Non-flat plate surface detection device and detection method thereof
By using a non-flat material surface inspection device, which combines lifting, supplementary lighting, and moving units with homogenizing line laser technology, full coverage and high-precision inspection of non-flat material surfaces is achieved. This solves the problems of imaging blur and compatibility in traditional inspection methods, and improves inspection efficiency and result reliability.
Patent Information
- Authority / Receiving Office
- CN · China
- Patent Type
- Applications(China)
- Current Assignee / Owner
- KEPENG INTELLIGENT TECH (SUZHOU) CO LTD
- Filing Date
- 2026-02-05
- Publication Date
- 2026-05-05
AI Technical Summary
Existing technologies struggle to achieve high-precision and high-efficiency defect identification on uneven metal sheet surfaces. They are affected by factors such as uneven light reflection, shadows, highlights, and surface deformation, resulting in poor image quality and making it difficult to accurately identify defects.
A non-flat board surface inspection device was designed, including a lifting unit, an inspection unit, a supplementary lighting unit, a moving unit, a support unit, a loading robotic arm, an unloading robotic arm, and a flipping robotic arm. The inspection height is adjusted by the lifting unit, the supplementary lighting unit provides uniform supplementary lighting, the moving unit drives the board to move, and the inspection unit adopts homogenized line laser surface image acquisition technology to achieve full coverage inspection.
It achieves full coverage inspection of uneven board surfaces, improves inspection accuracy and efficiency, reduces image blurring and missed or false defects, adapts to boards of different thicknesses, lengths and materials, reduces equipment maintenance difficulty and cost, and improves the reliability and automation of inspection results.
Smart Images
Figure CN121978112A_ABST
Abstract
Description
Technical Field
[0001] This invention relates to the field of metal sheet production technology, and in particular to a device and method for detecting the surface of non-flat sheets. Background Technology
[0002] Metal sheets are widely used in industrial production, and their surface quality directly affects product performance and aesthetics. Traditional inspection methods mainly rely on manual visual inspection or single-point instrument measurement. With the development of industrial automation, machine vision inspection technology has been gradually applied to the field of sheet surface inspection. However, non-flat metal sheets, due to their complex surface geometry and reflective properties, pose a huge challenge to automated inspection. Existing technologies are unable to achieve high-precision and high-efficiency surface defect identification.
[0003] Traditional inspection methods are often affected by factors such as uneven light reflection, shadows, highlights, and surface deformation, resulting in poor image quality and difficulty in accurately identifying defects. Therefore, it is necessary to design an inspection device and method for non-flat board surfaces to solve the problems mentioned above. Summary of the Invention
[0004] To achieve the above objectives, the present invention provides the following technical solution: a non-flat board surface inspection device, comprising a lifting unit, an inspection unit fixedly connected to the upper part of the lifting unit, supplementary lighting units fixedly arranged on both the front and rear sides of the lifting unit, a moving unit arranged in the middle of the lifting unit, a support unit movably arranged on the upper part of the moving unit, a board mounted on the upper part of the support unit, a loading robotic arm arranged on the right front side of the lifting unit, a unloading robotic arm arranged on the left front side of the lifting unit, and a flipping robotic arm arranged on the right rear side of the lifting unit; The lifting unit is used to drive the lifting of the detection unit to adapt to boards of different thicknesses. The detection unit is used to detect surface defects of the board. The supplementary lighting unit is used to provide uniform supplementary lighting to the surface of the board. The moving unit is used to drive the support unit to move back and forth, so that the plate mounted on the upper part of the support unit moves along the bottom of the detection unit. The loading robot arm is used to transfer the plate to be detected to the support unit. The unloading robot arm is used to remove the plate after detection from the support unit. The flipping robot arm is used to flip the plate 180° so that both sides of the plate can be detected by the detection unit.
[0005] Preferably, the lifting unit includes a base plate symmetrically arranged on the left and right and fixedly connected to the ground by bolts. A telescopic cylinder is fixedly installed in the middle of the upper end of each base plate. A first fixed plate is fixedly connected to the telescopic end of each telescopic cylinder. A connecting frame is fixedly connected to the inner side of each first fixed plate by bolts. Sliding blocks are welded to the four corners of the outer end of each connecting frame. Vertical guide frames are welded to the front and rear sides of the upper part of both base plates. The sliding blocks are slidably connected to the inner side of the corresponding vertical guide frame to realize the smooth lifting of the connecting frame. The detection unit includes a horizontally arranged mounting bracket, the left and right ends of which are rotatably connected to two connecting brackets arranged on the left and right sides.
[0006] Preferably, the bottom of the mounting bracket is fixedly connected to several fixing blocks at equal intervals by bolts, and the bottom of each fixing block is threaded with a detection probe; A first drive motor is fixedly connected to the outer side of the connecting frame on the right, and the shaft of the first drive motor is fixedly connected to the right end of the mounting frame. Each of the supplementary lighting units includes a horizontally arranged mounting frame. A second fixing plate is welded to the left and right ends of the mounting frame. The second fixing plate is fixedly connected to the inner side of the corresponding connecting frame by bolts. Several mounting clamps are equidistantly arranged on the outer side of the mounting frame. A supplementary light is threaded to the bottom of each mounting clamp. A first fixing clamp is fixedly connected to the upper part of each mounting clamp by bolts.
