An automated vision inspection system and method

Abstract

The application provides an automatic visual detection system and method, and the automatic visual detection system comprises a rack, a conveying mechanism, a visual detection mechanism, a material distributing mechanism and a control system, the conveying mechanism, the visual detection mechanism, the material distributing mechanism and the control system are all installed on the rack, the material distributing mechanism is in process communication with the conveying mechanism, and the conveying mechanism, the visual detection mechanism and the material distributing mechanism are all electrically connected with the control system.

Description

Technical Field

[0001] This invention relates to the field of product quality inspection technology, and in particular to an automatic visual inspection system and method. Background Technology

[0002] Currently, there are two main types of quality inspection methods on the market: manual inspection and robot inspection. Both of these methods have obvious drawbacks.

[0003] Disadvantages of manual inspection: 1. Poor stability and consistency: The test results are significantly affected by the visual state, emotional fluctuations, work experience and fatigue level of the testers. The implementation of standards is not uniform, and the consistency in batch testing is poor. Industry data shows that the manual omission rate is usually 5%-20%. After working continuously for 4 hours, the defect omission rate may even rise from the initial 2% to 8%, which is difficult to meet the high quality control requirements.

[0004] 2. Significant bottleneck in detection efficiency: Relying on human senses and manual judgment, the speed is far lower than that of automated detection. In normal scenarios, it can only reach 20-50 pieces per minute, with an average effective working time of only 6-7 hours per day.

[0005] 3. Significant issues related to cost and manpower: Labor costs continue to rise, and the training cycle for senior quality inspectors is as long as 1-3 months, resulting in difficulties in recruitment and retention.

[0006] 4. Insufficient data capabilities: Manual recording of test results is prone to errors, and it is impossible to store and trace test data in real time. It is also difficult to connect with intelligent manufacturing systems and cannot meet the digital management and quality analysis and optimization needs of Industry 4.0.

[0007] Disadvantages of robot inspection: 1. High initial investment costs: The cost of a complete robot inspection system includes industrial cameras, processing hardware, algorithm licensing, installation and debugging, etc. The initial investment is much higher than that of manual inspection. For small and micro enterprises with small and medium batch production, the financial threshold is high. Even if the cost can be recovered gradually, the payback period in a typical scenario is 6-18 months, which puts a lot of pressure on the company's cash flow.

[0008] 2. High deployment and debugging threshold: Traditional robot inspection systems require professional vision engineers to write inspection logic and debug parameters, resulting in long deployment cycles and high requirements for the technical team's capabilities. If product specifications and inspection standards change frequently, the time and financial costs of re-debugging are high, and the system lacks flexibility to adapt to flexible production.

[0009] 3. Hidden maintenance costs: The hardware of the robot inspection system (such as industrial camera lenses and sensors) requires regular calibration, cleaning and maintenance. The replacement cost of some core components after wear and tear is high. If the system algorithm needs to be upgraded and iterated, additional licensing fees may be incurred. There are hidden costs in long-term operation and maintenance. Summary of the Invention

[0010] The technical problem to be solved by the present invention is to provide an automatic visual inspection system and method to address the shortcomings of the prior art.

[0011] The technical solution of the present invention to solve the above-mentioned technical problems is as follows: An automatic visual inspection system includes: a frame, a conveying mechanism, a visual inspection mechanism, a material distribution mechanism, and a control system. The conveying mechanism, the visual inspection mechanism, the material distribution mechanism, and the control system are all installed on the frame. The material distribution mechanism is connected to the conveying mechanism in process, and the conveying mechanism, the visual inspection mechanism, and the material distribution mechanism are all electrically connected to the control system.

[0012] The beneficial effects of adopting the technical solution of this invention are as follows: By designing an automated quality control device that links vision, conveying, and sorting, the conveyor belt moves the parts forward to the working range of the vision inspection camera. The camera takes a picture for inspection, and after the picture inspection is completed, the vision system provides an OK or NG signal to the device. Simultaneously, the product continues to the next process along the conveyor belt. If the device receives an OK signal, the conveyor belt directly transports the product to the unloading port, completing all processes. It occupies little space and has high site adaptability; the system is streamlined and has low cost. High-quality product control is achieved with a smaller space and lower investment.

