Automatic visual inspection device for product defects

Abstract

The invention discloses an automatic visual inspection device for product defects, and belongs to the field of visual inspection, the automatic visual inspection device comprises vertical rails, a cross beam is fixed at the tops of the two vertical rails, an electric telescopic rod is fixed in the middle of the cross beam in a penetrating manner, a middle column is fixed at the bottom end of the electric telescopic rod, and the outer surface of the middle column is rotatably connected with a rotating drum and a rotating frame; through the multi-position layout of the top camera II and the cameras I on the two sides, and in cooperation with the circumferential rotation of the rotating frame, the angle fine adjustment of the rotating wheel and the height adjustment driven by the electric telescopic rod, a three-dimensional shooting system is formed; the device not only can cover conventional areas such as the top and the side surface of a product, but also can accurately capture various defects such as scratches, recesses, deformation and chromatic aberration of complicated parts such as corners, curved surfaces and radians, thoroughly solves the problem of pain points of multiple detection blind areas of traditional equipment, and realizes full-dimensional and dead-corner-free defect investigation.

Description

Technical Field

[0001] This invention relates to the field of visual inspection technology, and in particular to an automated visual inspection device for product defects. Background Technology

[0002] In large-scale manufacturing, product defect detection is a crucial step in ensuring product quality and enhancing brand reputation. Traditional defect detection methods rely heavily on manual visual inspection, which is not only labor-intensive and inefficient, but also susceptible to the subjective experience, fatigue, and visual acuity of the inspectors, leading to a high rate of missed and false detections. This makes it difficult to meet the high-efficiency inspection requirements of modern production lines.

[0003] With the upgrading of production technology, some companies have introduced early visual inspection equipment, but the existing equipment still has many limitations: the inspection coverage is limited, most equipment can only take pictures of fixed angles or single surfaces, and it is easy to form blind spots for complex parts such as product edges and curved surfaces, and cannot fully capture various types of defects such as scratches, dents, deformation, and color difference.

[0004] Therefore, there is a need for a product defect visual inspection device with full-angle coverage, high adaptability, high-precision recognition and full-process automation to solve the problems of low efficiency, many blind spots, poor adaptability and insufficient accuracy in the existing technology, and to meet the quality control needs of large-scale and diversified production in the manufacturing industry. Summary of the Invention

[0005] To address the shortcomings of existing technologies, this invention provides an automated visual inspection device for product defects, which solves the problems mentioned in the background section.

[0006] Technical Solution: To solve the above-mentioned technical problems, according to one aspect of the present invention, more specifically, an automated visual inspection device for product defects includes vertical rails, with a crossbeam fixed to the top of two vertical rails, an electric telescopic rod fixed through the middle of the crossbeam, a central column fixed to the bottom end of the electric telescopic rod, a rotating cylinder and a rotating frame rotatably connected to the outer surface of the central column, the rotating cylinder and the rotating frame being integrally formed, a lifting frame rotatably connected to the outer surface of the rotating cylinder, the lifting frame being located on the upper surface of the rotating frame, the central column being fixedly connected to the upper surface of the lifting frame, and rotating wheels rotatably connected to both ends of the bottom of the rotating frame, a camera one being provided on the outer surface of the rotating wheel, and a camera two being provided at the bottom of the central column.

[0007] Furthermore, a bottom groove is formed on the lower surface of the lifting frame, and a bevel gear four is rotatably connected to the upper surface inside the bottom groove. Two running wheels are rotatably connected to the inner sides of the left and right ends of the lifting frame. A rotating shaft is fixed between the two running wheels. A bevel gear one is fixed to the outer surface of the rotating shaft. A bevel gear two is meshed with the outer side of the bevel gear one. A rotating rod is fixed to the middle of the bevel gear two. The end of the rotating rod away from the bevel gear two passes through the bottom groove and is fixed with a bevel gear three. The bevel gear three meshes with the bevel gear four. A spur gear is fixed to the bottom of the bevel gear four.

[0008] Furthermore, the outer surface of the rotating drum is provided with a circumferential array of toothed grooves, and the rotating drum is connected to the two spur gears through the toothed grooves.