[0007] Preferably, the moving unit includes a base symmetrically arranged front and rear and fixedly connected to the ground by bolts. A second drive motor is fixedly installed at the front part of the front base, and a threaded screw is rotatably connected to the middle of the front and rear bases. The rotating shaft of the second drive motor is fixedly connected to the front end of the threaded screw. The support unit includes a movable frame, the middle of which is threaded to the outside of the threaded screw. Sliding frames are fixedly connected to the upper left and right sides of the movable frame by bolts. Support sliders are slidably arranged at the front and rear ends of the middle of the sliding frames. Support rods are welded to the upper parts of the left and right sides corresponding to the support sliders. The plate is mounted on the upper part of the front and rear support rods.
[0008] Preferably, each of the bases is provided with a bearing seat fixed to the ground by bolts on its inner side, and the front and rear ends of the threaded screw are rotatably connected to the inner side of the corresponding bearing seat; Guide rods are fixedly installed on the left and right ends of the inner side of the base, and the left and right sides of the movable frame are slidably connected to the outer sides of the corresponding guide rods.
[0009] Preferably, a plurality of insertion holes are equidistantly arranged laterally on the middle part of the support slider and on the sliding frame, and a plug is provided in the insertion hole; The support unit also includes two longitudinally symmetrically arranged longitudinal guide frames that are fixedly connected to the ground by bolts. Each longitudinal guide frame has a guide groove on its upper part. The bottom front and rear sides of the sliding frame are fixedly connected to guide pulleys, and the front and rear guide pulleys are slidably connected to the inner side of the corresponding guide groove.
[0010] Preferably, each of the support rods is provided with a rubber pad at its upper part, and each of the rubber pads is provided with a semi-circular groove at its bottom. The semi-circular grooves are engaged with the upper part of the support rod to achieve quick positioning and installation of the rubber pads. The bottom end of each rubber pad is fixedly connected with several second fixing clamps by bolts.
[0011] The surface inspection method for non-flat materials, applied to the surface inspection device for non-flat materials, specifically includes the following inspection methods: S1. Loading and Positioning: The non-flat plate to be inspected is transferred to the upper part of the front and rear support rods of the support unit by the loading robotic arm. The semi-circular groove of the rubber pad is used to engage with the support rod to achieve quick positioning. The rubber pad is locked by the second fixing clamp. According to the length of the non-flat plate, the position of the sliding support slider on the sliding frame is adjusted, and the plug is inserted into the corresponding hole to lock the spacing between the front and rear support rods, thus completing the mounting and fixing of the plate. S2. Detection height adaptation: Activate the telescopic cylinder of the lifting unit to drive the first fixed plate to lift the connecting frame. The connecting frame moves smoothly along the vertical guide frame through the sliding block to adjust the distance between the detection unit and the non-flat plate, adapting to the detection needs of plates of different thicknesses. S3. Fill light adjustment: Loosen the first fixing clamp of the fill light unit, adjust the position of the mounting clamp on the mounting bracket, and adjust the illumination angle of the fill light through the thread to make the fill light form uniform fill light illumination on the non-flat board surface. After adjustment, tighten the first fixing clamp. S4, Front Inspection: Start the first drive motor of the inspection unit to drive the mounting bracket to rotate around the left and right connecting brackets, adjust the inspection angle of the inspection probe, and at the same time adjust the extension length of the inspection probe on the fixed block through the thread; The detection probe uses homogenized line laser surface image acquisition technology. By precisely controlling the laser projection angle and light intensity distribution, it achieves uniform illumination on the non-flat material surface. Combined with an area array camera, it obtains stable surface images, thus solving the problem of blurred imaging on non-flat surfaces. The second drive motor of the moving unit is started synchronously, driving the threaded screw to rotate around the bearing seat, which in turn drives the moving frame to move back and forth along the guide rod. The support unit moves synchronously and smoothly along the guide groove of the longitudinal guide frame through the guide pulley, so that the non-flat plate moves backward at a uniform speed under the detection unit, and the detection probe completes the full detection of the front of the plate.
[0012] Preferably, the following detection methods are also included: S5, Panel Flipping: The moving unit drives the support unit to move the non-flat panel to the corresponding position of the flipping robot arm, and the non-flat panel is flipped 180° by the flipping robot arm. S6. Reverse Inspection: The inspection probe switches to the self-measuring servo vision surface inspection mode, which can perceive the dimensional changes of non-flat boards in real time and automatically adjust the inspection parameters of the inspection probe and the rotation angle of the mounting bracket to ensure stable imaging quality. Repeat the driving process of the moving unit in step S4 to make the flipped non-flat board move forward at a constant speed along the bottom of the detection unit, and the detection probe completes the full detection of the back of the board. S7. Unloading: After the inspection is completed, the moving unit drives the support unit to move the non-flat plate to the corresponding position of the unloading robot arm. The unloading robot arm removes the inspected plate from the support rod, completing a single inspection process.
