Power takeoff gear optical visual detection device and method

Abstract

The invention relates to the technical field of optical visual detection devices, and discloses a power takeoff gear optical visual detection device and method.The power takeoff gear optical visual detection device comprises a fixing frame, a mounting rack, an inner limiting structure, a gear driving structure, an imaging structure, a light supplementing lamp structure and a camera moving structure; precise assembly of all parts is realized through the fixing frame, the influence of assembly deviation on detection precision is avoided, the problem of shielding of the outer surface, the inner hole surface and the front and back surfaces of the to-be-detected gear is solved through the special design of the mounting frame and the inner limiting structure, so that a turnover mechanism is not needed, and the detection efficiency is improved. The problems of large secondary positioning error, low detection efficiency, permanent shielding of a clamping area and incapability of realizing full-surface detection of the gear in the traditional single-station serial overturning detection are thoroughly avoided, the gear driving structure realizes automatic rotation of the gear to be detected, and the gear driving structure is matched with the movable imaging structure and the light supplementing lamp structure to realize full-surface detection of the gear to be detected. The detection requirements of power takeoff gears of various specifications can be met, and the detection efficiency and the imaging quality can be improved.

Description

Technical Field

[0001] This invention relates to the field of optical vision inspection devices, specifically to an optical vision inspection device and method for power take-off gears. Background Technology

[0002] Defects commonly found in PTO gears machined using the cutting method include tooth tip / edge chipping, chipped edges, built-up edge adhesion, root and root cutting marks, overcutting, and tool deflection pits. These defects are machining error-type defects caused by deviations in size, shape, and surface due to the tool, machine tool, and process parameters. These defects are concentrated at the surface and precision levels. The internal metal structure of the gear is continuous and dense, with no internal defects. Moreover, most defects can be corrected by adjusting the process and subsequent finishing (shaving, grinding). Therefore, it is necessary to use an optical vision inspection device for PTO gears to inspect the gears. The optical vision inspection device for PTO gears is a high-precision, non-contact, automated quality inspection device specifically designed for automotive PTO gears. Through optical imaging and machine vision algorithms, it can achieve comprehensive inspection of gear dimensional accuracy, appearance defects, and surface quality, solving the pain points of low efficiency, poor consistency, and high rate of missed and false detections in traditional manual inspection. It is a key piece of equipment for intelligent manufacturing of automotive parts.

[0003] Existing optical vision inspection devices for power take-off gears employ single-station serial operation when inspecting the front and back sides of the gears. The flipping mechanism is a single-station clamping and flipping mechanism, which requires repositioning after flipping. This not only results in low inspection efficiency but also large secondary positioning errors. Furthermore, the clamping structure is mostly fully enclosed or hard contact type, which can easily cause gear clamping deformation and surface damage. In addition, the clamping area is permanently blocked, making it impossible to achieve full surface inspection of the gears. Summary of the Invention

[0004] The purpose of this invention is to address the shortcomings of existing power take-off gear optical vision inspection devices, which employ single-station serial operation, require gear repositioning after the flipping mechanism flips the gear, and have permanent obstruction of the clamping area of ​​the clamping structure, thus failing to achieve full-surface inspection of the gear. Therefore, this invention proposes an optical vision inspection device and method for power take-off gears.

[0005] To achieve the above objectives, the present invention provides the following technical solution: an optical vision inspection device for power take-off gears, comprising:

[0006] The fixed frame is set inside the cavity of the detection device to ensure that the various components installed on it are accurately positioned, providing a stable installation benchmark for subsequent collaborative operation of various structures, avoiding detection deviations caused by component offset, and providing rigid installation support for the front and back synchronous detection structure.

[0007] The mounting bracket, which is set on the fixed frame, is used to place the gear to be tested. By reducing the support surface and setting the opening, the mounting bracket ensures that the fan-shaped surface of the gear to be tested in a certain position of the mounting surface is not blocked by the mounting bracket. This ensures that the imaging structure and the supplementary light structure have an unobstructed field of view during subsequent shooting and inspection. Clear shooting and illumination of the front, back and outer peripheral surfaces can be achieved without flipping the gear to be tested, avoiding the occlusion problem caused by traditional flipping clamping.

[0008] The inner limiting structure is set on the mounting bracket and uses an abutment method to limit the inner hole of the gear under test. The inner limiting structure uses a staggered break to offset itself from the abutment surface of the gear under test, so that the inner hole surface of the gear under test can form a continuous and stable test surface. This avoids the limiting structure from blocking the inner hole test area, and at the same time avoids the deformation and surface damage of the gear under test caused by traditional full-coverage and hard contact clamping, ensuring that the inner hole surface and the front and back of the gear under test are tested without omission.

[0009] The gear drive structure, in conjunction with the inner limiting structure, is used to drive the gear under test to rotate. It can drive the gear under test to rotate at a uniform speed and smoothly, so that the imaging structure can take a comprehensive picture of the entire circumference and the front and back edge areas of the gear under test. There is no need to manually adjust the position of the gear under test, and there is no need to set up a flipping mechanism for single-station serial flipping detection, which greatly improves the detection efficiency and avoids the secondary positioning error caused by flipping.

[0010] The imaging structure is used to image various parts of the gear under test, capturing detailed features of the gear surface, tooth surface, inner hole, hidden edge parts, and front and back sides of the gear under test. It can complete synchronous or step-by-step detection of the front and back sides without flipping the gear under test, replacing the traditional single-station serial flipping detection mode, providing clear image data support for subsequent defect identification, and completely solving the problems of permanent occlusion of the clamping area and inability to detect the entire surface in traditional flipping detection.

[0011] The supplementary light structure improves the imaging quality of the imaging structure through the lighting method and optical path design. It optimizes the lighting effect for the front and back of the gear under test and different detection parts, reduces interference such as shadows and reflections, enhances image contrast and clarity, and does not require adjustment of the illumination angle with the flipping mechanism, thus adapting to the needs of simultaneous detection of the front and back.