[0009] Furthermore, the rotating frame has side grooves on both the left and right sides, and a worm gear is rotatably connected inside the side groove. A worm is meshed above the worm gear, and a transmission gear is fixed at the opposite end of each of the two worms. The transmission gear is rotatably connected to the inner side of the rotating frame, and the top of the transmission gear extends through to the upper surface of the rotating frame. A transmission roller is fixed at the front end of the worm gear and the front end of the rotating wheel. The front end of the transmission roller extends through to the front of the rotating frame, and a transmission belt is provided on the outer surface of the two transmission rollers.

[0010] Furthermore, the lower surface of the lifting frame is provided with several toothed grooves, and the lifting frame is connected to the two transmission gears through the toothed grooves.

[0011] Furthermore, the rotating frame has a U-shaped structure, and the vertical rail is made of C-shaped steel.

[0012] Furthermore, the lifting frame is located inside the two vertical rails, the lifting frame is slidably connected to the two vertical rails, and the running wheel is in contact with the inner wall of the vertical rail.

[0013] Furthermore, the detection methods are also included, with the following steps: S1. The top image of the product is captured by camera 2, and the two cameras 1 rotate to capture the outside image of the product. During the shooting process, the electric telescopic rod drives the central column to move camera 2 up and down to adapt to the top shooting needs of products of different heights. At the same time, the rotating frame drives the wheel and camera 1 to rotate in a circle. With the fine adjustment of the wheel itself, the product's outside is captured without blind spots, and the image data is transmitted to the background processing system in real time. S2. The backend system preprocesses the acquired images, optimizing image quality through grayscale conversion, noise reduction, and image enhancement algorithms to eliminate interference from ambient light and shooting angle. Then, it extracts feature parameters such as product outline and surface texture from the images and compares them with a preset standard product feature library to identify whether there are defects such as scratches, dents, deformation, and color difference. S3. The system determines whether a product is qualified or not based on the comparison results. For products with defects, it marks the location, type and severity of the defects and generates an inspection report. At the same time, the control device sends a signal to link the subsequent sorting mechanism to classify and transfer qualified and defective products, completing the entire automated inspection process. S4. During the testing process, the height of the lifting frame, the rotation speed of the rotating frame, and the shooting parameters of the camera can be adjusted to adapt to the testing of products of different specifications and materials, thereby improving the versatility of the device. After the testing is completed, the system automatically saves the testing data and images for subsequent traceability and statistical analysis.

[0014] The beneficial effects of the automated visual inspection device for product defects of the present invention are as follows: This invention utilizes a multi-camera setup consisting of "two top cameras + one side camera," combined with a rotating frame that rotates in a circular motion, a fine-tuning wheel angle, and an electric telescopic rod to drive height adjustment, forming a three-dimensional imaging system. This system can not only cover conventional areas such as the top and sides of a product, but also accurately capture various defects such as scratches, dents, deformations, and color differences in complex areas such as corners, curved surfaces, and arcs. It completely solves the pain point of traditional equipment having many blind spots and achieves full-dimensional, no-dead-angle defect inspection. Attached Figure Description

[0015] The present invention will now be described in further detail with reference to the accompanying drawings and specific implementation methods.

[0016] Figure 1 This is a schematic diagram of the structure of the present invention; Figure 2 This is a schematic diagram of the lifting frame and rotating frame in this invention; Figure 3 For the present invention Figure 2 A schematic diagram of the cross-sectional structure; Figure 4 This is a schematic diagram of the internal structure of the lifting frame in this invention; Figure 5 For the present invention Figure 2 A schematic diagram of the cross-sectional structure; Figure 6 This is a bottom view of the lifting frame structure in this invention.

[0017] In the diagram: 1. Vertical rail; 2. Crossbeam; 3. Electric telescopic rod; 4. Central column; 5. Rotary drum; 6. Lifting frame; 7. Rotating frame; 8. Rotating wheel; 9. Camera 1; 10. Camera 2; 11. Bottom groove; 12. Running wheel; 13. Rotating shaft; 14. Bevel gear 1; 15. Bevel gear 2; 16. Rotating rod; 17. Bevel gear 3; 18. Bevel gear 4; 19. Spur gear; 20. Side groove; 21. Transmission gear; 22. Worm gear; 23. Worm wheel; 24. Transmission roller; 25. Transmission belt. Detailed Implementation

[0018] The present invention will be described in detail below with reference to the accompanying drawings and embodiments. It should be noted that, unless otherwise specified, the embodiments and features described in the present application can be combined with each other.

[0019] To make the technical solution of the present invention clearer, the present invention will be further described in detail below with reference to the accompanying drawings and specific embodiments.