[0013] Preferably, during the homogenization line laser surface image acquisition process in step S4, the laser intensity output is adjusted in real time according to the material characteristics of the non-flat plate to ensure that uniform illumination can be formed in both the raised and recessed areas of the plate, thus avoiding imaging distortion caused by reflection or shadow. In the self-measurement servo vision surface inspection process in step S6, the detection probe analyzes the collected image data in real time. If the thickness or position of the board material changes, it automatically feeds back signals to the lifting unit and the detection unit. The detection height is finely adjusted by the telescopic cylinder, the detection angle is finely adjusted by the first drive motor, and the driving speed of the moving unit is adjusted synchronously to keep the detection probe at the optimal detection distance and acquisition frequency from the board surface. The image data collected by the detection probe is transmitted to the background processing system in real time. The system identifies defects in the images under laser illumination and, combined with the plate posture data fed back by the self-measuring servo module, accurately locates the position and size of defects. The lifting unit, moving unit, detection unit, loading robotic arm, unloading robotic arm, and tilting robotic arm achieve coordinated action through a linkage control module. When the detection probe detects a serious defect, it can trigger the moving unit to pause its movement and continue detection after manual confirmation, or directly transfer the defective product to the non-conforming product area through the unloading robotic arm.
[0014] In summary, the present invention provides a device and method for detecting non-flat material surfaces, which has the following beneficial effects: The base plate of the lifting unit is fixed to the ground, and the telescopic cylinder on its upper part connects the first fixing plate and the connecting frame, stably fixing the detection unit on the connecting frame. At the same time, it drives the detection unit to rise and fall synchronously, so that the distance between the detection unit and the plate mounted on the support rod of the support unit can be flexibly adjusted. The support slider of the support unit can slide along the sliding frame and lock its position through the insertion hole and the plug, adjusting the distance between the front and rear support rods to adapt to plates of different lengths. The mounting frame of the detection unit is rotatably connected to the connecting frame and can rotate around its own axis to adjust the detection angle. The supplementary lighting unit is fixed to the connecting frame through the fixing plate, and rises and falls synchronously with the detection unit and can be adjusted independently. Without major modifications to the equipment, it can adapt to plates of different thicknesses, lengths and flatnesses, and is compatible with the detection needs of plates of different materials. It solves the limitation of traditional detection devices that can only adapt to a single specification of plate, achieving a wide compatibility effect and greatly improving the applicability and practicality of the device.
[0015] The lifting unit is slidably connected to the vertical guide frame via a connecting frame and sliding blocks at the four corners. The vertical guide frame is fixed to the base plate, ensuring smooth and unbiased movement of the connecting frame when lifting and lowering the detection unit, thus avoiding impact on detection accuracy due to shaking during lifting. The second drive motor of the moving unit drives the threaded screw to rotate, moving the threaded moving frame. The guide rod on the base provides lateral guidance for the moving frame, and the guide pulley of the support unit is slidably connected to the guide groove of the longitudinal guide frame for longitudinal guidance. This dual-guide structure allows the support unit to move the board material at a uniform and smooth speed. The supplementary lighting unit adjusts the position and angle of the supplementary light by installing clamps, coordinating with the detection angle adjustment of the detection unit to ensure uniform illumination of the board surface. The detection probe of the detection unit is threadedly connected to the fixed block, allowing for fine-tuning of the extension length. This, combined with the angle adjustment of the mounting frame, enables detection without blind spots. This effectively reduces problems such as positional deviation and uneven illumination during the detection process, avoiding blurred images, missed or false defects, and significantly improving the stability and accuracy of board surface defect detection.
[0016] A rubber pad is installed on the upper part of the support rod of the support unit. The rubber pad is engaged with the support rod through a semi-circular groove at the bottom for quick positioning, and then locked in place by a second fixing clamp. The plate is mounted on the rubber pad, avoiding direct contact between the plate and the metal support rod, effectively preventing the plate surface from being scratched or slipping during the testing process, and providing good protection. The core structures of the device adopt a modular design. The base plate, telescopic cylinder, and connecting frame of the lifting unit are fixedly connected by bolts. The mounting frame, fixing block, and testing probe of the testing unit are connected by bolts or threads. The mounting crossbeam of the supplementary lighting unit is fixed by fixing plate bolts. The mounting clamp is locked to the mounting crossbeam by the first fixing clamp. The connection method of each component is simple and reliable, and the disassembly and assembly are convenient. This not only facilitates daily cleaning and component replacement, reducing maintenance difficulty and cost, but also reduces the equipment failure rate and extends the overall service life of the equipment, taking into account both protection and practicality.