[0013] Furthermore, the visual inspection mechanism includes a camera and a darkroom, the darkroom being mounted on the frame, the camera being mounted in the darkroom, and the camera being electrically connected to the control system.

[0014] The beneficial effects of adopting the above-mentioned further technical solution are that the conveyor belt moves the parts forward into the working range of the visual inspection camera, where the camera takes pictures for inspection. The darkroom is set up to create a light-proof environment, improve the accuracy of camera shooting, prevent external light interference, improve accuracy, and enhance the stability and reliability of the system.

[0015] Furthermore, the material distribution mechanism includes: a first conveyor plate, a second conveyor plate, and a drive mechanism for driving the first conveyor plate to rotate. The second conveyor plate and the drive mechanism are both mounted on the frame. The first conveyor plate is rotatably mounted on the frame. The drive mechanism is drively connected to the first conveyor plate and electrically connected to the control system. The conveying mechanism is connected to one end of the first conveyor plate. When the product is qualified, the other end of the first conveyor plate is connected to the second conveyor plate. When the product is unqualified, the other end of the first conveyor plate is connected to the bottom of the frame.

[0016] The beneficial effect of adopting the above-mentioned further technical solution is that the conveyor belt moves the parts forward to the working range of the vision inspection camera, the camera takes pictures for inspection, and after the picture inspection is completed, the vision system provides an OK or NG signal to the equipment; at the same time, the product continues to the next process with the conveyor belt. If the equipment receives an OK signal, the conveyor belt directly transports the product to the unloading port to complete all processes.

[0017] Furthermore, the driving mechanism is a telescopic cylinder, a telescopic hydraulic cylinder, or an electric actuator.

[0018] The beneficial effect of adopting the above-mentioned further technical solutions is that it facilitates the selection of the type of drive mechanism according to actual needs, thereby improving applicability.

[0019] Furthermore, both the first conveyor plate and the second conveyor plate are inclined, and baffles are provided on both sides of the first conveyor plate and the second conveyor plate.

[0020] The beneficial effects of adopting the above-mentioned further technical solution are that both the first and second conveyor plates are inclined, which facilitates the product's downward sliding under its own gravity, eliminating the need for the conveyor plates to provide power, simplifying the structure, and reducing costs. The baffles are used to limit the conveying direction of the product, prevent leakage on both sides of the conveyor plates, and improve stability and reliability.

[0021] Furthermore, a qualified product material box is provided on one side of the frame, and a defective product buffer area is provided at the bottom of the frame. When the product is qualified, the material distribution mechanism is connected to the qualified product material box; when the product is unqualified, the material distribution mechanism is connected to the defective product buffer area.

[0022] The beneficial effect of adopting the above-mentioned further technical solution is that the qualified product bin is used to collect qualified products, and the defective product buffer area is used to buffer unqualified products.

[0023] Furthermore, a projection welding device is provided near the frame location; the conveying mechanism is a conveyor belt.

[0024] The beneficial effect of adopting the above-mentioned further technical solution is that the product after projection welding is manually placed at the loading port of the conveyor belt, and the conveyor belt moves the part forward into the working range of the vision inspection camera. This shortens the process distance and improves efficiency.

[0025] In addition, the present invention also provides an automatic visual inspection method. Based on the above-mentioned automatic visual inspection system, the automatic visual inspection method includes: S1, inspecting the products on the conveying mechanism through a visual inspection mechanism and generating inspection information; S2, determining whether the products are qualified based on the inspection information through a control system; S3, when the products are qualified, controlling the material distribution mechanism through the control system to transport the products to the qualified product area.

[0026] The beneficial effects of adopting the technical solution of this invention are as follows: By designing an automated quality control device that links vision, conveying, and sorting, the conveyor belt moves the parts forward to the working range of the vision inspection camera. The camera takes a picture for inspection, and after the picture inspection is completed, the vision system provides an OK or NG signal to the device. Simultaneously, the product continues to the next process along the conveyor belt. If the device receives an OK signal, the conveyor belt directly transports the product to the unloading port, completing all processes. It occupies little space and has high site adaptability; the system is streamlined and has low cost. High-quality product control is achieved with a smaller space and lower investment.