[0020] Reference Figures 1-6 An automated visual inspection device for product defects includes a vertical rail 1, with a crossbeam 2 fixed to the top of two vertical rails 1. An electric telescopic rod 3 is fixed through the middle of the crossbeam 2. A central column 4 is fixed to the bottom of the electric telescopic rod 3. A rotating cylinder 5 and a rotating frame 7 are rotatably connected to the outer surface of the central column 4. The rotating cylinder 5 and the rotating frame 7 are integrally formed. A lifting frame 6 is rotatably connected to the outer surface of the rotating cylinder 5. The lifting frame 6 is located on the upper surface of the rotating frame 7. The central column 4 is fixedly connected to the upper surface of the lifting frame 6. Rotary wheels 8 are rotatably connected to both ends of the bottom of the rotating frame 7. A camera 9 is installed on the outer surface of the rotating wheel 8. A camera 10 is installed at the bottom of the central column 4. The lower surface of the lifting frame 6 has a bottom groove 11. The upper surface of the bottom groove 11 is rotatably connected to a bevel gear 18. The inner sides of the left and right ends of the lifting frame 6 are rotatably connected to two running wheels 12. The two running wheels 12 are fixed together with a rotating shaft 13. The outer surface of the rotating shaft 13 is fixed with a bevel gear 14. The outer side of the bevel gear 14 is meshed with a bevel gear 15. The middle of the bevel gear 15 is fixed with a rotating rod 16. The end of the rotating rod 16 away from the bevel gear 15 passes through the bottom groove 11 and is fixed with a bevel gear 17. The bevel gear 17 is meshed with the bevel gear 18. The bottom of the bevel gear 18 is fixed with a spur gear 19.

[0021] Preferably, the outer surface of the rotating cylinder 5 is provided with a circumferential array of toothed grooves, and the rotating cylinder 5 is connected to two spur gears 19 through the toothed grooves.

[0022] Preferably, the rotating frame 7 has side grooves 20 on both the left and right sides. A worm gear 23 is rotatably connected inside the side groove 20. A worm 22 is meshed above the worm gear 23. A transmission gear 21 is fixed at the opposite end of each of the two worms 22. The transmission gear 21 is rotatably connected to the inside of the rotating frame 7. The top of the transmission gear 21 extends through to the upper surface of the rotating frame 7. A transmission roller 24 is fixed at the front end of the worm gear 23 and the front end of the rotating wheel 8. The front end of the transmission roller 24 extends through to the front of the rotating frame 7. A transmission belt 25 is provided on the outer surface of the two transmission rollers 24. While the rotating frame 7 drives the camera 9 to rotate and shoot, the camera 9 can be adjusted to shoot from above or below.

[0023] Preferably, the lower surface of the lifting frame 6 is provided with several toothed grooves, and the lifting frame 6 is connected to two transmission gears 21 through the toothed grooves.

[0024] Preferably, the rotating frame 7 has a U-shaped structure and the vertical rail 1 is made of C-shaped steel; The lifting frame 6 is located inside the two vertical rails 1. The lifting frame 6 is slidably connected to the two vertical rails 1. The running wheel 12 is in contact with the inner wall of the vertical rail 1. When lifting, the running wheel 12 rubs against the vertical rail 1, thereby causing the running wheel 12 to rotate.

[0025] Preferably, it also includes a detection method, the steps of which are as follows: S1. The top image of the product is captured by camera 2 10, and the two cameras 1 9 rotate to capture the outside image of the product. During the shooting process, the electric telescopic rod 3 drives the central column 4 to move the camera 2 10 up and down to adapt to the top shooting needs of products of different heights. At the same time, the rotating frame 7 drives the rotating wheel 8 and the camera 1 9 to rotate in a circle. With the fine adjustment of the rotating wheel 8 itself, the product's outside is captured without blind spots, and the image data is transmitted to the background processing system in real time. S2. The backend system preprocesses the acquired images, optimizing image quality through grayscale conversion, noise reduction, and image enhancement algorithms to eliminate interference from ambient light and shooting angle. Then, it extracts feature parameters such as product outline and surface texture from the images and compares them with a preset standard product feature library to identify whether there are defects such as scratches, dents, deformation, and color difference. S3. The system determines whether a product is qualified or not based on the comparison results. For products with defects, it marks the location, type and severity of the defects and generates an inspection report. At the same time, the control device sends a signal to link the subsequent sorting mechanism to classify and transfer qualified and defective products, completing the entire automated inspection process. S4. During the testing process, the height of the lifting frame 6, the rotation speed of the rotating frame 7, and the shooting parameters of the camera can be adjusted to adapt to the testing of products of different specifications and materials, thereby improving the versatility of the device. After the testing is completed, the system automatically saves the testing data and images for subsequent traceability and statistical analysis.