[0017] Through the S1-S7 inspection process, the various structures work together to form a complete automated inspection closed loop. In S1, the loading robotic arm transfers the sheet material to be inspected onto the support rod of the support unit. The rubber pad quickly positions the sheet material through the semi-circular groove, and the bolts are inserted into the holes to lock the spacing between the support rods, ensuring stable mounting of the sheet material. In S2, the lifting unit drives the inspection unit to rise and fall, precisely adjusting the inspection spacing. In S3, the supplementary lighting unit adjusts the position and angle of the supplementary lights to achieve uniform supplementary lighting. In S4, the moving unit drives the support unit to move the sheet material to the rear, and the inspection unit performs a comprehensive inspection of the front of the sheet material. In S5, the moving unit transfers the sheet material to the flipping position. At the rotating robotic arm, the flipping robotic arm flips the board 180°; in S6, the moving unit drives the support unit again to move the flipped board forward, and the detection unit completes the reverse side detection; in S7, the unloading robotic arm removes the detected board; the entire process requires no manual intervention. Through the continuous actions of loading, positioning, fitting, detection, flipping, re-detection, and unloading, full coverage detection of both sides of the board is achieved. This solves the problems of many manual auxiliary links, low efficiency, and easy errors in the traditional detection process, greatly improving detection efficiency. At the same time, it ensures that the detection standards for both sides are consistent, further guaranteeing the reliability of the detection results. Attached Figure Description
[0018] Figure 1 This is a three-dimensional structural schematic diagram of the non-flat plate surface detection device and detection method of the present invention; Figure 2 This is a top view of the non-flat plate surface detection device and detection method of the present invention; Figure 3 This is a schematic diagram of the lifting unit structure of the non-flat plate surface detection device and detection method of the present invention; Figure 4 This is a schematic diagram of the moving unit and support unit structure of the non-flat plate surface detection device and detection method of the present invention; Figure 5 This is a schematic diagram of the support unit structure of the non-flat plate surface detection device and detection method of the present invention; Figure 6 This is a schematic diagram of the lifting unit, detection unit, and supplementary lighting unit of the non-flat plate surface detection device and detection method of the present invention. Figure 7 This is a schematic diagram of the supplementary lighting unit structure of the non-flat plate surface detection device and detection method of the present invention; Figure 8 This is a schematic diagram of the rubber pad structure of the non-flat plate surface detection device and detection method of the present invention.
[0019] Explanation of reference numerals in the attached figures: 1. Lifting Unit; 101. Base Plate; 102. Telescopic Cylinder; 103. First Fixed Plate; 104. Connecting Frame; 105. Vertical Guide Frame; 106. Sliding Block; 2. Detection Unit; 201. Mounting Frame; 202. Fixed Block; 203. Detection Probe; 204. First Drive Motor; 3. Moving Unit; 301. Base; 302. Second Drive Motor; 303. Threaded Screw; 304. Guide Rod; 305. Bearing Seat; 4. Support Unit; 401. Moving Frame; 402. 403. Sliding frame; 404. Support slider; 405. Support rod; 406. Insertion hole; 407. Bolt; 408. Longitudinal guide frame; 409. Guide groove; 4000. Guide pulley; 5. Loading robot arm; 6. Unloading robot arm; 7. Tilting robot arm; 8. Lighting unit; 801. Mounting crossbeam; 802. Second fixing plate; 803. Mounting clamp; 804. First fixing clamp; 805. Lighting lamp; 9. Rubber pad; 901. Semi-circular groove; 10. Second fixing clamp; 11. Sheet metal. Detailed Implementation
[0020] The following is in conjunction with the appendix Figure 1 - Appendix Figure 8 This application will be described in further detail below. Example
[0021] Please see Figures 1-8 As shown, the present invention provides a technical solution: a non-flat board surface inspection device, including a lifting unit 1, an inspection unit 2 fixedly connected to the upper part of the lifting unit 1, supplementary lighting units 8 fixedly arranged on the front and rear sides of the lifting unit 1, a moving unit 3 arranged in the middle of the lifting unit 1, a support unit 4 movably arranged on the upper part of the moving unit 3, a board 11 mounted on the upper part of the support unit 4, a loading robotic arm 5 arranged on the right front side of the lifting unit 1, a unloading robotic arm 6 arranged on the left front side of the lifting unit 1, and a flipping robotic arm 7 arranged on the right rear side of the lifting unit 1. The lifting unit 1 is used to drive the lifting of the detection unit 2 to adapt to the different thicknesses of the board 11. The detection unit 2 is used to detect surface defects of the board 11. The supplementary lighting unit 8 is used to provide uniform supplementary lighting to the surface of the board 11. The moving unit 3 is used to drive the support unit 4 to move back and forth, so that the plate 11 mounted on the upper part of the support unit 4 moves along the bottom of the detection unit 2. The loading robot arm 5 is used to transfer the plate 11 to be tested to the support unit 4. The unloading robot arm 6 is used to remove the plate 11 after testing from the support unit 4. The flipping robot arm 7 is used to flip the plate 11 180° so that both sides of the plate 11 can be detected by the detection unit 2.
[0022] The lifting unit 1 includes a base plate 101 that is symmetrically arranged on the left and right and fixed to the ground by bolts. A telescopic cylinder 102 is fixedly installed in the middle of the upper end of the base plate 101. The telescopic end of the telescopic cylinder 102 is fixedly connected to a first fixed plate 103. A connecting frame 104 is fixedly connected to the inner side of the first fixed plate 103 by bolts. Sliding blocks 106 are welded to the four corners of the outer end of the connecting frame 104. Vertical guide frames 105 are welded to the front and rear sides of the upper part of the two base plates 101. The sliding blocks 106 are slidably connected to the inner side of the corresponding vertical guide frame 105 to realize the smooth lifting and lowering of the connecting frame 104. The sliding blocks 106 cooperate with the vertical guide frame 105 to ensure the smooth lifting and lowering of the connecting frame 104 and accurately adapt to the testing requirements of plates 11 of different thicknesses. The detection unit 2 includes a horizontally arranged mounting bracket 201. The left and right ends of the mounting bracket 201 are rotatably connected to two connecting brackets 104 arranged on the left and right sides. It can rotate around the connecting brackets 104 to flexibly adjust the detection angle, expand the detection coverage area, and improve the flexibility of plate detection.