[0012] The camera moving structure is used to change the position of the imaging structure and the illumination angle of the supplementary light structure, adapting to power take-off gears of different specifications and thicknesses. This ensures that the front and back of the gear under test and all detection parts can be accurately photographed and fully illuminated. Multi-specification adaptation can be completed without disassembling or flipping the gear under test, avoiding the accuracy deviation caused by flipping adaptation.

[0013] As a further embodiment of the present invention, the mounting frame includes a connecting frame and a support frame;

[0014] The connecting frame is set on the outside to connect the fixed frame and the mounting frame. The connecting frame has a small area occupied in the plane space to minimize the obstruction of the imaging light path and the supplementary light path, especially to avoid obstructing the detection field of the front and back of the gear under test. At the same time, it ensures the connection stability and ensures that the mounting frame and the gear under test are firmly installed, and reserves sufficient light path space for simultaneous detection of the front and back.

[0015] The support frame is located on the inside to support the gear under test. Its shape is a non-closed curve with a break, and the position of the break is offset from the position of the connecting frame. That is, the support frame reduces the contact area with the gear under test through the non-closed structure. The design of the break and the connecting frame can avoid the two from forming an obstruction and superposition in the same position, further expanding the unobstructed detection area of ​​the gear under test. In particular, it ensures the integrity of the fan-shaped detection surface and the edge area of ​​the front and back of the gear under test. At the same time, the non-closed curve structure can adapt to the outer contour of the gear under test, improve the stability of the gear under test after placement, and prevent the gear under test from shifting. Unobstructed support of the front and back and outer circumference of the gear under test can be achieved without flipping.

[0016] As a further embodiment of the present invention, the inner limiting structure includes a mounting part and a limiting part;

[0017] The mounting section is used to connect the mounting frame and overlaps with the mounting frame in the vertical plane to avoid obstructing the vertical light path of the imaging structure and the supplementary light structure. In particular, it avoids obstructing the detection light path of the front and back sides of the gear under test and the front and back sides of the inner hole. It makes full use of the space layout, reduces the overall size of the device, and ensures that the vertical light transmission is unobstructed, improves the imaging clarity, and is suitable for simultaneous detection of the front and back sides.

[0018] The limiting part includes two annular roller bearings with fractures. The fracture directions of the two annular roller bearings are misaligned. The two annular roller bearings are connected to each other on the vertical plane by a connecting rod. The annular roller bearings can adapt to the circumferential contour of the inner hole of the gear under test, achieving precise and flexible contact limiting. The misaligned fracture design can prevent the limiting part itself from obstructing the inner hole surface and the front and back areas of the inner hole of the gear under test, ensuring that the inner hole surface forms a continuous detection area. At the same time, the structure of the roller bearings can reduce the friction force when the gear under test rotates, ensuring that the gear under test rotates smoothly, avoiding wear or displacement of the gear under test, improving detection accuracy, replacing the traditional full-coverage clamping, avoiding clamping deformation and surface damage, and achieving comprehensive detection of the front and back areas of the inner hole without flipping the gear under test, avoiding secondary positioning errors caused by flipping.

[0019] As a further aspect of the present invention, a plurality of sliding frames with radial sliding capability are equally spaced inside the annular roller bearing. A compression spring is provided between the sliding frame and the inner wall of the annular roller bearing. A roller is provided inside the sliding frame. The compression spring always generates a radially outward elastic force on the sliding frame, pushing the sliding frame to drive the roller to abut against the inner wall of the gear under test. The roller can rotate synchronously with the gear under test, reducing the friction between the two, realizing flexible adaptive limiting, and avoiding excessive local force that could cause deformation of the gear under test.

[0020] As a further embodiment of the present invention, the imaging structure includes two coaxial camera structures, a side camera structure, a side-view camera structure, and an inner camera structure.

[0021] Two coaxial camera structures are respectively set above and below the gear under test. Their imaging direction is coaxial with the gear under test. They are used to photograph the front and back of the gear under test. They can be used to photograph the front and back of the gear under test simultaneously or in stages. There is no need to set up a flipping mechanism. It replaces the traditional single-station serial flipping detection mode. It can capture surface defects, tooth tip contours and other features on both sides of the gear under test. It completely avoids the pain points of traditional flipping detection, such as large secondary positioning error, clamping deformation, permanent occlusion and inability to detect the entire surface.

[0022] The side camera structure is set on the side of the gear under test to capture the tooth surface of the gear under test, accurately capturing detailed features such as tooth shape, tooth thickness, tooth surface wear, and cracks. Combined with the rotation of the gear drive structure, it can achieve full circumference detection of the tooth surface.

[0023] The side-view camera structure is set on the other side of the gear under test. The side-view camera structure includes two sets of miniature cameras, which are used to photograph the hidden parts such as the tooth root, the bottom of the keyway, and the chamfer root on the upper and lower sides of the gear under test. This solves the problem that traditional cameras and traditional flip-up inspections cannot capture the hidden parts on the edge of the gear under test, avoids missed defects, and can achieve full-dimensional inspection of hidden parts without flipping.

[0024] The internal camera structure includes a telescopic rod and an internal camera body. The internal camera body has two imaging surfaces, which correspond to the fracture positions of two annular roller bearings, respectively, and correspond to the front and back areas of the inner hole of the gear under test. The telescopic rod can adjust the position of the internal camera body to ensure that the internal camera can capture a complete image of the inner hole surface of the gear under test through the fracture of the annular roller bearing, realizing comprehensive detection of the inner hole surface and the front and back areas of the inner hole, and completing the full surface detection of the inner hole without flipping the gear under test.

[0025] As a further embodiment of the present invention, the supplementary lighting structure includes a coaxial light structure, a ring light structure, and a strip light structure;

[0026] The coaxial optical structure includes a light-emitting unit and a semi-transparent and semi-reflective beam splitter. The light-emitting unit emits light that shines on the semi-transparent and semi-reflective beam splitter. A portion of the light is reflected perpendicularly onto the surface of the gear under test. The surface of the gear under test produces a specular reflection, and the light returns along the original optical path, passing through the semi-transparent and semi-reflective beam splitter again and entering the coaxial camera structure. This can enhance the contrast of details on the front and back surfaces of the gear under test. It is especially suitable for detecting tiny scratches, dents and other defects on the front and back surfaces of the gear under test. It does not require adjusting the angle with the flipping mechanism and is suitable for simultaneous detection of the front and back surfaces.