[0026] In summary, the working principle is as follows: 1. Shooting angle and direction adjustment principle: The displacement and rotation of the device are achieved through multi-stage gear and worm gear transmission, ensuring motion accuracy and stability.

[0027] The electric telescopic rod 3 retracts, driving the central column 4 and other structures to rise and fall. The lifting frame 6 slides with the vertical rail 1 through the running wheels 12 at both ends. When the running wheels 12 rotate due to friction, they drive the rotating shaft 13 to rotate synchronously. The bevel gear 14 on the rotating shaft 13 drives the meshing bevel gear 2 15 to rotate, which in turn drives the bevel gear 3 17 and bevel gear 4 18 through the rotating rod 16, ultimately causing the spur gear 19 to rotate. The spur gear 19 meshes with the tooth groove on the outer surface of the rotating cylinder 5. Since the rotating cylinder 5 and the rotating frame 7 are integrally formed, the rotating frame 7 ultimately drives the camera 9 to rise and fall while rotating and shooting around the product. While rotating and shooting the outside of the product for inspection, it performs all-round inspection at different heights.

[0028] When the rotating frame 7 drives the camera 9 to rotate, the toothed groove on the lower surface of the lifting frame 6 meshes with the transmission gear 21, the transmission gear 21 drives the worm 22 to rotate, the worm 22 meshes with the worm wheel 23 in the side groove 20, and drives the worm wheel 23 and the front transmission roller 24 to rotate; through the linkage of the transmission belt 25, the rotating wheel 8 rotates synchronously with the transmission roller 24, so as to realize the continuous fine adjustment of the angle of the camera 9. Finally, by using two cameras to move and change height along the circumference of the product, full-range coverage shooting of the outside of the product can be achieved.

[0029] 2. Image Acquisition Principle: Based on the above transmission structure, camera 2 10 is vertically aligned with the top of the product. By adjusting the height, it can adapt to different product specifications and acquire a complete image of the top. Two cameras 1 9 are symmetrically arranged at the bottom of the rotating frame 7. As the rotating frame 7 rotates and the rotating wheel 8 is finely adjusted, it forms a multi-angle shooting perspective, which can cover easily missed areas such as the sides and corners of the product, avoiding blind spots in the detection. The acquired image data is sent to the background processing system in real time through wired or wireless transmission to ensure the timeliness of the detection.

[0030] 3. Data Processing and Execution Principle: After receiving image data, the backend system first uses a preprocessing algorithm to eliminate interference factors such as noise and uneven lighting, thereby improving image clarity. Then, it uses a feature extraction algorithm to capture key information such as the product's surface contour, texture, and color, and compares it with a preset standard feature library. The system then uses thresholds to determine and identify the type and severity of defects. Finally, the system generates detection results and reports, and simultaneously outputs control signals to link the sorting mechanism, completing the classification of qualified and defective products. This achieves a fully automated closed-loop operation of "collection-processing-judgment-sorting" without manual intervention.

[0031] The embodiments described above are merely illustrative of several implementations of the present invention, and while the descriptions are specific and detailed, they should not be construed as limiting the scope of the present invention. It should be noted that those skilled in the art can make various modifications and improvements without departing from the concept of the present invention, and these modifications and improvements all fall within the scope of protection of the present invention. Therefore, the scope of protection of this patent should be determined by the appended claims.

Claims

1. An automated visual inspection device for product defects, comprising a vertical rail (1), characterized in that: A crossbeam (2) is fixed to the top of both vertical rails (1). An electric telescopic rod (3) is fixed through the middle of the crossbeam (2). A central column (4) is fixed to the bottom of the electric telescopic rod (3). A rotating cylinder (5) and a rotating frame (7) are rotatably connected to the outer surface of the central column (4). The rotating cylinder (5) and the rotating frame (7) are integrally formed. A lifting frame (6) is rotatably connected to the outer surface of the rotating cylinder (5). The lifting frame (6) is located on the upper surface of the rotating frame (7). The central column (4) is fixedly connected to the upper surface of the lifting frame (6). Rotary wheels (8) are rotatably connected to both ends of the bottom of the rotating frame (7). A camera (9) is provided on the outer surface of the rotating wheel (8). A camera (10) is provided at the bottom of the central column (4).

