Zipper detection equipment
By combining horizontal and vertical inspection mechanisms and a multi-angle imaging system, integrating multiple optical inspection units and customized light sources, the problems of numerous blind spots and weak defect adaptability in zipper inspection are solved, realizing high-precision, full-surface, and automated inspection of various types of defects in zippers.
Patent Information
- Authority / Receiving Office
- CN · China
- Patent Type
- Applications(China)
- Current Assignee / Owner
- DSTEK CO LTD
- Filing Date
- 2025-12-31
- Publication Date
- 2026-04-21
AI Technical Summary
Existing technologies cannot perform high-precision and comprehensive detection of various types of minute defects in zippers, especially in complex three-dimensional structures, where there are many blind spots, weak defect adaptability, and low degree of automation.
By combining horizontal and vertical detection mechanisms with a rotating conveyor mechanism, multiple types of optical detection units and customized light sources are integrated to achieve multi-angle imaging.
It achieves high-precision and high-stability detection of multiple types and locations of defects in the complex three-dimensional structure of zippers, improving detection efficiency and result reliability, and reducing the risk of false detection and missed detection.
Smart Images
Figure CN121899148A_ABST
Abstract
Description
Technical Field
[0001] This application relates to the field of imaging detection technology, and in particular to a zipper detection device. Background Technology
[0002] In the zipper manufacturing industry, zippers are key accessories in clothing, bags, and home furnishings, and their appearance quality directly affects the quality and user experience of the final product. With the increasing demands for product refinement in the consumer market, minor defects on the zipper surface (such as discoloration, burrs, defects, and bubbles) have become crucial indicators for quality control. Traditional manual visual inspection methods are not only inefficient but also susceptible to factors such as worker fatigue and subjective judgment, making it difficult to achieve stable and high-precision defect identification, especially in high-volume, high-paced production environments. Automated, high-precision appearance inspection technology has become an urgent need for the industry.
[0003] Currently, some automated inspection equipment based on machine vision has been applied in the zipper production process. Common technical solutions mainly employ single or simple combinations of optical imaging systems, such as using a fixed-angle ring light source with a common industrial camera for surface imaging, or detecting contour defects through backlighting. These methods improve the automation level of inspection to some extent, but their imaging methods are often limited to a certain type of defect or a fixed angle, and cannot fully cover the multiple types and locations of defects under the complex three-dimensional structure of zippers.
[0004] Therefore, there is currently a technical problem that makes it impossible to perform high-precision and comprehensive detection of various minor defects in zippers. Summary of the Invention
[0005] The purpose of this application is to provide a zipper inspection device to solve the above-mentioned problems.
[0006] To achieve the above objectives, in a first aspect, this application proposes a zipper inspection device, which includes: The feeding mechanism is used to transport the zippers one by one to the horizontal detection mechanism; A horizontal detection mechanism, located downstream of the feeding mechanism, is used to perform imaging detection on the preset surface area of the zipper and the connection point of the body, and to transport the zipper to the rotary conveying mechanism. A rotary conveying mechanism is located downstream of the horizontal detection mechanism and is used to rotate the zipper output by the horizontal detection mechanism by a preset angle and then convey it to the vertical detection mechanism. A vertical detection mechanism, located downstream of the rotary conveyor mechanism, is used to perform imaging detection on the side area, body cover area, body connection area and perforation area of the rotated zipper, and to convey the zipper to the unloading mechanism. The feeding mechanism is used to sort zippers based on the detection results of the horizontal and vertical detection mechanisms. The horizontal detection mechanism and the vertical detection mechanism are both integrated with multiple types of optical detection units corresponding to different detection parts of the zipper. Each of the multiple types of optical detection units is equipped with a global camera and at least two custom light sources.
[0007] In some embodiments, the level detection mechanism includes: Horizontal support; A horizontal detection track is fixed to the waist of the horizontal support. The horizontal detection track is used to hold the zipper and forms a sliding connection with the zipper. A transport module fixed to the top of the horizontal support includes a servo motor and a material feeding claw. The material feeding claw is used to drive the zipper to move along the horizontal detection track to each detection station of the horizontal imaging module and the rotary conveying mechanism under the drive of the servo motor. The horizontal imaging module includes multiple optical detection units arranged along both sides of the horizontal detection track, used to sequentially perform imaging detection on the preset surface area of the zipper and the body connection.
[0008] In some embodiments, the horizontal imaging module includes: A first horizontal imaging component arranged along the first side of the horizontal detection track is used to perform imaging detection on the back of the zipper body and the front of the handle; A second horizontal imaging component arranged along the second side of the horizontal detection track is used to perform imaging detection on the front of the zipper body, the back of the handle, and the body connection. Both the first horizontal imaging component and the second horizontal imaging component integrate a first type of optical detection unit and a second type of optical detection unit.
[0009] In some embodiments, the bottom of the horizontal detection track is provided with a shield for blocking the hand, wherein the shield has a light-transmitting window in the area where imaging detection is performed on the front and back of the hand.