[0027] The ring light structure is set on the outside of the side camera structure and integrated with the side camera structure. It is used to illuminate the tooth surface of the gear under test. The ring light can achieve uniform illumination of the tooth surface, reduce the shadows caused by the uneven structure of the tooth surface, improve the image clarity of the tooth surface, and help to accurately identify tooth surface defects.

[0028] The bar light structure is integrated with the side-view camera structure and is used to illuminate the hidden parts such as the tooth root, keyway bottom, and chamfer root on the upper and lower sides of the gear under test. The bar light is concentrated and can accurately illuminate the hidden parts, eliminate the shadow interference of the hidden parts, and ensure that the side-view camera can capture a clear image. The hidden parts can be fully illuminated without flipping.

[0029] As a further aspect of the present invention, the coaxial optical structure also includes an anti-reflection grating, which is installed in the optical path of the coaxial optical structure to filter stray reflected light, prevent stray reflected light from entering the coaxial camera structure, reduce image glare, light spots and other interference, and ensure that the front and back images of the gear under test captured by the coaxial camera are clear and stable.

[0030] As a further embodiment of the present invention, the camera moving structure includes a side moving structure and a lateral moving structure;

[0031] The side-moving structure includes a lead screw structure and a side mounting plate. The side mounting plate is equipped with a drive turntable, which is used to drive the side camera structure and the ring light structure to rotate. For helical gears with different helix angles, the illumination angle of the ring light structure is adjusted so that the illumination angle is directly facing the tooth surface of the gear under test. The lead screw structure can drive the side mounting plate to move up and down, adjust the height of the side camera structure and the ring light structure, adapt to the gear under test with different thicknesses, and ensure that the tooth surface and the edge areas of the front and back sides of the gear under test can be accurately photographed and illuminated.

[0032] The side-moving structure includes a fixed plate, a movable plate, and a telescopic structure. The fixed plate is fixedly mounted on the fixed frame, corresponding to the lower edge of the gear under test. The fixed plate drives the movable plate to extend and retract through the telescopic structure, so that the movable plate corresponds to the upper edge of the gear under test. This adjusts the height of the side-view camera structure to accommodate gears of different thicknesses, ensuring that the side-view camera can accurately align with the hidden parts of the upper and lower edges of the gear under test. This allows for accurate detection of hidden parts of gears of different thicknesses without the need for flipping.

[0033] As a further embodiment of the present invention, a gear drive structure is installed on the side of the gear under test, which is different from the side camera structure and the side-view camera structure. The gear drive structure includes a telescopic cylinder, a drive motor, and a drive wheel. The telescopic cylinder drives the drive motor to move, so that the drive wheel set on the output end of the drive motor abuts against the tooth surface of the gear under test. The drive motor drives the drive wheel to rotate, thereby driving the gear under test to rotate uniformly around the inner limit structure. In conjunction with the upper and lower coaxial cameras, the side camera, and the side-view camera, the full circumference synchronous detection of the front and back surfaces, tooth surfaces, and hidden parts of the gear under test can be achieved, and the full surface detection can be completed without flipping the gear under test.

[0034] A method of using a power take-off gear optical vision inspection device includes the following steps:

[0035] Step 1: Install a suitable inner limiting structure according to the inner diameter of the gear to be tested, and then place the gear to be tested on the mounting bracket and fit it onto the outside of the inner limiting structure;

[0036] Step 2: Activate the coaxial light structure and coaxial camera structure located above the mounting bracket to take a picture of the front of the gear under test. At this time, the front and tooth surfaces of the gear under test are unobstructed. After the picture is taken, activate the coaxial light structure located below the mounting bracket as a backlight to take an ultra-high contrast silhouette image of the gear under test and measure the outline of the gear under test.

[0037] Step 3: Activate the camera moving structure. Based on the thickness of the gear to be measured, adjust the height of the side camera structure using the side moving structure so that it faces the tooth surface of the gear to be measured. Then, adjust the height of the side camera structure using the side moving structure so that the side camera corresponds to the two side positions of the gear to be measured. If the gear to be measured is a helical gear, adjust the rotation angle of the side camera structure and the ring light structure by driving the turntable so that the illumination angle faces the tooth surface of the gear to be measured.

[0038] Step 4: Start the gear drive structure. The telescopic cylinder drives the drive motor to move, so that the drive wheel touches the tooth surface of the gear to be tested. Then the drive motor drives the drive wheel to rotate, which in turn drives the gear to be tested to rotate slowly.

[0039] Step 5: Simultaneously or sequentially activate the coaxial camera structure, side camera structure, side-mounted camera structure, inner camera structure, and corresponding supplementary lighting structure located below the mounting bracket to photograph the back of the gear under test, the tooth surface, the quasi-tooth root of the edge, the bottom of the keyway, the chamfer root, and other concealed parts, as well as the inner hole surface.

[0040] Compared with the prior art, the beneficial effects of the present invention are:

[0041] This invention achieves precise assembly of components through a fixed frame, avoiding assembly deviations that could affect detection accuracy. The special design of the mounting bracket and internal limiting structure solves the problems of obstruction on the outer surface, inner hole surface, and front and back sides of the gear, respectively. Flexible contact replaces traditional hard-contact clamping, preventing gear deformation and surface damage. No flipping mechanism is needed, completely avoiding the pain points of traditional single-station serial flipping detection, such as large secondary positioning errors, low detection efficiency, permanent obstruction of the clamping area, and inability to achieve full-surface gear detection. The gear drive structure enables automatic gear rotation, and combined with a movable imaging structure and supplementary lighting structure, it can adapt to the detection needs of various specifications of PTO gears, while improving detection efficiency and imaging quality. It can complete full-surface, full-dimensional gear detection without flipping, providing reliable assurance for the accurate identification of gear surface defects and dimensional deviations. Compared with traditional manual or single-view detection, the comprehensiveness, accuracy, and automation of detection are significantly improved, reducing manual operation intensity and human error. Attached Figure Description

[0042] Figure 1 This is a schematic diagram of the overall structure of a power take-off gear optical vision inspection device according to the present invention;

[0043] Figure 2 This is a schematic diagram of the components inside the fixed frame in the optical vision inspection device for a power take-off gear according to the present invention;

[0044] Figure 3 This is a schematic diagram of the mounting bracket in the optical vision inspection device for a power take-off gear according to the present invention;

[0045] Figure 4 This is a schematic diagram showing the positions of the gear drive structure, the side camera structure, and the side-view camera structure in a power take-off gear optical vision inspection device of the present invention.