[0023] The bottom of the mounting bracket 201 is fixedly connected to several fixing blocks 202 at equal intervals by bolts. The bottom of each fixing block 202 is threaded with a detection probe 203. The threaded connection makes it easy to adjust the extension length, adapt to different flatness plates, and is convenient to disassemble and maintain, ensuring the accuracy of detection. A first drive motor 204 is fixedly connected to the outer side of the right connecting frame 104. The rotating shaft of the first drive motor 204 is fixedly connected to the right end of the mounting frame 201. The mounting frame 201 is automatically driven to rotate, and the detection angle is precisely adjusted, reducing manual intervention and improving detection efficiency. Each supplementary lighting unit 8 includes a horizontally arranged mounting frame 801. A second fixing plate 802 is welded to both the left and right ends of the mounting frame 801. The second fixing plates 802 are bolted to the inner side of the corresponding connecting frame 104. Several mounting clamps 803 are equidistantly arranged on the outer side of the mounting frame 801. A supplementary light 805 is threaded to the bottom of each mounting clamp 803. A first fixing clamp 804 is bolted to the upper part of each mounting clamp 803. The position of the mounting clamp 803 and the angle of the supplementary light 805 can be adjusted to adapt to uneven surfaces, providing uniform supplementary lighting to avoid reflections and shadows, and ensuring clear imaging.
[0024] The moving unit 3 includes a base 301 that is symmetrically arranged at the front and back and fixed to the ground by bolts. A second drive motor 302 is fixedly installed at the front of the front base 301. A threaded screw 303 is rotatably connected to the middle of the front and rear bases 301. The rotating shaft of the second drive motor 302 is fixedly connected to the front end of the threaded screw 303. The second drive motor 302 drives the threaded screw 303 to rotate, driving the support unit 4 to move smoothly and realize the continuous and uniform speed of the plate for inspection. The support unit 4 includes a movable frame 401, the middle of which is threaded to the outside of the threaded screw 303. The upper left and right sides of the movable frame 401 are fixedly connected to sliding frames 402 by bolts. The front and rear ends of the middle of the sliding frame 402 are slidably provided with support sliders 403. Support rods 404 are welded to the upper parts of the left and right sides corresponding to the support sliders 403. The plate 11 is mounted on the upper part of the front and rear support rods 404. The support sliders 403 can slide to adjust the spacing to adapt to different lengths of plate 11, and are firmly mounted to prevent displacement.
[0025] The base 301 is provided with a bearing seat 305 fixed to the ground by bolts on the inner side. The front and rear ends of the threaded screw 303 are rotatably connected to the inner side of the corresponding bearing seat 305 to support the rotation of the threaded screw 303, reduce friction loss, improve the operating stability of the moving unit 3, and extend the service life of the equipment. Guide rods 304 are fixedly installed on the left and right ends of the inner side of the base 301. The left and right sides of the moving frame 401 are slidably connected to the outer side of the corresponding guide rods 304 to guide and limit the moving frame 401, prevent movement deviation, ensure the movement accuracy of the support unit 4, and improve the detection stability.
[0026] Several insertion holes 405 are equidistantly arranged laterally in the middle of the support slider 403 and on the sliding frame 402. Inserts 406 are provided in the insertion holes 405 to quickly lock the spacing of the support rods 404. The operation is convenient and efficient, improving the positioning and fixing efficiency of the plate 11. The support unit 4 also includes two longitudinally symmetrically arranged longitudinal guide frames 407 that are fixed to the ground by bolts. The upper part of each longitudinal guide frame 407 is provided with a guide groove 408. The bottom front and rear sides of the sliding frame 402 are fixedly connected with guide pulleys 409. The front and rear guide pulleys 409 are slidably connected to the inner side of the corresponding guide groove 408, which reduces the moving resistance of the support unit 4, further improves the moving stability, and ensures the continuous and smooth testing process.
[0027] Each support rod 404 is equipped with a rubber pad 9 on its upper part, and each rubber pad 9 is equipped with a semi-circular groove 901 on its bottom. The semi-circular groove 901 is engaged with the upper part of the support rod 404 to achieve quick positioning and installation of the rubber pad 9. The bottom end of each rubber pad 9 is fixedly connected with several second fixing clamps 10 by bolts to avoid scratching the surface of the plate 11, and to achieve quick positioning and installation, taking into account both protection and installation efficiency.