[0010] In some embodiments, the vertical detection mechanism includes: Vertical support; The vertical detection track fixed to the vertical bracket is used to hold the zipper and form a sliding connection with the zipper so that the zipper can slide to each detection station of the vertical imaging module and the unloading mechanism under the action of gravity. The blocking component fixed to the vertical bracket is used to block the downward movement of the zipper when it slides down to each detection station of the vertical imaging module. The vertical imaging module includes multiple optical detection units arranged along the vertical detection track, used for imaging detection of the side area of the zipper, the body-covered area, the body connection area, and the perforation area.
[0011] In some embodiments, the vertical detection track includes: a vertical track segment and a translational track segment located downstream of the vertical track segment; The vertical imaging module includes: The first vertical imaging component, arranged along the vertical track segment, is used to perform imaging detection on the side area of the zipper, the part obscured by the body, and the connection point of the body. The second vertical imaging component, arranged along the translation track segment, is used to perform imaging detection on the perforated area of the zipper; The first vertical imaging component integrates a first type of optical detection unit, a second type of optical detection unit, and a third type of optical detection unit, while the second vertical imaging component integrates a fourth type of optical detection unit.
[0012] In some embodiments, the first type of optical detection unit includes a first global camera, a first bright field light source, and a first dark field light source. The first bright field light source is a planar coaxial light source, and the illumination light of the first bright field light source is parallel to the optical axis of the lens of the first global camera. The first dark field light source is a shadowless ring light, and the central axis of the first dark field light source is coaxial with both the optical axis of the lens of the first global camera and the imaging aperture of the first bright field light source. The second type of optical detection unit includes a second global camera, a second bright field light source, and a second dark field light source. The second bright field light source is a parallel coaxial light source, and the illumination light of the second bright field light source is parallel and coaxial with the lens optical axis of the second global camera. The second dark field light source is a ring light source whose emission direction forms a preset angle with the lens optical axis of the second global camera.
[0013] In some embodiments, the third type of optical detection unit includes a third global camera, a third bright field light source, and a high-angle stripe light. The third bright field light source is a planar coaxial light source. The lens optical axis of the third global camera has a preset tilt angle with the central axis of the imaging aperture of the third bright field light source. The high-angle stripe light is combined with the third bright field light source to provide supplementary illumination to the curved surface area of the torso of the zipper. The fourth type of optical detection unit includes a vertically arranged fourth global camera, a horizontally arranged fourth bright field light source and a backlight light source. The fourth bright field light source is a planar coaxial light source, and the backlight light source is a parallel plane light source. It is set at the bottom of the zipper to generate the outline silhouette of the perforated area of the zipper.
[0014] In some embodiments, the feeding mechanism includes: A vibratory feeder is used to hold batches of zipper products and output the zipper products one by one through directional vibration. A linear vibrating track, connected to the output end of the vibrating plate, is used to receive the zipper products output by the vibrating plate and transport the zipper products to the cutting structure; The cutting mechanism, located downstream of the linear vibrating track, is used to separate the zipper products conveyed by the linear vibrating track into individual zippers, and to convey the zippers one by one to the horizontal detection mechanism with a preset posture and preset spacing.
[0015] In some embodiments, the rotary conveying mechanism includes a rotary drive assembly and a clamping assembly. The clamping assembly is used to clamp the zipper output by the horizontal detection mechanism and, after being rotated by a preset angle under the drive of the rotary drive assembly, releases the rotated zipper to the vertical detection mechanism.
[0016] Compared with the prior art, the beneficial effects of this application include: Firstly, this application establishes a multi-angle imaging system by setting up horizontal and vertical detection mechanisms and utilizing a rotating conveyor mechanism for attitude conversion. This physically solves the limitations of single-angle imaging, enabling imaging detection of complex surfaces and hidden parts of the zipper, such as its surface, sides, body-covered areas, body joints, and perforation areas, covering multiple types and locations of defects in the complex three-dimensional structure of the zipper.
[0017] Secondly, this application integrates multiple types of optical detection units corresponding to different detection parts of the zipper, and employs various customized light sources, including planar coaxial light, parallel coaxial light, and shadowless ring light. This allows for the provision of the most suitable lighting environment for defects with different shapes and reflective properties (such as discoloration on smooth surfaces, burrs on rough surfaces, and defects at the contours) in different detection parts of the zipper, thereby significantly improving imaging contrast and clarity. Combined with a high-resolution global camera, it enables high-precision and high-stability identification of minute defects in the zipper.
[0018] Thirdly, this application integrates multiple functional modules such as feeding, horizontal detection, posture rotation, vertical detection, and sorting and unloading into one, forming a complete automated detection pipeline, which improves the overall detection efficiency. Furthermore, through the continuity and controllability of the process, it can reduce the risk of false detection and missed detection that may be caused by multiple feeding and unloading, thereby improving the reliability of the detection results. Attached Figure Description
[0019] To more clearly illustrate the technical solutions of the embodiments of this application, the accompanying drawings used in the embodiments will be briefly described below. It should be understood that the following drawings only show some embodiments of this application and should not be regarded as a limitation on the scope of this application.