[0046] Figure 5 This is a cross-sectional schematic diagram of the coaxial optical structure in the optical vision inspection device for a power take-off gear according to the present invention;

[0047] Figure 6 This is a schematic diagram of the side-moving structure in the optical vision inspection device for a power take-off gear according to the present invention;

[0048] Figure 7 This is a schematic diagram of the lateral movement structure in a power take-off gear optical vision inspection device of the present invention;

[0049] Figure 8 This is a schematic diagram of an annular roller bearing in a power take-off gear optical vision inspection device of the present invention;

[0050] Figure 9 This is a cross-sectional schematic diagram of the annular roller bearing in the optical vision inspection device for a power take-off gear according to the present invention.

[0051] In the diagram: 100, fixed frame; 200, mounting bracket; 210, connecting bracket; 220, bearing bracket; 300, inner limiting structure; 310, mounting part; 320, limiting part; 321, annular roller bearing; 322, sliding frame; 323, compression spring; 324, roller; 400, gear drive structure; 410, telescopic cylinder; 420, drive motor; 430, drive wheel; 500, imaging structure; 510, coaxial camera structure; 520, side camera structure; 530, side-view camera structure 540. Internal camera structure; 600. Fill light structure; 610. Coaxial light structure; 611. Light-emitting unit; 612. Semi-transparent and semi-reflective beam splitter; 613. Anti-reflective grating; 620. Ring light structure; 630. Strip light structure; 700. Camera moving structure; 710. Side moving structure; 711. Lead screw structure; 712. Side mounting plate; 713. Drive turntable; 720. Side moving structure; 721. Fixed plate; 722. Moving plate; 723. Telescopic structure; 800. Gear to be tested. Detailed Implementation

[0052] The technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.

[0053] like Figure 1 and 2 As shown, a power take-off gear optical vision inspection device includes: a fixed frame 100, a mounting bracket 200, an inner limiting structure 300, a gear drive structure 400, an imaging structure 500, a supplementary light structure 600, and a camera moving structure 700.

[0054] like Figure 2 As shown, the fixed frame 100 is set inside the cavity of the detection device to ensure that the installation positions of the various components installed on it are accurate, to provide a stable installation benchmark for the subsequent collaborative operation of various structures, to avoid detection deviation caused by component offset, and to provide rigid installation support for the front and back synchronous detection structure.

[0055] like Figure 2 and Figure 3As shown, the mounting bracket 200 is set on the fixed frame 100 and is used to place the gear 800 to be tested. By reducing the support surface and setting an opening, the mounting bracket 200 ensures that the fan-shaped surface of the gear 800 to be tested in a certain position on the mounting surface is not blocked by the mounting bracket 200. This ensures that the imaging structure 500 and the supplementary light structure 600 have an unobstructed detection field of view during subsequent shooting and inspection. Clear shooting and illumination of the front, back and outer peripheral surfaces can be achieved without flipping the gear 800 to be tested, avoiding the occlusion problem caused by traditional flipping clamping.

[0056] like Figure 3 and Figure 4 As shown, the inner limiting structure 300 is set on the mounting bracket 200 and uses a flexible contact method to limit the inner hole of the gear 800 under test. The inner limiting structure 300 uses a staggered break to offset itself from the contact surface of the gear 800 under test, so that the inner hole surface of the gear 800 under test can form a continuous and stable test surface, avoiding the limiting structure from blocking the inner hole test area, and avoiding the deformation and surface damage of the gear 800 under test caused by traditional full-coverage and hard contact clamping, ensuring that the inner hole surface and the front and back of the gear 800 under test are tested without omission.

[0057] like Figure 2 and Figure 4 As shown, the gear drive structure 400, together with the inner limiting structure 300, is used to drive the gear under test 800 to rotate. It can drive the gear under test 800 to rotate at a uniform speed and smoothly, so that the imaging structure 500 can take a comprehensive picture of the entire circumference and the front and back edge areas of the gear under test 800. There is no need to manually adjust the position of the gear under test 800, and there is no need to set up a flipping mechanism for single-station serial flipping detection, which greatly improves the detection efficiency and avoids the secondary positioning error caused by flipping.

[0058] like Figure 2 As shown, the imaging structure 500 is used to image various parts of the gear 800 under test, capturing detailed features of the surface, tooth surface, inner hole, hidden edge parts, and front and back of the gear 800. It can complete the synchronous or stepwise detection of the front and back without flipping the gear 800 under test, replacing the traditional single-station serial flip detection mode, providing clear image data support for subsequent defect identification, and completely solving the problems of permanent occlusion of the clamping area and inability to detect the entire surface in traditional flip detection.

[0059] like Figure 2 As shown, the supplementary light structure 600 improves the imaging quality of the imaging structure 500 through the lighting method and optical path design. It optimizes the lighting effect for the front and back sides of the gear 800 under test and different detection parts, reduces interference such as shadows and reflections, enhances image contrast and clarity, and does not require adjustment of the illumination angle with the flipping mechanism, thus adapting to the requirements of simultaneous detection of the front and back sides.