[0028] Specifically, the following detection methods are included: S1. Loading and Positioning: The loading robotic arm 5 moves the plate 11 to be inspected to the upper part of the front and rear support rods 404 of the support unit 4. The semi-circular groove 901 of the rubber pad 9 engages with the support rod 404 to achieve quick positioning. The rubber pad 9 is locked by the second fixing clamp 10. According to the length of the plate 11, the sliding support slider 403 is positioned on the sliding frame 402. The plug 406 is inserted into the corresponding hole 405 to lock the spacing between the front and rear support rods 404, thus completing the loading and fixing of the plate. The loading robotic arm 5 automatically loads the plate, adapts to plates of different lengths, and provides a stable foundation for inspection, improving loading efficiency. S2, Detection height adaptation: Start the telescopic cylinder 102 of the lifting unit 1 to drive the first fixed plate 103 to lift the connecting frame 104. The connecting frame 104 moves smoothly along the vertical guide frame 105 through the sliding block 106 to adjust the distance between the detection unit 2 and the plate 11 to adapt to the detection requirements of plates of different thicknesses. The telescopic cylinder 102 precisely adjusts the distance between the detection unit 2 and the plate to adapt to different thicknesses and ensure the detection effect of the detection probe 203. S3. Supplemental Light Adjustment: Loosen the first fixing clamp 804 of the supplemental light unit 8, adjust the position of the mounting clamp 803 on the mounting crossbeam 801, and adjust the illumination angle of the supplemental light lamp 805 through the thread so that the supplemental light lamp 805 forms uniform supplemental light illumination on the surface of the board 11. After adjustment, tighten the first fixing clamp 804, flexibly adjust the supplemental light parameters to adapt to the surface condition of the board, achieve uniform supplemental light, ensure clear imaging, and improve detection accuracy. S4. Front inspection: Start the first drive motor 204 of the detection unit 2 to drive the mounting bracket 201 to rotate around the left and right connecting brackets 104, adjust the detection angle of the detection probe 203, and at the same time adjust the extension length of the detection probe 203 on the fixed block 202 by the thread, adjust the angle and length of the detection probe 203 in multiple dimensions, eliminate detection dead angles, and improve the comprehensiveness of the front inspection of the board. The detection probe 203 adopts homogenized line laser surface image acquisition technology. By precisely controlling the laser projection angle and light intensity distribution, it achieves uniform illumination on the surface of the board 11. Combined with the area array camera, it obtains stable surface images, solving the problem of blurry imaging on non-flat surfaces. The homogenized line laser technology solves the problem of blurry imaging and obtains stable and clear images, laying the foundation for subsequent defect identification. The second drive motor 302 of the moving unit 3 is started synchronously, driving the threaded screw 303 to rotate around the bearing seat 305, which drives the moving frame 401 to move back and forth along the guide rod 304. The support unit 4 moves synchronously and smoothly along the guide groove 408 of the longitudinal guide frame 407 through the guide pulley 409, so that the plate 11 moves backward at a uniform speed below the detection unit 2. The detection probe 203 completes the full front detection of the plate, driving the plate 11 to be sent for inspection at a uniform speed, ensuring that the detection probe 203 fully covers the plate and improving the integrity of the front detection.
[0029] It also includes the following detection methods: S5. Board flipping: The moving unit 3 drives the support unit 4 to move the board 11 to the corresponding position of the flipping robot arm 7. The flipping robot arm 7 flips the board 11 180°. The flipping robot arm 7 automatically flips the board 11 180° without manual intervention, realizing continuous detection of the front and back sides and improving the efficiency of the detection process. S6. Reverse inspection: The detection probe 203 switches to the self-measuring servo vision surface inspection mode, which senses the specification changes of the board 11 in real time, automatically adjusts the detection parameters of the detection probe 203 and the rotation angle of the mounting bracket 201 to ensure stable imaging quality. The self-measuring servo mode adapts to the specification changes of the board, maintains stable imaging, and ensures the accuracy of reverse inspection. Repeat the driving process of moving unit 3 in step S4, so that the flipped board 11 moves forward at a constant speed along the bottom of detection unit 2. Detection probe 203 completes the full detection of the back side of the board. The constant speed movement ensures the full detection of the back side, which is consistent with the front side process and ensures the consistency of the detection of the front and back sides of the board. S7. Unloading: After the inspection is completed, the moving unit 3 drives the support unit 4 to move the plate 11 to the corresponding position of the unloading robot arm 6. The unloading robot arm 6 removes the inspected plate from the support rod 404, completing a single inspection process. The unloading robot arm 6 automatically unloads the plate, quickly completing the inspection loop and improving the overall inspection process efficiency and automation.
[0030] During the homogenization line laser surface image acquisition process in step S4, the laser intensity output is adjusted in real time according to the material characteristics of the board 11 to ensure that uniform illumination can be formed in the raised and recessed areas of the board, avoiding imaging distortion caused by reflection or shadow. The laser intensity output is adjusted in real time to adapt to the board material, avoid imaging distortion, further improve the quality of the front detection image, and ensure the accuracy of defect identification. In the self-measurement servo vision surface inspection process in step S6, the detection probe 203 analyzes the acquired image data in real time. If it detects changes in the thickness or position of the board material, it automatically feeds back signals to the lifting unit 1 and the detection unit 2. The detection height is finely adjusted by the telescopic cylinder 102, the detection angle is finely adjusted by the first drive motor 204, and the driving speed of the moving unit 3 is adjusted synchronously. This ensures that the detection probe 203 maintains the optimal detection distance and acquisition frequency with the board surface. The lifting, detection, and moving parameters are finely adjusted in real time to dynamically maintain the optimal detection state and improve the adaptability and accuracy of the detection. The image data collected by the detection probe 203 is transmitted to the background processing system in real time. The system performs defect identification on the image under laser illumination and combines the plate posture data fed back by the self-measurement servo module to accurately locate the defect location and size. The image data is transmitted and analyzed in real time to accurately locate the defect location and size, providing a reliable basis for quality judgment and improving the efficiency of defect identification. The lifting unit 1, moving unit 3, detection unit 2, loading robotic arm 5, unloading robotic arm 6, and tilting robotic arm 7 achieve coordinated action through a linkage control module. When the detection probe 203 detects a serious defect, it can trigger the moving unit 3 to pause its movement and continue detection after manual confirmation, or directly transfer the defective product to the non-conforming product area through the unloading robotic arm 6.