[0020] Figure 1 This is a schematic diagram of the overall structure of the zipper detection device from a first-view perspective in one embodiment. Figure 2 This is a schematic diagram of the overall structure of the zipper detection device in one embodiment, viewed from a second perspective. Figure 3 This is a schematic diagram of the feeding mechanism in one embodiment; Figure 4 This is a schematic diagram of the horizontal detection mechanism in one embodiment; Figure 5 This is a schematic diagram of the structure of the transport component in one embodiment; Figure 6 This is a schematic diagram of the structure of a rotation drive component in one embodiment; Figure 7 This is a schematic diagram of the vertical detection mechanism in one embodiment; Figure 8 This is a schematic diagram of the blocking component in one embodiment; Figure 9 This is a schematic diagram of the structure of the first type of optical detection unit in one embodiment; Figure 10 This is a schematic diagram of the structure of the second type of optical detection unit in one embodiment; Figure 11 This is a schematic diagram of the parallel coaxial light source setup in one embodiment; Figure 12 This is a schematic diagram of the structure of the third type of optical detection unit in one embodiment; Figure 13 This is a schematic diagram of the structure of the fourth type of optical detection unit in one embodiment.
[0021] Reference numerals in the attached diagrams are as follows: 1. Feeding mechanism; 11. Vibratory feeder; 12. Straight vibratory track; 13. Cutting mechanism; 2. Horizontal detection mechanism; 21. Horizontal support; 22. Horizontal detection track; 221. Baffle plate; 222. Light-transmitting window; 23. Handling module; 231. Servo motor; 232. Feeding claw; 24. Horizontal imaging module; 241. First horizontal imaging component; 242. Second horizontal imaging component; 3. Rotary conveying mechanism; 31. Rotary drive component; 32. Clamping component; 4. Vertical detection mechanism; 41. Vertical support; 42. Vertical detection track; 421. Vertical track section; 422. Translation track section; 43. Blocking component; 44. Vertical imaging module; 441. First vertical imaging component; 442. Second vertical imaging component; 5. Unloading mechanism; 01. First type of optical detection unit; 011. First global camera; 012. First bright field light source; 013. First dark field light source; 02. Second type of optical detection unit; 021. Second global camera; 022. Second bright field light source; 023. Second dark field light source; 03. Third type of optical detection unit; 031. Third global camera; 032. Third bright field light source; 033. High-angle stripe light; 04. Fourth type of optical detection unit; 041. Fourth global camera; 042. Fourth bright field light source; 043. Backlight source. Detailed Implementation
[0022] To make the objectives, technical solutions, and advantages of this application clearer, the following detailed description is provided in conjunction with the accompanying drawings and embodiments. It should be understood that the specific embodiments described herein are merely illustrative and not intended to limit the scope of this application.
[0023] All terms used in this application (including technical and scientific terms) have the meanings commonly understood by those skilled in the art, unless otherwise defined. It should be noted that the terms used herein should be interpreted in a manner consistent with the context of this specification, and not in an idealized or overly rigid way.
[0024] For example, the terms "first," "second," etc., used in this application may be used herein to describe various elements, but these elements are not limited by these terms. These terms are only used to distinguish one element from another. For instance, without departing from the scope of this application, a first horizontal imaging component may be referred to as a second horizontal imaging component, and similarly, a second horizontal imaging component may be referred to as a first horizontal imaging component. Both the first and second horizontal imaging components are horizontal imaging components, but they are not the same horizontal imaging component.
[0025] For example, the terms "comprising" or "including" used in this application indicate the presence of features, steps, operations and / or components, but do not exclude the presence or addition of one or more other features, steps, operations or components.
[0026] As mentioned earlier, some automated inspection equipment based on machine vision is already being used in the zipper production process. Common technical solutions mainly employ single or simple combinations of optical imaging systems, such as using a fixed-angle ring light source with a common industrial camera for surface imaging, or detecting contour defects through backlighting. These methods improve the automation level of inspection to some extent, but their imaging methods are often limited to a certain type of defect or a fixed angle, failing to comprehensively cover the multiple types and locations of defects under the complex three-dimensional structure of zippers. Therefore, there is currently a technical problem of not being able to perform high-precision and comprehensive inspection of multiple types of minute defects in zippers. To address this, this application proposes a zipper inspection device that, through the spatial combination of horizontal and vertical inspection mechanisms and the targeted configuration of various customized light sources, effectively solves the industry problems of numerous blind spots, weak defect adaptability, and low automation in existing technologies, achieving one-time, high-precision, and automated inspection of the entire surface and multiple types of minute defects in zipper products.
[0027] like Figure 1 and Figure 2 As shown in the figure, this application embodiment provides a zipper inspection device, which includes a feeding mechanism 1, a horizontal inspection mechanism 2, a rotary conveying mechanism 3, a vertical inspection mechanism 4, and a discharging mechanism 5. The horizontal inspection mechanism 2 and the vertical inspection mechanism 4 each integrate multiple types of optical inspection units corresponding to different inspection parts of the zipper. Each of these multiple types of optical inspection units is equipped with a global camera (a 500W global camera with a single pixel accuracy of 0.01mm / pixel, capable of accurately and clearly imaging defects as small as 0.1mm*0.1mm) and at least two custom light sources. The custom light sources include a planar coaxial light source, a parallel coaxial light source, a shadowless ring light, a ring light source, a high-angle stripe light, and a parallel planar light source.