[0060] like Figure 2 As shown, the camera moving structure 700 is used to change the position of the imaging structure 500 and the illumination angle of the supplementary light structure 600 to adapt to the power take-off gears 800 of different specifications and thicknesses. This ensures that the front and back of the gear 800 and all detection parts can be accurately photographed and fully illuminated. Multi-specification adaptation can be completed without disassembling or flipping the gear 800, avoiding the accuracy deviation caused by flipping adaptation.

[0061] This invention achieves precise assembly of all components through a fixed frame 100, avoiding assembly deviations that could affect detection accuracy. The special design of the mounting bracket 200 and the inner limiting structure 300 solves the problems of obstruction on the outer surface, inner hole surface, and front and back surfaces of the gear 800 under test, respectively. Flexible contact replaces traditional hard-contact clamping, preventing deformation and surface damage to the gear 800 under test. No flipping mechanism is needed, completely avoiding the pain points of traditional single-station serial flipping detection, such as large secondary positioning errors, low detection efficiency, permanent obstruction of the clamping area, and inability to achieve full-surface detection of the gear 800 under test. The moving structure 400 enables the automatic rotation of the gear 800 under test. Combined with the movable imaging structure 500 and the supplementary lighting structure 600, it can not only adapt to the testing needs of various specifications of power take-off gears 800 under test, but also improve the testing efficiency and imaging quality. It can complete the full surface and full-dimensional testing of the gear 800 under test without flipping it, providing a reliable guarantee for the accurate identification of surface defects, dimensional deviations and other problems of the gear 800 under test. Compared with traditional manual testing or single-view testing, the comprehensiveness, accuracy and automation of testing are significantly improved, reducing the intensity of manual operation and reducing human testing errors.

[0062] like Figure 3 As shown, the mounting bracket 200 includes a connecting bracket 210 and a support bracket 220;

[0063] The connecting frame 210 is located on the outside and is used to connect the fixed frame 100 and the mounting frame 220. The connecting frame 210 adopts a shape that occupies a small area of ​​planar space (such as a rod-shaped or arc-shaped narrow structure) to minimize the obstruction of the imaging optical path and the supplementary optical path, especially to avoid obstructing the detection field of the front and back of the gear under test 800, while ensuring connection stability and ensuring that the mounting frame 220 and the gear under test 800 are firmly installed, and reserving sufficient optical path space for synchronous detection of the front and back sides;

[0064] The support frame 220 is located on the inner side to support the gear 800 under test. Its shape is a non-closed curve with a break, and the position of the break is offset from the position of the connecting frame 210. That is, the support frame 220 reduces the contact area with the gear 800 under test through the non-closed structure. The design of the break and the connecting frame 210 can avoid the two from forming an obstruction and superposition in the same position, further expanding the unobstructed detection area of ​​the gear 800 under test. In particular, it ensures the integrity of the fan-shaped detection surface and the front and back edge areas of the gear 800 under test. At the same time, the non-closed curve structure can adapt to the outer contour of the gear 800 under test, improve the stability of the gear 800 under test after placement, and prevent the gear 800 under test from shifting. Unobstructed support of the front and back and outer periphery of the gear 800 under test can be achieved without flipping.

[0065] This application divides the mounting frame 200 into a connecting frame 210 and a support frame 220, with clear division of labor. The connecting frame 210 balances connection stability and space utilization, reducing optical path obstruction, especially avoiding obstruction of the front and back sides of the gear 800 under test, providing sufficient space for imaging and supplementary lighting for simultaneous detection of the front and back sides. The non-closed break design of the support frame 220, which is offset from the connecting frame 210, not only achieves stable support of the gear 800 under test, but also maximizes the avoidance of obstruction of the detection surface and front and back sides of the gear 800 by the mounting frame 200, ensuring the imaging structure 500 It can capture complete images of the sector surface and front and back sides of the gear under test 800, avoiding missed defects caused by occlusion. At the same time, it does not require flipping the gear under test 800 to achieve front and back side detection, avoiding the problem of overlapping occlusion of the bearing surface caused by traditional flipping clamping. The small-space-occupying connecting frame 210 design provides sufficient space for the installation and movement of the supplementary light structure 600 and imaging structure 500, improving the rationality and layout flexibility of the overall structure of the device, further adapting to the needs of synchronous front and back side detection, and replacing the traditional single-station serial flipping support mode.

[0066] like Figure 3 As shown, the inner limiting structure 300 includes a mounting part 310 and a limiting part 320;

[0067] The mounting part 310 is used to connect the mounting frame 200 and overlaps with the mounting frame 200 in the vertical plane. This avoids blocking the vertical light path of the imaging structure 500 and the supplementary light structure 600, especially avoiding blocking the detection light path of the front and back sides and the front and back sides of the inner hole of the gear under test 800. This makes full use of the space layout, reduces the overall size of the device, and ensures that the vertical light transmission is unobstructed, improves the imaging clarity, and is suitable for simultaneous detection of the front and back sides.

[0068] like Figure 3 and Figure 4As shown, the limiting part 320 includes two annular roller bearings 321 with breaks. The breaks of the two annular roller bearings 321 are misaligned. The two annular roller bearings 321 are connected to each other on the vertical plane by a connecting rod. The annular roller bearings 321 can adapt to the circumferential contour of the inner hole of the gear 800 under test, achieving precise and flexible contact limiting. The misaligned break design can prevent the limiting part 320 itself from blocking the inner hole surface and the front and back areas of the inner hole of the gear 800 under test, ensuring that the inner hole surface forms a continuous detection area. At the same time, the structure of the roller bearing can reduce the friction force when the gear 800 under test rotates, ensuring that the gear 800 under test rotates smoothly, avoiding wear or displacement of the gear 800 under test, improving detection accuracy, replacing the traditional full-coverage clamping, avoiding clamping deformation and surface damage, and achieving full detection of the front and back areas of the inner hole without flipping the gear 800 under test, avoiding secondary positioning errors caused by flipping.

