rotatably installed between the two sets of L-shaped brackets (308) and can be rotated to press the bottom of the mounting plate (309) against the upper surface by flipping.

10. The visual inspection system for the surface quality of automotive parts according to claim 9, characterized in that: The mounting plate (309) has a window (310) at one end of its upper surface, and a connecting plate (302) is fixedly installed on the lower surface of the window (310). A third electric push rod (307) is rotatably installed on one end of the connecting plate (302), and the piston rod of the third electric push rod (307) is rotatably installed on the lower surface of the second U-shaped frame (102) through the window (310).

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