[0028] In this embodiment, the feeding mechanism 1 refers to an automated module used to receive batches of zipper products and transport the zippers one by one to the horizontal detection mechanism 2 in a predetermined posture and spacing through directional vibration, separation, sorting and other methods.
[0029] In some implementations, such as Figure 3 As shown, the feeding mechanism 1 includes a vibratory plate 11, a linear vibrating track 12, and a cutting mechanism 13.
[0030] The vibratory feeder 11 is used to hold batches of zipper products and output the zipper products one by one through directional vibration. Specifically, the vibratory feeder 11 may include a hopper, a spiral track connected to the bottom of the hopper, and a vibration generator (electromagnet or piezoelectric ceramic).
[0031] The hopper is an open container at the top of the vibratory feeder 11, used to receive and hold a large number of randomly arranged zipper products. Under the action of the vibration generator, the hopper causes the zipper products to creep towards the spiral track inlet. The spiral track is a spiral-shaped channel rising along the inner wall of the vibratory feeder 11. The shape of the spiral track (width, depth, sidewall morphology) can be customized according to the geometry of the zipper products. The vibration generator is used to generate directional vibration, causing the zippers on the spiral track to move forward directionally along the spiral track.
[0032] The linear vibrating track 12 is a linear vibrating conveyor track connected to the output end of the vibrating plate 11. It is used to receive the zipper products output by the vibrating plate 11 and to convey the zipper products to the cutting structure in a straight line by vibration.
[0033] The cutting mechanism 13 is located downstream of the linear vibration track 12 and is used to separate the zipper products conveyed by the linear vibration track 12 into independent zippers, and to convey the zippers one by one to the horizontal detection mechanism 2 with a preset posture and preset spacing.
[0034] The feeding mechanism 1 proposed in this embodiment achieves a stable transition from no-material-receiver zipper supply to orderly individual zipper supply through the vibration and sorting of the vibratory plate 11, the linear conveying of the straight track 12, and the individual separation of the cutting mechanism 13. This provides a stable, reliable, and fully automatic feeding foundation for zipper testing equipment, ensuring the continuity of the testing process and the consistency of imaging from the source.
[0035] In this embodiment, the horizontal detection mechanism 2 is located downstream of the feeding mechanism 1. It is used to perform imaging detection on the preset surface area of the zipper and the connection point of the body, and to transport the zipper to the rotary conveying mechanism 3. The preset surface area includes the front and back of the zipper body, the front and back of the handle.
[0036] In some implementations, such as Figure 4 As shown, the horizontal detection mechanism 2 includes a horizontal support 21, a horizontal detection track 22 fixed to the waist of the horizontal support 21, a transport module 23 fixed to the top of the horizontal support 21, and a horizontal imaging module 24.
[0037] The horizontal support 21 is the load-bearing base and structural frame of the horizontal detection mechanism 2, providing a stable installation reference and spatial positioning for all other components.
[0038] The horizontal detection track 22 is used to hold the zipper and form a sliding connection with the zipper, thereby guiding the zipper to move smoothly along a straight trajectory.
[0039] like Figure 5 As shown, the conveying module 23 includes a servo motor 231 and a feeding claw 232. The servo motor 231 is used to provide controllable power and displacement, and the feeding claw 232 is used to drive the zipper to move along the horizontal detection track 22 under the drive of the servo motor 231, so as to convey the zipper to each detection station of the horizontal imaging module 24 and the rotary conveying mechanism 3 in sequence.
[0040] The horizontal imaging module 24 includes multiple optical detection units arranged on both sides of the horizontal detection track 22, which are used to sequentially perform imaging detection on the preset surface area of the zipper and the body connection.
[0041] In this embodiment, the rotary conveying mechanism 3 is located downstream of the horizontal detection mechanism 2 and is used to rotate the zipper output by the horizontal detection mechanism 2 by a preset angle (such as 180°) and then convey it to the vertical detection mechanism 4.
[0042] In some implementations, such as Figure 6 As shown, the rotary conveying mechanism 3 includes a rotary drive assembly 31 and a clamping assembly 32. The clamping assembly 32 is used to clamp the zipper output by the horizontal detection mechanism 2, and after rotating by a preset angle under the drive of the rotary drive assembly 31, it releases the rotated zipper to the vertical detection mechanism 4.
[0043] In this embodiment, the vertical detection mechanism 4 is located downstream of the rotary conveying mechanism 3. It is used to perform imaging detection on the side area, body cover area, body connection area and perforation area of the rotated zipper, and to convey the zipper to the unloading mechanism 5.
[0044] In some implementations, such as Figure 7 As shown, the vertical detection mechanism 4 includes a vertical support 41, a vertical detection track 42 fixed to the vertical support 41, a blocking component 43, and a vertical imaging module 44.
[0045] The vertical support 41 is the main load-bearing and installation frame of the vertical detection mechanism 4, providing a stable and spatially accurate installation foundation for the vertical detection track 42, the blocking component 43 and the vertical imaging module 44.
[0046] The vertical inspection track 42 is used to hold the zipper and forms a sliding connection with it, so that the zipper slides under the action of gravity to each inspection station of the vertical imaging module 44 and the unloading mechanism 5. It not only guides the direction of movement, but also ensures that the zipper maintains a consistent inspection posture throughout the entire sliding process.