[0069] like Figure 8 and Figure 9 As shown, multiple sliding frames 322 are equally spaced inside the annular roller bearing 321, which can slide radially along the annular roller bearing 321. A compression spring 323 is provided between the sliding frame 322 and the inner wall of the annular roller bearing 321. A roller 324 is provided inside the sliding frame 322. The compression spring 323 always generates a radially outward elastic force on the sliding frame 322, pushing the sliding frame 322 to drive the roller 324 to abut against the inner wall of the test gear 800. The roller 324 can rotate synchronously with the test gear 800, reducing the friction between the two, realizing flexible adaptive limiting, and avoiding excessive local force that could cause deformation of the test gear 800.

[0070] like Figure 2 As shown, the imaging structure 500 includes two coaxial camera structures 510, a side camera structure 520, a side-viewing camera structure 530, and an inner camera structure 540.

[0071] Two coaxial camera structures 510 are respectively set above and below the gear under test 800. Their imaging direction is coaxial with the gear under test 800, corresponding to the front and back of the gear under test 800 respectively. They are used to synchronously or stepwise photograph the front and back of the gear under test 800. There is no need to set up a flipping mechanism. It replaces the traditional single-station serial flipping detection mode and can capture surface defects, tooth tip contours and other features on both sides of the gear under test 800. It completely avoids the pain points of large secondary positioning error, clamping deformation, permanent occlusion and inability to detect the entire surface in traditional flipping detection.

[0072] The side camera structure 520 is set on the side of the gear 800 under test to capture the tooth surface of the gear 800 under test, accurately capturing detailed features such as tooth shape, tooth thickness, tooth surface wear, and cracks. Combined with the rotation of the gear drive structure 400, it can realize full circumference detection of the tooth surface.

[0073] The side-view camera structure 530 is set on the other side of the gear 800 under test. The side-view camera structure 530 includes two sets of miniature cameras, which are used to photograph the hidden parts such as the tooth root, the bottom of the keyway, and the chamfer root on the upper and lower sides of the gear 800 under test. This solves the problem that traditional cameras and traditional flip-up inspections cannot capture the hidden parts on the edge of the gear 800 under test, avoids missed defects, and can achieve full-dimensional inspection of hidden parts without flipping.

[0074] The internal camera structure 540 includes a telescopic rod and an internal camera body. The internal camera body has two imaging surfaces, which correspond to the fracture positions of the two annular roller bearings 321, respectively, and correspond to the front and back areas of the inner hole of the gear 800 under test. The telescopic rod can adjust the position of the internal camera body to ensure that the internal camera can capture a complete image of the inner hole surface of the gear 800 under test through the fracture of the annular roller bearings 321, so as to realize the comprehensive detection of the inner hole surface and the front and back areas of the inner hole, and complete the full surface detection of the inner hole without flipping the gear 800 under test.

[0075] like Figure 4 and Figure 5 As shown, the fill light structure 600 includes a coaxial light structure 610, a ring light structure 620, and a strip light structure 630.

[0076] The coaxial light structure 610 includes a light-emitting unit 611 and a semi-transparent and semi-reflective beam splitter 612. Two sets are set for the two coaxial camera structures 510, respectively adapting to the shooting needs of the front and back of the gear under test 800. The light-emitting unit 611 emits light to illuminate the semi-transparent and semi-reflective beam splitter 612. A part of the light is vertically reflected to the corresponding surface (front or back) of the gear under test 800. The surface of the gear under test 800 produces a mirror reflection. The light returns along the original light path and passes through the semi-transparent and semi-reflective beam splitter 612 again to enter the corresponding coaxial camera structure 510. This can enhance the contrast of the details on the front and back surfaces of the gear under test 800. It is especially suitable for detecting small scratches, dents and other defects on the front and back surfaces of the gear under test 800. It does not require adjusting the angle with the flipping mechanism and is suitable for simultaneous detection of the front and back surfaces.

[0077] The ring light structure 620 is set on the outside of the side camera structure 520 and integrated with the side camera structure 520. It is used to illuminate the tooth surface of the gear 800 under test. The ring light can achieve uniform illumination of the tooth surface, reduce the shadows caused by the uneven structure of the tooth surface, improve the image clarity of the tooth surface, and help to accurately identify tooth surface defects.

[0078] The bar light structure 630 is integrated with the side-view camera structure 530 and is set on the side of the side-view camera structure 530. It is used to illuminate the hidden parts such as the tooth root, the bottom of the keyway, and the chamfer root on the upper and lower sides of the gear under test 800. The bar light is concentrated and can accurately illuminate the hidden parts, eliminate the shadow interference of the hidden parts, and ensure that the side-view camera can capture a clear image. The hidden parts can be fully illuminated without flipping.

[0079] like Figure 5 As shown, the coaxial optical structure 610 also includes an anti-reflection grating 613, which is installed on the optical path of the coaxial optical structure 610 and is respectively set for the illumination optical paths of the front and back sides of the gear 800 under test. It is used to filter stray reflected light, prevent stray reflected light from entering the coaxial camera structure 510, reduce image glare, light spots and other interference, and ensure that the front and back images of the gear 800 under test captured by the coaxial camera are clear and stable.

[0080] like Figure 6 and Figure 7 As shown, the camera moving structure 700 includes a side moving structure 710 and a side moving structure 720;

[0081] The side-moving structure 710 includes a lead screw structure 711 and a side mounting plate 712. The side mounting plate 712 is equipped with a drive turntable 713, which is used to drive the side camera structure 520 and the ring light structure 620 to rotate. For the inclined gears 800 with different helix angles, the illumination angle of the ring light structure 620 is adjusted so that the illumination angle is directly facing the tooth surface of the gear 800 under test. At the same time, the shooting angle of the side camera structure 520 is adjusted to ensure that the tooth surface is clearly imaged. The lead screw structure 711 can drive the side mounting plate 712 to move up and down, adjusting the height of the side camera structure 520 and the ring light structure 620 to adapt to the gears 800 with different thicknesses, ensuring that the tooth surface and the front and back edge areas of the gear 800 under test can be accurately photographed and illuminated.