[0031] The embodiments described in this specific implementation are preferred embodiments of this application and are not intended to limit the scope of protection of this application. Identical components are represented by the same reference numerals. Therefore, all equivalent changes made to the structure, shape, and principle of this application should be covered within the scope of protection of this application.
Claims
1. A non-flat material surface inspection device, comprising a lifting unit (1), characterized in that: The upper part of the lifting unit (1) is fixedly connected to the detection unit (2), and the front and rear sides of the lifting unit (1) are fixedly provided with supplementary lighting units (8). The middle part of the lifting unit (1) is provided with a moving unit (3), and the upper part of the moving unit (3) is provided with a support unit (4). The upper part of the support unit (4) is equipped with a plate (11). The right front side of the lifting unit (1) is provided with a loading robot arm (5), the left front side of the lifting unit (1) is provided with a unloading robot arm (6), and the right rear side of the lifting unit (1) is provided with a flipping robot arm (7). The lifting unit (1) is used to drive the lifting of the detection unit (2) to adapt to different thicknesses of the board (11). The detection unit (2) is used to detect surface defects of the board (11). The supplementary lighting unit (8) is used to provide uniform supplementary lighting to the surface of the board (11). The moving unit (3) is used to drive the support unit (4) to move back and forth, so that the plate (11) mounted on the upper part of the support unit (4) moves along the bottom of the detection unit (2). The loading robot arm (5) is used to transfer the plate (11) to be tested to the support unit (4). The unloading robot arm (6) is used to remove the plate (11) after testing from the support unit (4). The flipping robot arm (7) is used to flip the plate (11) 180° so that both sides of the plate (11) can be detected by the detection unit (2).
2. The non-flat plate surface detection device according to claim 1, characterized in that: The lifting unit (1) includes a base plate (101) symmetrically arranged on the left and right and fixedly connected to the ground by bolts. A telescopic cylinder (102) is fixedly installed at the middle of the upper end of the base plate (101). A first fixed plate (103) is fixedly connected to the telescopic end of the telescopic cylinder (102). A connecting frame (104) is fixedly connected to the inner side of the first fixed plate (103) by bolts. A sliding block (106) is welded to the four corners of the outer end of the connecting frame (104). A vertical guide frame (105) is welded to the front and rear sides of the upper part of the two base plates (101). The sliding block (106) is slidably connected to the inner side of the corresponding vertical guide frame (105) to realize the smooth lifting of the connecting frame (104). The detection unit (2) includes a horizontally arranged mounting bracket (201), the left and right ends of which are rotatably connected to two connecting brackets (104) arranged on the left and right sides.
3. The non-flat plate surface detection device according to claim 2, characterized in that: The bottom of the mounting bracket (201) is fixedly connected to several fixing blocks (202) at equal intervals by bolts, and the bottom of each fixing block (202) is threaded with a detection probe (203). A first drive motor (204) is fixedly connected to the outer side of the connecting frame (104) on the right side, and the shaft of the first drive motor (204) is fixedly connected to the right end of the mounting frame (201); Each of the supplementary lighting units (8) includes a horizontally arranged mounting frame (801). The left and right ends of the mounting frame (801) are each welded with a second fixing plate (802). The second fixing plate (802) is fixedly connected to the inner side of the corresponding connecting frame (104) by bolts. Several mounting clamps (803) are equidistantly arranged on the outer side of the mounting frame (801). The bottom of each mounting clamp (803) is threaded with a supplementary light (805). The upper part of each mounting clamp (803) is fixedly connected with a first fixing clamp (804) by bolts.
4. The non-flat plate surface detection device according to claim 1, characterized in that: The moving unit (3) includes a base (301) symmetrically arranged at the front and back and fixedly connected to the ground by bolts. A second drive motor (302) is fixedly arranged at the front of the base (301). A threaded screw (303) is rotatably connected to the middle of the base (301) at the front and back. The rotating shaft of the second drive motor (302) is fixedly connected to the front end of the threaded screw (303). The support unit (4) includes a movable frame (401), the middle part of which is threaded to the outside of the threaded screw (303). The upper left and right sides of the movable frame (401) are fixedly connected to sliding frames (402) by bolts. The front and rear ends of the middle part of the sliding frame (402) are slidably provided with support sliders (403). Support rods (404) are welded to the upper parts of the support sliders (403) on the left and right sides. The plate (11) is mounted on the upper part of the support rods (404) on the front and rear sides.
5. The non-flat plate surface detection device according to claim 4, characterized in that: Each of the bases (301) has a bearing seat (305) fixed to the ground by bolts on its inner side. The front and rear ends of the threaded screw (303) are rotatably connected to the inner side of the corresponding bearing seat (305). Guide rods (304) are fixedly installed on the left and right ends of the inner side of the base (301), and the left and right sides of the movable frame (401) are slidably connected to the outer sides of the corresponding guide rods (304).
6. The non-flat plate surface detection device according to claim 4, characterized in that: The middle part of the support slider (403) and the sliding frame (402) are provided with a number of insertion holes (405) at equal intervals in the horizontal direction, and the insertion holes (405) are provided with insertion bolts (406). The support unit (4) also includes two longitudinally symmetrically arranged longitudinal guide frames (407) that are fixedly connected to the ground by bolts. The upper part of each longitudinal guide frame (407) is provided with a guide groove (408). The bottom front and rear sides of the sliding frame (402) are fixedly connected with guide pulleys (409). The front and rear guide pulleys (409) are slidably connected to the inner side of the corresponding guide groove (408).