[0047] like Figure 8As shown, the blocking component 43 can be composed of a cylinder, an electromagnet, or a servo-driven stop bar or block, fixed on the vertical bracket 41 and corresponding to each detection station of the vertical imaging module 44, and used to block the downward movement of the zipper when it slides down to each detection station of the vertical imaging module 44.
[0048] The vertical imaging module 44 includes multiple optical detection units arranged along the vertical detection track 42, used for imaging detection of the side area of the zipper, the body-covered area, the body connection area and the perforation area.
[0049] It should be noted that, in this embodiment, each detection station of the horizontal imaging module 24 or the vertical detection module refers to the field of view center of each optical detection unit integrated in the horizontal imaging module 24 or the vertical imaging module 44.
[0050] For example, when the zipper slides down to the center of the field of view (i.e., the detection station) of an optical detection unit of the vertical imaging module 44, the blocking component 43 quickly acts (e.g., extends a stop bar) to precisely block and position the zipper, making it completely stationary at the detection station, so as to perform high-definition image acquisition without motion blur. After completion, the blocking component 43 retracts, releasing the zipper to continue sliding down to the next detection station.
[0051] In this embodiment, the feeding mechanism 5 is used to sort the zippers into two categories, "qualified" and "unqualified", according to the detection results of the horizontal detection mechanism 2 and the vertical detection mechanism 4, and guide them to the corresponding collection containers respectively.
[0052] In the zipper inspection device proposed in this application embodiment, a multi-angle imaging system is formed by setting up a horizontal inspection mechanism 2 and a vertical inspection mechanism 4, and using a rotating conveying mechanism 3 for attitude conversion. This solves the limitations of single-angle imaging in physical space, enabling imaging inspection of complex surfaces and hidden parts of the zipper, such as the surface, sides, body-covered areas, body-connecting areas, and perforation areas, covering multiple types and locations of defects under the complex three-dimensional structure of the zipper.
[0053] Secondly, this application integrates multiple types of optical detection units corresponding to different detection parts of the zipper, and employs various customized light sources, including planar coaxial light, parallel coaxial light, and shadowless ring light. This allows for the provision of the most suitable lighting environment for defects with different shapes and reflective properties (such as discoloration on smooth surfaces, burrs on rough surfaces, and defects at the contours) in different detection parts of the zipper, thereby significantly improving imaging contrast and clarity. Combined with a high-resolution global camera, it enables high-precision and high-stability identification of minute defects in the zipper.
[0054] Thirdly, this application integrates multiple functional modules such as feeding, horizontal detection, posture rotation, vertical detection, and sorting into one, forming a complete automated detection pipeline, which improves the overall detection efficiency. Furthermore, through the continuity and controllability of the process, it reduces the risk of false detection and missed detection that may be caused by multiple feeding and unloading, and improves the reliability of the detection results.
[0055] In one embodiment, such as Figure 4 As shown, the horizontal imaging module 24 includes a first imaging component and a second imaging component. Both the first horizontal imaging component 241 and the second horizontal imaging component 242 integrate a first type of optical detection unit 01 and a second type of optical detection unit 02.
[0056] The first horizontal imaging component 241 is arranged along the first side of the horizontal detection track 22 (e.g., the left side along the zipper's forward direction) and is used to perform imaging detection on the back of the zipper body and the front of the handle.
[0057] Specifically, for imaging detection of the back of the torso, the first horizontal imaging component 241 is provided with a first type of optical detection unit 01 and a second type of optical detection unit 02. For imaging detection of the front of the hand, the first horizontal imaging component 241 is also provided with a first type of optical detection unit 01 and a second type of optical detection unit 02.
[0058] like Figure 9 As shown, the first type of optical detection unit 01 includes a first global camera 011, a first bright-field light source 012, and a first dark-field light source 013. The first bright-field light source 012 is a planar coaxial light source with an imaging aperture at its center. The illumination light from the first bright-field light source 012 is parallel to the optical axis of the lens of the first global camera 011, and the imaging aperture is coaxial with the optical axis of the lens. Light reflected from the surface of the zipper (mainly from smooth and flat areas) can pass through the imaging aperture and enter the lens of the first global camera 011. However, most of the stray light reflected from the object cannot effectively enter the lens of the first global camera 011. Therefore, the smooth and flat areas seen by the first global camera 011 are very bright, while rough, defective, or tilted areas appear very dark, thus forming a high-contrast image that can be used to detect defects such as discoloration, foreign objects, damage, deformation, and poor pre-processing.
[0059] The first dark-field light source 013 is a shadowless ring light. The central axis of the first dark-field light source 013 is coaxial with the lens optical axis of the first global camera 011 and the imaging aperture of the first bright-field light source 012. The shadowless ring light creates a ring illumination environment with multi-directional angles and uniform diffusion, achieving near-perfect "shadowless" illumination at the physical level. It also effectively suppresses interfering reflections caused by complex reflective surfaces, solving the surface imaging problem of "three-dimensional complex shapes". It can be used to detect defects such as burrs, pattern errors, bubbles, and pits.