[0027] Furthermore, after step S2, the process includes: S4, when a product is defective, controlling the material distribution mechanism through the control system to transport the product to the defective product buffer area; S5, re-executing step S1 for the products in the defective product buffer area.

[0028] The beneficial effect of adopting the above-mentioned further technical solution is that if the equipment receives an NG signal, the cylinder of the equipment sorting device will move to transport the product with quality defects to the defective product storage area. After production is completed, all products that may have quality defects will be re-inspected to avoid misoperation when manually putting products into the equipment. Repeat the above process. If the product is still identified as defective, it will be reworked or scrapped.

[0029] Furthermore, before step S1, the process includes: performing projection welding on the product using projection welding equipment, and then placing the projected product into a conveying mechanism for conveying; in step S3, a qualified product material box is placed in the qualified product area.

[0030] The beneficial effects of adopting the above-mentioned further technical solution are that the finished projection welded products are manually placed at the loading port of the conveyor belt, and the conveyor belt moves the parts forward into the working range of the vision inspection camera. This shortens the process distance and improves efficiency. A qualified product bin is used to collect qualified products.

[0031] The advantages of additional aspects of the invention will be set forth in part in the description which follows, and in part will be obvious from the description, or may be learned by practice of the invention. Attached Figure Description

[0032] To more clearly illustrate the technical solutions of the embodiments of the present invention, the accompanying drawings used in the embodiments will be briefly introduced below. It should be understood that the following drawings only show some embodiments of the present invention and should not be regarded as a limitation on the scope. For those skilled in the art, other related drawings can be obtained based on these drawings without creative effort.

[0033] Figure 1 This is a schematic diagram of the structure of the automatic visual inspection system provided in an embodiment of the present invention.

[0034] Figure 2 This is a schematic flowchart illustrating the automatic visual inspection method provided in an embodiment of the present invention.

[0035] The following are the symbols and their meanings: 1. Frame; 2. Conveying mechanism; 3. Vision inspection mechanism; 4. Material sorting mechanism; 5. Darkroom; 6. First conveyor plate; 7. Second conveyor plate; 8. Drive mechanism; 9. Qualified product material box; 10. Defective product buffer area; 11. Projection welding equipment. Detailed Implementation

[0036] The principles and features of the present invention are described below with reference to the accompanying drawings. The embodiments described are only for explaining the present invention and are not intended to limit the scope of the present invention.

[0037] To make the objectives, technical solutions, and advantages of the embodiments of the present invention clearer, 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. The components of the embodiments of the present invention described and shown in the accompanying drawings can generally be arranged and designed in various different configurations.

[0038] Therefore, the following detailed description of the embodiments of the invention provided in the accompanying drawings is not intended to limit the scope of the claimed invention, but merely to illustrate selected embodiments of the invention. All other embodiments obtained by those skilled in the art based on the embodiments of the invention without inventive effort are within the scope of protection of the invention.

[0039] It should be noted that similar labels and letters in the following figures indicate similar items. Therefore, once an item is defined in one figure, it does not need to be further defined and explained in subsequent figures.

[0040] In the description of the embodiments of the present invention, it should be noted that if terms such as "upper", "lower", "horizontal", "inner" indicate the orientation or positional relationship based on the orientation or positional relationship shown in the accompanying drawings, or the orientation or positional relationship in which the product of the invention is usually placed during use, they are only for the convenience of describing the present invention and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation, and therefore should not be construed as a limitation of the present invention.

[0041] In the description of the embodiments of the present invention, it should also be noted that, unless otherwise explicitly specified and limited, the terms "set," "install," "connect," and "link" should be interpreted broadly. For example, they can refer to a fixed connection, a detachable connection, or an integral connection; they can refer to a mechanical connection or an electrical connection; they can refer to a direct connection or an indirect connection through an intermediate medium; and they can refer to the internal connection of two components. Those skilled in the art can understand the specific meaning of the above terms in the present invention according to the specific circumstances.