7. The non-flat plate surface detection device according to claim 4, characterized in that: Each of the support rods (404) is provided with a rubber pad (9) on its upper part. Each of the rubber pads (9) is provided with a semi-circular groove (901) on its bottom. The semi-circular groove (901) is engaged with the upper part of the support rod (404) to achieve quick positioning and installation of the rubber pad (9). The bottom end of each of the rubber pads (9) is fixedly connected with several second fixing clamps (10) by bolts.
8. A method for detecting the surface of non-flat materials, applied to the non-flat material surface detection device according to any one of claims 1-7, characterized in that: Specifically, the following detection methods are included: S1. Loading and positioning: The loading robot arm (5) moves the plate (11) to be inspected to the upper part of the front and rear support rods (404) of the support unit (4). The semi-circular groove (901) of the rubber pad (9) is engaged with the support rod (404) to achieve quick positioning. The rubber pad (9) is locked by the second fixing clamp (10). According to the length of the plate (11), the position of the sliding support slider (403) on the sliding frame (402) is adjusted, and the plug (406) is inserted into the corresponding hole (405) to lock the spacing between the front and rear support rods (404). S2, detection height adaptation: start the telescopic cylinder (102) of the lifting unit (1) to drive the first fixed plate (103) to drive the connecting frame (104) to rise and fall. The connecting frame (104) moves smoothly along the vertical guide frame (105) through the sliding block (106) to adjust the distance between the detection unit (2) and the plate (11); S3. Lighting adjustment: Loosen the first fixing clamp (804) of the lighting unit (8), adjust the position of the mounting clamp (803) on the mounting bracket (801), adjust the irradiation angle of the lighting lamp (805) by threading, so that the lighting lamp (805) forms uniform lighting on the surface of the board (11), and lock the first fixing clamp (804) after adjustment. S4. Front detection: Start the first drive motor (204) of the detection unit (2) to drive the mounting bracket (201) to rotate around the left and right side connecting brackets (104), adjust the detection angle of the detection probe (203), and at the same time adjust the extension length of the detection probe (203) on the fixed block (202) by the thread. The detection probe (203) adopts homogenized line laser surface image acquisition technology, and achieves uniform illumination of the surface of the board (11) by precisely controlling the laser projection angle and light intensity distribution; The second drive motor (302) of the synchronously started moving unit (3) drives the threaded screw (303) to rotate around the bearing seat (305), which drives the moving frame (401) to move back and forth along the guide rod (304). The support unit (4) moves synchronously and smoothly along the guide groove (408) of the longitudinal guide frame (407) through the guide pulley (409), so that the plate (11) moves backward at a uniform speed below the detection unit (2), and the detection probe (203) completes the full detection of the front of the plate.
9. The method for detecting the surface of non-flat plates according to claim 8, characterized in that: It also includes the following detection methods: S5, Plate flipping: The moving unit (3) drives the support unit (4) to move the plate (11) to the corresponding position of the flipping robot arm (7), and flips the plate (11) 180° through the flipping robot arm (7); S6, Reverse inspection: The inspection probe (203) switches to the self-measurement servo vision surface inspection mode, senses the specification changes of the board (11) in real time, and automatically adjusts the inspection parameters of the inspection probe (203) and the rotation angle of the mounting bracket (201); Repeat the driving process of the moving unit (3) in step S4 to make the flipped board (11) move forward at a constant speed along the bottom of the detection unit (2), and the detection probe (203) completes the full detection of the back of the board. S7. Unloading: After the inspection is completed, the moving unit (3) drives the support unit (4) to move the plate (11) to the corresponding position of the unloading robot arm (6). The unloading robot arm (6) removes the inspected plate from the support rod (404) to complete the single inspection process.
10. The method for detecting the surface of non-flat plates according to any one of claims 8 or 9, characterized in that: During the homogenization line laser surface image acquisition process in step S4, the laser intensity output is adjusted in real time according to the material characteristics of the plate (11) to ensure that uniform illumination can be formed in the raised and recessed areas of the plate, and to avoid imaging distortion caused by reflection or shadow. In the self-measurement servo vision surface detection process in step S6, the detection probe (203) analyzes the collected image data in real time. If the thickness or position of the plate material changes, it automatically feeds back signals to the lifting unit (1) and the detection unit (2). The detection height is finely adjusted by the telescopic cylinder (102), the detection angle is finely adjusted by the first drive motor (204), and the driving speed of the moving unit (3) is adjusted synchronously so that the detection probe (203) maintains the optimal detection distance and acquisition frequency with the plate surface. The image data collected by the detection probe (203) is transmitted to the background processing system in real time. The system performs defect identification on the image under laser illumination and, combined with the plate posture data fed back by the self-measurement servo module, accurately locates the defect position and size. The lifting unit (1), the moving unit (3), the detection unit (2), the loading robot arm (5), the unloading robot arm (6) and the flipping robot arm (7) achieve coordinated action through the linkage control module. When the detection probe (203) detects a serious defect, it can trigger the moving unit (3) to pause its movement and continue detection after manual confirmation, or directly transfer it to the non-conforming product area through the unloading robot arm (6).