[0060] like Figure 10 As shown, the second type of optical inspection unit 02 includes a second global camera 021, a second bright-field light source 022, and a second dark-field light source 023. The second bright-field light source 022 is a parallel coaxial light source, and its illumination light is parallel and coaxial with the lens optical axis of the second global camera 021. That is, the photographic light from the parallel coaxial light source is incident perpendicularly, and its positively reflected light also returns perpendicularly, entering the lens of the second global camera 021. For a perfectly flat and smooth surface, the second global camera 021 sees a uniform, bright, and featureless area. However, any tiny bumps, scratches, engravings, or contamination will disrupt this perfect positive reflection, causing light scattering and thus presenting clear black or dark features on a uniform, bright background. This achieves the ultimate contrast between the "defect / feature" and the "background," and can be used to detect defects such as poor laser processing, paint drips, and incomplete plating.
[0061] As a feasible implementation method for setting up a parallel coaxial light source, such as Figure 11 As shown, a high-density LED array is set at a position offset from the lens optical axis of the second global camera 021 by a parallel coaxial light source. The light emitted by the high-density LED array first passes through a diffuser plate to homogenize the light and prevent the LED array from directly imaging. After the first reflection, the uniform light shines on a beam splitter, which is placed at a 45-degree angle to the horizontal plane. The beam splitter reflects most of the light vertically downward (about a 90-degree turn), so that the light shining on the zipper surface is perpendicular (or nearly perpendicular) and returns to the lens of the second global camera 021 through the same path.
[0062] The second dark-field light source 023 is a ring light source whose emission direction forms a preset angle (e.g., 30°) with the optical axis of the lens of the second global camera 021. The light from the ring light source shines obliquely onto the zipper from all sides at a certain angle. The raised parts of the zipper (such as the edge of the zipper, raised burrs) will become brighter on the side facing the light, while the side facing away from the light will be shadowed. This contrast between light and dark greatly enhances the three-dimensional sense of the zipper, making the outline and height difference very clear, which can be used to detect defects such as burrs, bubbles, and pits.
[0063] The second horizontal imaging component 242 is arranged along the second side of the horizontal detection track 22 (e.g., the right side along the zipper's forward direction) for imaging detection of the front of the zipper body, the back of the handle, and the body connection.
[0064] Specifically, for imaging detection of the front of the torso, the second horizontal imaging component 242 is provided with a first type optical detection unit 01 and a second type optical detection unit 02. For imaging detection of the back of the hand, the second horizontal imaging component 242 is also provided with a first type optical detection unit 01 and a second type optical detection unit 02. For imaging detection of the torso connection point, the second horizontal imaging component 242 is provided with a first type optical detection unit 01.
[0065] It is understood that the arrangement order of the optical detection units in the first horizontal imaging component 241 and the second horizontal imaging component 242 can be set according to actual detection requirements. The implementation method is not unique, and this embodiment does not limit it.
[0066] It should be noted that, in the first horizontal imaging component 241 and the second horizontal imaging component 242, in order to achieve separate imaging of the front and back of the carcass (without the hand appearing in the imaging), in some embodiments, such as Figure 4 As shown, the bottom of the horizontal detection track 22 is provided with a shielding plate 221 for blocking the guide hand. The shielding plate 221 has light-transmitting windows 222 in the areas where imaging detection is performed on the front and back of the guide hand. In addition, the shielding plate 221 can also mechanically constrain the suspended part of the guide hand, suppress the shaking and rotation of the guide hand during the transport process, and ensure the consistency of the guide hand posture during each imaging.
[0067] In the zipper inspection device proposed in this application embodiment, by arranging the first horizontal imaging component 241 and the second horizontal imaging component 242 on both sides and combining multiple types of optical detection units, high-quality images of each surface under different customized light source illumination can be obtained synchronously or sequentially during a single horizontal conveying process of the zipper. This allows for a comprehensive screening of various defects such as discoloration, foreign objects, defects and deformation, pre-processing defects, burrs, laser defects, paint drips, and plating omissions in one go, greatly improving the completeness and efficiency of defect detection.
[0068] In one embodiment, such as Figure 7 As shown, the vertical detection track 42 includes a vertical track segment 421 and a translation track segment 422 located downstream of the vertical track segment 421.
[0069] The vertical track section 421 is used to allow the zipper to slide quickly and smoothly from one inspection station to the next under the influence of gravity. The zipper's orientation on the vertical track section 421 is with the handle facing upwards. One end of the translation track section 422 is connected to the downstream end of the vertical track section 421, and the other end is connected to the unloading mechanism 5. The translation track section 422 is used to reduce the zipper's sliding speed and change its orientation, so that the zipper's handle faces downwards, thus stably presenting the perforated area in the middle of the body within the observation field of the fourth type of optical inspection unit 04 directly above.
[0070] The vertical imaging module 44 includes a first vertical imaging component 441 and a second vertical imaging component 442. The first vertical imaging component 441 integrates a first type of optical detection unit 01, a second type of optical detection unit 02 and a third type of optical detection unit 03, and the second vertical imaging component 442 integrates a fourth type of optical detection unit 04.
[0071] The first vertical imaging component 441 is arranged along the vertical track segment 421 and is used to perform imaging detection on the side areas of the zipper (body side and handle side), the body obstruction area and the body connection area.