2. The automated visual inspection device for product defects according to claim 1, characterized in that: The lower surface of the lifting frame (6) is provided with a bottom groove (11). The upper surface of the bottom groove (11) is rotatably connected to a bevel gear four (18). The inner sides of the left and right ends of the lifting frame (6) are rotatably connected to two running wheels (12). A rotating shaft (13) is fixed between the two running wheels (12). A bevel gear one (14) is fixed on the outer surface of the rotating shaft (13). A bevel gear two (15) is meshed on the outer side of the bevel gear one (14). A rotating rod (16) is fixed in the middle of the bevel gear two (15). The end of the rotating rod (16) away from the bevel gear two (15) passes through the bottom groove (11) and is fixed with a bevel gear three (17). The bevel gear three (17) meshes with the bevel gear four (18). A spur gear (19) is fixed at the bottom of the bevel gear four (18).

3. The automated visual inspection device for product defects according to claim 2, characterized in that: The outer surface of the rotating cylinder (5) is provided with a circumferential array of toothed grooves, and the rotating cylinder (5) is connected to the two spur gears (19) through the toothed grooves.

4. The automated visual inspection device for product defects according to claim 1, characterized in that: The rotating frame (7) has side grooves (20) on both the left and right sides. A worm wheel (23) is rotatably connected inside the side groove (20). A worm (22) is meshed above the worm wheel (23). A transmission gear (21) is fixed at the opposite end of each of the two worms (22). The transmission gear (21) is rotatably connected to the inside of the rotating frame (7). The top of the transmission gear (21) extends through to the upper surface of the rotating frame (7). A transmission roller (24) is fixed at the front end of the worm wheel (23) and the front end of the rotating wheel (8). The front end of the transmission roller (24) extends through to the front of the rotating frame (7). A transmission belt (25) is provided on the outer surface of the two transmission rollers (24).

5. The automated visual inspection device for product defects according to claim 4, characterized in that: The lower surface of the lifting frame (6) is provided with several toothed grooves, and the lifting frame (6) is connected to the two transmission gears (21) through the toothed grooves.

6. The automated visual inspection device for product defects according to claim 1, characterized in that: The rotating frame (7) has a U-shaped structure, and the vertical rail (1) is made of C-shaped steel.

7. The automated visual inspection device for product defects according to claim 2, characterized in that: The lifting frame (6) is located inside the two vertical rails (1), the lifting frame (6) is slidably connected to the two vertical rails (1), and the running wheel (12) is in contact with the inner wall of the vertical rail (1).

8. The automated visual inspection device for product defects according to claim 1, characterized in that: It also includes detection methods, the steps of which are as follows: S1. The top image of the product is captured by camera 2 (10), and the two cameras 1 (9) rotate to capture the outside image of the product. During the shooting process, the electric telescopic rod (3) drives the central column (4) to move camera 2 (10) up and down to adapt to the top shooting needs of products of different heights. At the same time, the rotating frame (7) drives the rotating wheel (8) and camera 1 (9) to rotate in a circle. With the fine adjustment of the rotating wheel (8) itself, the product's outside is captured without blind spots, and the image data is transmitted to the background processing system in real time. S2. The backend system preprocesses the acquired images, optimizing image quality through grayscale conversion, noise reduction, and image enhancement algorithms to eliminate interference from ambient light and shooting angle. Then, it extracts feature parameters such as product outline and surface texture from the images and compares them with a preset standard product feature library to identify whether there are defects such as scratches, dents, deformation, and color difference. S3. The system determines whether a product is qualified or not based on the comparison results. For products with defects, it marks the location, type and severity of the defects and generates an inspection report. At the same time, the control device sends a signal to link the subsequent sorting mechanism to classify and transfer qualified and defective products, completing the entire automated inspection process. S4. During the testing process, the height of the lifting frame (6), the rotation speed of the rotating frame (7) and the shooting parameters of the camera can be adjusted to adapt to the testing of products of different specifications and materials, thereby improving the versatility of the device. After the testing is completed, the system automatically saves the testing data and images for subsequent traceability and statistical analysis.

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