[0082] The side-moving structure 720 includes a fixed plate 721, a movable plate 722, and a telescopic structure 723. The fixed plate 721 is fixedly mounted on the fixed frame 100, corresponding to the lower edge of the gear 800 to be tested. The fixed plate 721 drives the movable plate 722 to extend and retract through the telescopic structure 723, so that the movable plate 722 corresponds to the upper edge of the gear 800 to be tested, thereby adjusting the height of the side-viewing camera structure 530 to adapt to gears 800 of different thicknesses. This ensures that the side-viewing camera can accurately align with the hidden parts of the upper and lower edges of the gear 800 to be tested, achieving accurate detection of the hidden parts of gears 800 of different thicknesses without flipping them over.

[0083] like Figure 4As shown, the gear drive structure 400 is installed on the side of the gear under test 800, which is different from the side camera structure 520 and the side-view camera structure 530. This avoids the drive structure from blocking the imaging light path and the supplementary light path, especially avoiding blocking the detection light path of the front and back of the gear under test 800. The gear drive structure 400 includes a telescopic cylinder 410, a drive motor 420 and a drive wheel 430. The telescopic cylinder 410 drives the drive motor 420 to move, so that the drive wheel 430 set on the output end of the drive motor 420 abuts against the tooth surface of the gear under test 800. The drive motor 420 drives the drive wheel 430 to rotate, thereby driving the gear under test 800 to rotate uniformly around the inner limiting structure 300. With the cooperation of the upper and lower coaxial cameras, the side camera and the side-view camera, the full-circumference synchronous detection of the front and back, tooth surface and hidden parts of the gear under test 800 can be realized. The full surface detection can be completed without flipping the gear under test 800.

[0084] A method for using an optical vision inspection device for a power take-off gear 800:

[0085] Step 1: Install the appropriate inner limiting structure 300 according to the inner diameter of the gear 800 to be tested, and then place the gear 800 to be tested on the mounting bracket 200 and fit it on the outside of the inner limiting structure 300.

[0086] Step 2: Activate the coaxial light structure 610 located above the mounting bracket 200 and the coaxial camera structure 510 located above the mounting bracket 200 to take a picture of the front of the gear 800 under test. At this time, the front and tooth surface of the gear 800 under test are unobstructed. After the picture is taken, activate the coaxial light structure 610 located below the mounting bracket 200 as a backlight to take a picture of the gear 800 under test with an extremely high contrast silhouette image and measure the outline of the gear 800 under test.

[0087] Step 3: Activate the camera moving structure 700. Based on the thickness of the gear 800 to be tested, adjust the height of the side camera structure 520 using the side moving structure 710 so that it faces the tooth surface of the gear 800 to be tested. Then, adjust the height of the side-viewing camera structure 530 using the side moving structure 720 so that the side-viewing camera corresponds to the two side positions of the gear 800 to be tested. If the gear 800 to be tested is an inclined gear 800, adjust the rotation angle of the side camera structure 520 and the ring light structure 620 by driving the turntable 713 so that the illumination angle faces the tooth surface of the gear 800 to be tested.

[0088] Step 4: Start the gear drive structure 400. The telescopic cylinder 410 drives the drive motor 420 to move, so that the set drive wheel 430 abuts against the tooth surface of the gear 800 to be tested. Then the drive motor 420 drives the drive wheel 430 to rotate, which in turn drives the gear 800 to be tested to rotate slowly.

[0089] Step 5: Simultaneously or sequentially activate the coaxial camera structure 510, the side camera structure 520 and the side-mounted camera structure 520, the inner camera structure 540 and the corresponding supplementary light structure 600 located below the mounting bracket 200 to take pictures of the back, tooth surface, edge tooth root, keyway bottom, chamfer root and other hidden parts and inner hole surface of the gear 800 under test.

[0090] Although the present invention has been described in detail with reference to the foregoing embodiments, those skilled in the art can still modify the technical solutions described in the foregoing embodiments or make equivalent substitutions for some of the technical features. Any modifications, equivalent substitutions, improvements, etc., made within the spirit and principles of the present invention should be included within the protection scope of the present invention.

Claims

1. A power take-off gear optical vision inspection device, characterized in that, include: A fixed frame (100) is set inside the cavity of the detection device to ensure that the various components installed on it are in precise positions. Mounting bracket (200), which is set on fixed frame (100), is used to place gear (800) to be tested. The mounting bracket (200) reduces the support surface and sets an opening so that the fan-shaped surface of gear (800) to be tested in a certain position of the mounting surface is not blocked by the mounting bracket (200). An inner limiting structure (300) is installed on the mounting bracket (200) and limits the inner hole of the gear (800) to be tested by abutting. The inner limiting structure (300) offsets its abutting surface with the gear (800) by staggering the break, so that the inner hole surface of the gear (800) to be tested can form a continuous and stable test surface. A gear drive structure (400), which works in conjunction with an inner limiting structure (300) to drive the gear under test (800) to rotate; Imaging structure (500), which is used to image various parts of the gear (800) under test; The supplementary lighting structure (600) improves the imaging quality of the imaging structure (500) through the illumination method and optical path design; A camera moving structure (700) is used to change the position of the imaging structure (500) and the illumination angle of the fill light structure (600).

2. The optical vision inspection device for power take-off gears according to claim 1, characterized in that: The mounting bracket (200) includes a connecting bracket (210) and a support bracket (220); The connecting frame (210) is provided on the outside for connecting the fixed frame (100) and the mounting bracket (220). The connecting frame (210) has a shape that occupies a small area of ​​planar space. The support frame (220) is located on the inner side to support the gear (800) to be tested. Its shape is a non-closed curve with a break, and the position of the break is misaligned with the position of the connecting frame (210).

3. The optical vision inspection device for power take-off gears according to claim 1, characterized in that: The inner limiting structure (300) includes a mounting part (310) and a limiting part (320). The mounting part (310) is used to connect the mounting frame (200) and overlaps with the space occupied by the mounting frame (200) on the vertical plane to avoid blocking the vertical optical path of the imaging structure (500) and the supplementary light structure (600). The limiting part (320) includes two annular roller bearings (321) with breaks, the breaks of the two annular roller bearings (321) are misaligned, and the two annular roller bearings (321) are connected to each other on the vertical plane by a connecting rod.