[0072] Specifically, for imaging detection of the sides of the torso, the first vertical imaging component 441 has a third type optical detection unit 03 on each side of the vertical track section 421. For imaging detection of the sides of the hand, the first vertical imaging component 441 has a first type optical detection unit 01 on each side of the vertical track section 421. For imaging detection of the torso obstruction area, the first vertical imaging component 441 has a first type optical detection unit 01 and a second type optical detection unit 02. For imaging detection of the torso connection area, the first vertical imaging component 441 has a first type optical detection unit 01.
[0073] like Figure 12 As shown, the third type of optical inspection unit 03 includes a third global camera 031, a third bright-field light source 032, and a high-angle stripe light 033. The third bright-field light source 032 is a planar coaxial light source. The optical axis of the lens of the third global camera 031 has a preset tilt angle with the central axis of the imaging aperture of the third bright-field light source 032 (the tilt angle can be adjusted according to the side imaging requirements). The high-angle stripe light 033 and the third bright-field light source 032 are combined to supplement the illumination of the irregular curved surface area on the side of the zipper body, forming a complete, clear, and uniform image. At the same time, by adding the mode of simultaneous illumination of the high-angle stripe light 033, the existence of dark corner blind spots in the curved corner area can be avoided, the feature capture image of the narrow area can be increased, the risk of missed detection can be avoided, and it can be used to detect defects such as discoloration, paint drips, and unplated areas on the side of the body.
[0074] The second vertical imaging component 442 is arranged along the translation track segment 422 and is used to perform imaging detection on the perforated area of the zipper.
[0075] Specifically, for imaging detection of the perforated area of the zipper, the second vertical imaging component 442 is equipped with a fourth type of optical detection unit 04.
[0076] like Figure 13 As shown, the fourth type of optical inspection unit 04 includes a vertically positioned fourth global camera 041, a horizontally positioned fourth bright-field light source 042, and a backlight source 043. The fourth bright-field light source 042 is a planar coaxial light source used to detect burr defects. The planar coaxial light source has the characteristic of a highly uniform optical path, which can uniformly reflect the features of the top region of the carcass into the field of view of the fourth global camera 041, especially the small burr defects in the top region of the carcass, which can be clearly imaged.
[0077] The backlight source 043 is a parallel-plane light source located at the bottom of the zipper, relative to the fourth global camera 041 located at the top of the zipper. When the backlight source 043 is turned on, it creates a high-contrast silhouette of the zipper's perforated area. The parallel-plane light source minimizes light scattering and diffraction at the zipper edges, ensuring absolutely accurate pixel-level edge positioning of the silhouette, unaffected by minor changes in zipper height or position, and enabling clear and intuitive capture of edge burrs and contours.
[0078] In the zipper detection device proposed in this application embodiment, in the first aspect, by setting up a vertical track section 421 and a translational track section 422, the zipper can accurately and stably expose its complex three-dimensional surfaces and hidden parts, such as its side area, body covering area, body connection area and perforation area, to the field of view of the corresponding optical detection unit during continuous and automated conveying, thereby achieving full-position, blind-spot-free optical coverage of the zipper's three-dimensional structure.
[0079] Secondly, by combining four types of optical detection units, the zipper can simultaneously or sequentially obtain high-quality images of each detection position under different customized light sources during a single vertical conveying process. This allows for a comprehensive screening of various defects such as discoloration, foreign objects, defects and deformations, poor pre-processing, burrs, laser defects, paint drips, and missed plating, greatly improving the completeness and efficiency of defect detection.
[0080] Finally, it should be noted that the above embodiments are only used to illustrate the technical solutions of this application, and are not intended to limit them. Although this application has been described in detail with reference to the foregoing embodiments, those skilled in the art should understand that modifications can still be made to the technical solutions described in the foregoing embodiments, or equivalent substitutions can be made to some or all of the technical features therein. Such modifications or substitutions do not cause the essence of the corresponding technical solutions to deviate from the scope of the technical solutions of the embodiments of this application.
[0081] Furthermore, those skilled in the art will understand that although some embodiments herein include certain features included in other embodiments but not others, combinations of features from different embodiments are intended to be within the scope of this application and form different embodiments. For example, any of the embodiments or implementations claimed above can be used in any combination. The information disclosed in this background section is intended only to enhance the understanding of the general background of this application and should not be construed as an admission or in any way implying that such information constitutes prior art known to those skilled in the art.
Claims
1. A zipper inspection device, characterized in that, The zipper testing equipment includes: The feeding mechanism is used to transport the zippers one by one to the horizontal detection mechanism; A horizontal detection mechanism, located downstream of the feeding mechanism, is used to perform imaging detection on the preset surface area of the zipper and the connection point of the body, and to transport the zipper to the rotary conveying mechanism. A rotary conveying mechanism is located downstream of the horizontal detection mechanism and is used to rotate the zipper output by the horizontal detection mechanism by a preset angle and then convey it to the vertical detection mechanism. A vertical detection mechanism, located downstream of the rotary conveyor mechanism, is used to perform imaging detection on the side area, body cover area, body connection area and perforation area of the rotated zipper, and to convey the zipper to the unloading mechanism. The feeding mechanism is used to sort zippers based on the detection results of the horizontal and vertical detection mechanisms. The horizontal detection mechanism and the vertical detection mechanism are both integrated with multiple types of optical detection units corresponding to different detection parts of the zipper. Each of the multiple types of optical detection units is equipped with a global camera and at least two custom light sources.