[0042] like Figure 1 As shown, an embodiment of the present invention provides an automatic visual inspection system, including: a frame 1, a conveying mechanism 2, a visual inspection mechanism 3, a material distribution mechanism 4, and a control system. The conveying mechanism 2, the visual inspection mechanism 3, the material distribution mechanism 4, and the control system are all mounted on the frame 1. The material distribution mechanism 4 is connected to the conveying mechanism 2 in a process, and the conveying mechanism 2, the visual inspection mechanism 3, and the material distribution mechanism 4 are all electrically connected to the control system.

[0043] The beneficial effects of adopting the technical solution of this invention are as follows: By designing an automated quality control device that links vision, conveying, and sorting, the conveyor belt moves the parts forward to the working range of the vision inspection camera. The camera takes a picture for inspection, and after the picture inspection is completed, the vision system provides an OK or NG signal to the device. Simultaneously, the product continues to the next process along the conveyor belt. If the device receives an OK signal, the conveyor belt directly transports the product to the unloading port, completing all processes. It occupies little space and has high site adaptability; the system is streamlined and has low cost. High-quality product control is achieved with a smaller space and lower investment.

[0044] like Figure 1 As shown, the visual inspection mechanism 3 further includes a camera and a darkroom 5, the darkroom 5 being mounted on the frame 1, the camera being mounted in the darkroom 5, and the camera being electrically connected to the control system.

[0045] The beneficial effects of adopting the above-mentioned further technical solution are that the conveyor belt moves the parts forward into the working range of the visual inspection camera, where the camera takes pictures for inspection. The darkroom is set up to create a light-proof environment, improve the accuracy of camera shooting, prevent external light interference, improve accuracy, and enhance the stability and reliability of the system.

[0046] The camera can be installed in darkroom 5 via a multi-axis linear module. The drive unit in the multi-axis linear module is electrically connected to the control system.

[0047] The visual inspection agency 3 can also set up a camera or a combination of camera and camera in the darkroom 5 according to actual needs.

[0048] like Figure 1 As shown, the material distribution mechanism 4 further includes: a first conveying plate 6, a second conveying plate 7, and a drive mechanism 8 for driving the first conveying plate 6 to rotate. The second conveying plate 7 and the drive mechanism 8 are both mounted on the frame 1. The first conveying plate 6 is rotatably mounted on the frame 1. The drive mechanism 8 is connected to the first conveying plate 6 in a transmission connection. The drive mechanism 8 is electrically connected to the control system. The conveying mechanism 2 is connected to one end of the first conveying plate 6. When the product is qualified, the other end of the first conveying plate 6 is connected to the second conveying plate 7. When the product is unqualified, the other end of the first conveying plate 6 is connected to the bottom of the frame 1.

[0049] The beneficial effect of adopting the above-mentioned further technical solution is that the conveyor belt moves the parts forward to the working range of the vision inspection camera, the camera takes pictures for inspection, and after the picture inspection is completed, the vision system provides an OK or NG signal to the equipment; at the same time, the product continues to the next process with the conveyor belt. If the equipment receives an OK signal, the conveyor belt directly transports the product to the unloading port to complete all processes.

[0050] The two ends of the drive mechanism 8 are respectively hinged to the frame 1 and the other end of the first conveyor plate 6, and one end of the first conveyor plate 6 is hinged to the frame via a pin.

[0051] Furthermore, the drive mechanism 8 is a telescopic cylinder, a telescopic hydraulic cylinder, or an electric actuator.

[0052] The beneficial effect of adopting the above-mentioned further technical solutions is that it facilitates the selection of the type of drive mechanism according to actual needs, thereby improving applicability.

[0053] like Figure 1 As shown, both the first conveyor plate 6 and the second conveyor plate 7 are inclined, and baffles are provided on both sides of the first conveyor plate 6 and the second conveyor plate 7.

[0054] The beneficial effects of adopting the above-mentioned further technical solution are that both the first and second conveyor plates are inclined, which facilitates the product's downward sliding under its own gravity, eliminating the need for the conveyor plates to provide power, simplifying the structure, and reducing costs. The baffles are used to limit the conveying direction of the product, prevent leakage on both sides of the conveyor plates, and improve stability and reliability.