4. The optical vision inspection device for power take-off gears according to claim 3, characterized in that: Multiple sliding frames (322) that can slide radially along the annular roller bearing (321) are equally spaced inside the annular roller bearing (321). A compression spring (323) is provided between the sliding frame (322) and the inner wall of the annular roller bearing (321). A roller (324) is provided inside the sliding frame (322).

5. The optical vision inspection device for power take-off gears according to claim 1, characterized in that: The imaging structure (500) includes two coaxial camera structures (510), a side camera structure (520), a side-view camera structure (530), and an inner camera structure (540). The two coaxial camera structures (510) are respectively set above and below the gear under test (800), and their imaging direction is coaxial with the gear under test (800) to capture the front and back of the gear under test (800); The side camera structure (520) is set on the side of the gear to be tested (800) and is used to photograph the tooth surface of the gear to be tested (800); The side-view camera structure (530) is set on the other side of the gear to be tested (800). The side-view camera structure (530) includes two sets of miniature cameras, which are used to photograph the hidden parts such as the tooth root, the bottom of the keyway, and the chamfer root on the upper and lower sides of the gear to be tested (800). The internal camera structure (540) includes a telescopic rod and an internal camera body. The internal camera body is provided with two shooting surfaces, which correspond to the break positions of the two annular roller bearings (321).

6. The optical vision inspection device for power take-off gears according to claim 5, characterized in that: The supplementary light structure (600) includes a coaxial light structure (610), a ring light structure (620), and a strip light structure (630). The coaxial optical structure (610) includes a light-emitting unit (611) and a semi-transparent and semi-reflective beam splitter (612). The light-emitting unit (611) emits light that shines on the semi-transparent and semi-reflective beam splitter (612). A portion of the light is vertically reflected onto the surface of the gear (800) under test. The surface of the gear (800) under test produces a specular reflection. The light returns along the original optical path and passes through the semi-transparent and semi-reflective beam splitter (612) again to enter the coaxial camera structure (510). The ring light structure (620) is set on the outside of the side camera structure (520) and integrated with the side camera structure (520) to illuminate the tooth surface of the gear (800) to be tested; The strip light structure (630) is integrated with the side-view camera structure (530) on the side and is used to illuminate the hidden parts such as the tooth root, keyway bottom, and chamfer root on the upper and lower sides of the gear (800) under test.

7. The optical vision inspection device for power take-off gears according to claim 6, characterized in that: The coaxial optical structure (610) also includes an anti-reflection grating (613), which is installed in the optical path of the coaxial optical structure (610) to filter stray reflected light.

8. The optical vision inspection device for power take-off gears according to claim 6, characterized in that: The camera moving structure (700) includes a side moving structure (710) and a side moving structure (720). The side moving structure (710) includes a lead screw structure (711) and a side mounting plate (712). The side mounting plate (712) is provided with a drive turntable (713) for driving the side camera structure (520) and the ring light structure (620) to rotate. For helical gears with different helix angles, the illumination angle of the ring light structure (620) is adjusted so that the illumination angle is directly facing the tooth surface of the gear (800) to be tested. The side-moving structure (720) includes a fixed plate (721), a movable plate (722), and a telescopic structure (723). The fixed plate (721) is fixedly mounted on the fixed frame (100) and corresponds to the lower edge of the gear (800) to be tested. The fixed plate (721) drives the movable plate (722) to extend and retract through the telescopic structure (723) so that the movable plate (722) corresponds to the upper edge of the gear (800) to be tested.

9. The optical vision inspection device for power take-off gears according to claim 5, characterized in that: The gear drive structure (400) is installed on the side of the gear (800) to be tested, which is different from the side camera structure (520) and the side-view camera structure (530). The gear drive structure (400) includes a telescopic cylinder (410), a drive motor (420) and a drive wheel (430). The telescopic cylinder (410) drives the drive motor (420) to move, so that the drive wheel (430) set on the output end of the drive motor (420) abuts against the tooth surface of the gear (800) to be tested.

10. A method of using an optical vision inspection device for power take-off gears, characterized in that: The method of using any one of the power take-off gear optical vision inspection devices according to claims 1 to 9 includes the following steps: S1: Install the appropriate inner limiting structure (300) according to the inner diameter of the gear (800) to be tested, and then place the gear (800) to be tested on the mounting bracket (200) and fit it on the outside of the inner limiting structure (300); S2: Activate the coaxial light structure (610) located above the mounting bracket (200) and the coaxial camera structure (510) located above the mounting bracket (200) to take a picture of the front of the gear (800) under test. At this time, the front and tooth surface of the gear (800) under test are unobstructed. After the picture is taken, activate the coaxial light structure (610) located below the mounting bracket (200) as a backlight to take a picture of the extremely high contrast silhouette image of the gear (800) under test and measure the outline of the gear (800) under test. S3: Start the camera moving structure (700), adjust the height of the side camera structure (520) according to the thickness of the gear (800) to face the tooth surface of the gear (800) using the side moving structure (710), and adjust the height of the side-viewing camera structure (530) using the side moving structure (720) to make the side-viewing camera correspond to the two side positions of the gear (800) to be tested respectively. If the gear (800) to be tested is a helical gear, adjust the rotation angle of the side camera structure (520) and the ring light structure (620) by driving the turntable (713) to make the illumination angle face the tooth surface of the gear (800) to be tested. S4: Start the gear drive structure (400), the telescopic cylinder (410) drives the drive motor (420) to move, so that the set drive wheel (430) abuts against the tooth surface of the gear (800) to be tested, and then the drive motor (420) drives the drive wheel (430) to rotate, thereby driving the gear (800) to be tested to rotate slowly; S5: Simultaneously or sequentially activate the coaxial camera structure (510), side camera structure (520), side-mounted camera structure (520), inner camera structure (540), and corresponding supplementary light structure (600) located below the mounting bracket (200) to take pictures of the back, tooth surface, edge of the gear (800), the quasi-tooth root, the bottom of the keyway, the chamfer root, and other hidden parts and inner hole surfaces.

Images