2. The zipper testing equipment according to claim 1, characterized in that, The horizontal detection mechanism includes: Horizontal support; A horizontal detection track is fixed to the waist of the horizontal support. The horizontal detection track is used to hold the zipper and forms a sliding connection with the zipper. A transport module fixed to the top of the horizontal support includes a servo motor and a material feeding claw. The material feeding claw is used to drive the zipper to move along the horizontal detection track to each detection station of the horizontal imaging module and the rotary conveying mechanism under the drive of the servo motor. The horizontal imaging module includes multiple optical detection units arranged along both sides of the horizontal detection track, used to sequentially perform imaging detection on the preset surface area of the zipper and the body connection.
3. The zipper testing equipment according to claim 2, characterized in that, The horizontal imaging module includes: A first horizontal imaging component arranged along the first side of the horizontal detection track is used to perform imaging detection on the back of the zipper body and the front of the handle; A second horizontal imaging component arranged along the second side of the horizontal detection track is used to perform imaging detection on the front of the zipper body, the back of the handle, and the body connection. Both the first horizontal imaging component and the second horizontal imaging component integrate a first type of optical detection unit and a second type of optical detection unit.
4. The zipper testing equipment according to claim 3, characterized in that, The bottom of the horizontal detection track is provided with a shield to block the handrail, wherein the shield has a light-transmitting window in the area where imaging detection is performed on the front and back of the handrail.
5. The zipper testing equipment according to claim 1, characterized in that, The vertical detection mechanism includes: Vertical support; The vertical detection track fixed to the vertical bracket is used to hold the zipper and form a sliding connection with the zipper so that the zipper can slide to each detection station of the vertical imaging module and the unloading mechanism under the action of gravity. The blocking component fixed to the vertical bracket is used to block the downward movement of the zipper when it slides down to each detection station of the vertical imaging module. The vertical imaging module includes multiple optical detection units arranged along the vertical detection track, used for imaging detection of the side area of the zipper, the body-covered area, the body connection area, and the perforation area.
6. The zipper testing device according to claim 5, characterized in that, The vertical detection track includes: a vertical track section and a translational track section located downstream of the vertical track section; The vertical imaging module includes: The first vertical imaging component, arranged along the vertical track segment, is used to perform imaging detection on the side area of the zipper, the part obscured by the body, and the connection point of the body. The second vertical imaging component, arranged along the translation track segment, is used to perform imaging detection on the perforated area of the zipper; The first vertical imaging component integrates a first type of optical detection unit, a second type of optical detection unit, and a third type of optical detection unit, while the second vertical imaging component integrates a fourth type of optical detection unit.
7. The zipper testing equipment according to claim 3 or 6, characterized in that, The first type of optical detection unit includes a first global camera, a first bright field light source, and a first dark field light source. The first bright field light source is a planar coaxial light source, and the illumination light of the first bright field light source is parallel to the optical axis of the lens of the first global camera. The first dark field light source is a shadowless ring light, and the central axis of the first dark field light source is coaxial with the optical axis of the lens of the first global camera and the imaging aperture of the first bright field light source. The second type of optical detection unit includes a second global camera, a second bright field light source, and a second dark field light source. The second bright field light source is a parallel coaxial light source, and the illumination light of the second bright field light source is parallel and coaxial with the lens optical axis of the second global camera. The second dark field light source is a ring light source whose emission direction forms a preset angle with the lens optical axis of the second global camera.
8. The zipper testing equipment according to claim 6, characterized in that, The third type of optical detection unit includes a third global camera, a third bright field light source, and a high-angle strip light. The third bright field light source is a planar coaxial light source. The lens optical axis of the third global camera has a preset tilt angle with the central axis of the imaging aperture of the third bright field light source. The high-angle strip light is combined with the third bright field light source to provide supplementary illumination to the curved surface area of the zipper's body side. The fourth type of optical detection unit includes a vertically arranged fourth global camera, a horizontally arranged fourth bright field light source and a backlight light source. The fourth bright field light source is a planar coaxial light source, and the backlight light source is a parallel plane light source. It is set at the bottom of the zipper to generate the outline silhouette of the perforated area of the zipper.
9. The zipper testing device according to claim 1, characterized in that, The feeding mechanism includes: A vibratory feeder is used to hold batches of zipper products and output the zipper products one by one through directional vibration. A linear vibrating track, connected to the output end of the vibrating plate, is used to receive the zipper products output by the vibrating plate and transport the zipper products to the cutting structure; The cutting mechanism, located downstream of the linear vibrating track, is used to separate the zipper products conveyed by the linear vibrating track into individual zippers, and to convey the zippers one by one to the horizontal detection mechanism with a preset posture and preset spacing.
10. The zipper testing device according to claim 1, characterized in that, The rotary conveying mechanism includes a rotary drive assembly and a clamping assembly. The clamping assembly is used to clamp the zipper output by the horizontal detection mechanism, and after rotating it by a preset angle under the drive of the rotary drive assembly, it releases the rotated zipper to the vertical detection mechanism.