[0055] like Figure 1 As shown, a qualified product material box 9 is provided on one side of the frame 1, and a defective product buffer area 10 is provided at the bottom of the frame 1. When the product is qualified, the material distribution mechanism 4 is connected to the qualified product material box 9. When the product is unqualified, the material distribution mechanism 4 is connected to the defective product buffer area 10.

[0056] The beneficial effect of adopting the above-mentioned further technical solution is that the qualified product bin is used to collect qualified products, and the defective product buffer area is used to buffer unqualified products.

[0057] like Figure 1 As shown, a projection welding device 11 is further provided near the frame 1; the conveying mechanism 2 is a conveyor belt.

[0058] The beneficial effect of adopting the above-mentioned further technical solution is that the product after projection welding is manually placed at the loading port of the conveyor belt, and the conveyor belt moves the part forward into the working range of the vision inspection camera. This shortens the process distance and improves efficiency.

[0059] In addition, the present invention also provides an automatic visual inspection method. Based on the above-mentioned automatic visual inspection system, the automatic visual inspection method includes: S1, inspecting the products on the conveying mechanism through a visual inspection mechanism and generating inspection information; S2, determining whether the products are qualified based on the inspection information through a control system; S3, when the products are qualified, controlling the material distribution mechanism through the control system to transport the products to the qualified product area.

[0060] The beneficial effects of adopting the technical solution of this invention are as follows: By designing an automated quality control device that links vision, conveying, and sorting, the conveyor belt moves the parts forward to the working range of the vision inspection camera. The camera takes a picture for inspection, and after the picture inspection is completed, the vision system provides an OK or NG signal to the device. Simultaneously, the product continues to the next process along the conveyor belt. If the device receives an OK signal, the conveyor belt directly transports the product to the unloading port, completing all processes. It occupies little space and has high site adaptability; the system is streamlined and has low cost. High-quality product control is achieved with a smaller space and lower investment.

[0061] Furthermore, after step S2, the process includes: S4, when a product is defective, controlling the material distribution mechanism through the control system to transport the product to the defective product buffer area; S5, re-executing step S1 for the products in the defective product buffer area.

[0062] The beneficial effect of adopting the above-mentioned further technical solution is that if the equipment receives an NG signal, the cylinder of the equipment sorting device will move to transport the product with quality defects to the defective product storage area. After production is completed, all products that may have quality defects will be re-inspected to avoid misoperation when manually putting products into the equipment. Repeat the above process. If the product is still identified as defective, it will be reworked or scrapped.

[0063] Furthermore, before step S1, the process includes: performing projection welding on the product using projection welding equipment, and then placing the projected product into a conveying mechanism for conveying; in step S3, a qualified product material box is placed in the qualified product area.

[0064] The beneficial effects of adopting the above-mentioned further technical solution are that the finished projection welded products are manually placed at the loading port of the conveyor belt, and the conveyor belt moves the parts forward into the working range of the vision inspection camera. This shortens the process distance and improves efficiency. A qualified product bin is used to collect qualified products.

[0065] This invention provides an automated visual inspection system, which is an automated quality control device that uses vision to link conveying and sorting. The device mainly consists of two parts: 1. a mechanical transmission and diversion section; 2. a visual inspection and electrical section.

[0066] The manually placed product with projection welding completed is positioned at the loading port of the conveyor belt. The conveyor belt moves the part forward to the working range of the vision inspection camera, which takes a picture for inspection. After the picture inspection is completed, the vision system provides an OK or NG signal to the equipment. Simultaneously, the product continues to the next process with the conveyor belt. If the equipment receives an OK signal, the conveyor belt directly transports the product to the unloading port, completing the entire process. If the equipment receives an NG signal, the cylinder of the equipment's sorting device (material sorting mechanism) actuates to transport the defective product to the defective product storage area. After production is completed, all potentially defective products are re-inspected to avoid errors caused by manual product loading. Repeating the above process is necessary. If the product is still identified as defective, it is either reworked or scrapped. This system has a small footprint and high site adaptability; it is streamlined and has low cost. It achieves high-quality product control with a smaller footprint and lower investment.

[0067] like Figure 2As shown, the process begins with: 1. Manually placing the product at the loading port; 2. The conveyor belt carries the product to the vision inspection area; 3. The camera takes a picture for inspection; 4. Determining the signal provided by the vision system; 5. If the signal is OK, the conveyor belt transports the product to the unloading port, ending the process; 6. If the signal is NG, the sorting cylinder sends the product to the defective product area; 7. Re-inspecting the products in the defective product area and repeating step 3.

[0068] Finally, it should be noted that the above embodiments are only used to illustrate the technical solutions of the present invention, and not to limit them; although the present invention has been described in detail with reference to the foregoing embodiments, those skilled in the art should understand that modifications can still be made to the technical solutions described in the foregoing embodiments, or equivalent substitutions can be made to some or all of the technical features; and these modifications or substitutions do not cause the essence of the corresponding technical solutions to deviate from the scope of the technical solutions of the embodiments of the present invention.

Claims

1. An automatic visual inspection system, characterized in that, include: The system includes a frame, a conveying mechanism, a vision inspection mechanism, a material sorting mechanism, and a control system. The conveying mechanism, the vision inspection mechanism, the material sorting mechanism, and the control system are all mounted on the frame. The material sorting mechanism is connected to the conveying mechanism in a process, and the conveying mechanism, the vision inspection mechanism, and the material sorting mechanism are all electrically connected to the control system.

2. The automatic visual inspection system according to claim 1, characterized in that, The visual inspection mechanism includes a camera and a darkroom. The darkroom is mounted on the frame, and the camera is mounted in the darkroom. The camera is electrically connected to the control system.

3. The automatic visual inspection system according to claim 1, characterized in that, The material distribution mechanism includes: a first conveyor plate, a second conveyor plate, and a drive mechanism for driving the first conveyor plate to rotate. The second conveyor plate and the drive mechanism are both mounted on the frame. The first conveyor plate is rotatably mounted on the frame. The drive mechanism is drivenly connected to the first conveyor plate and electrically connected to the control system. The conveying mechanism is connected to one end of the first conveyor plate. When the product is qualified, the other end of the first conveyor plate is connected to the second conveyor plate. When the product is unqualified, the other end of the first conveyor plate is connected to the bottom of the frame.

4. The automatic visual inspection system according to claim 3, characterized in that, The drive mechanism is a telescopic cylinder, a telescopic hydraulic cylinder, or an electric actuator.

5. An automatic visual inspection system according to claim 3, characterized in that, Both the first conveyor plate and the second conveyor plate are inclined, and baffles are provided on both sides of the first conveyor plate and the second conveyor plate.

6. The automatic visual inspection system according to claim 1, characterized in that, A qualified product material box is provided on one side of the frame, and a defective product buffer area is provided at the bottom of the frame. When the product is qualified, the material distribution mechanism is connected to the qualified product material box; when the product is unqualified, the material distribution mechanism is connected to the defective product buffer area.

7. The automatic visual inspection system according to claim 1, characterized in that, A projection welding device is installed near the frame; the conveying mechanism is a conveyor belt.

8. An automatic visual inspection method, characterized in that, Based on any one of claims 1 to 7, the automatic visual inspection system and the automatic visual inspection method include: S1. The product on the conveyor is inspected by a visual inspection agency, and inspection information is generated; S2. The control system determines whether the product is qualified based on the detection information. S3. When the product is qualified, the material distribution mechanism is controlled by the control system to transport the product to the qualified product area.

9. The automatic visual inspection method according to claim 8, characterized in that, Step S2 is followed by: S4, when a product is defective, the control system controls the material distribution mechanism to transport the product to the defective product buffer area; S5. Re-execute step S1 for products in the defective product cache area.

10. The automatic visual inspection method according to claim 8, characterized in that, Before step S1, the process includes: performing projection welding on the product using projection welding equipment, and then placing the projected product into a conveyor mechanism for conveying; in step S3, qualified product material boxes are placed in the qualified product area.

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