Surface defect detection device

Abstract

This application provides a surface defect detection device, comprising: a support mechanism; a reflection mechanism disposed on the support mechanism and configured to form a detection space matching the workpiece to be tested; an imaging mechanism disposed above the detection space, adapted to simultaneously image the top surface and at least one side surface of the workpiece to be tested located in the detection space, generating a surface image; a processor configured to identify surface defects of the workpiece to be tested based on the surface image; and a conveying mechanism disposed below the reflection mechanism and configured to convey the workpiece to be tested in a first direction orthogonal to the vertical direction, and to lift the workpiece to be tested into the detection space when the workpiece to be tested is conveyed to the area below the imaging mechanism; the conveying width of the conveying mechanism in a second direction orthogonal to the first direction is adjustable to accommodate workpieces to be tested with different sizes in the second direction.

Description

Technical Field

[0001] At least one embodiment of this application relates to the field of detection device technology, and more particularly to a surface defect detection device. Background Technology

[0002] In industrial production, surface defect inspection of workpieces with multifaceted structures, such as electronic product casings, packaging boxes, and automotive parts, is a crucial step in ensuring product quality. Traditional inspection methods typically rely on manual visual inspection or sampling, which suffers from low efficiency, high subjectivity, and a high risk of missed defects, making them unsuitable for automated production lines. Summary of the Invention

[0003] In view of this, this application provides a surface defect detection device that can improve detection efficiency.

[0004] According to an embodiment of this application, a surface defect detection device is provided, comprising: a support mechanism; a reflection mechanism disposed on the support mechanism and configured to form a detection space matching the workpiece to be tested; an imaging mechanism disposed above the detection space and adapted to simultaneously image the top surface and at least one side surface of the workpiece to be tested located in the detection space to generate a surface image; a processor configured to identify surface defects of the workpiece to be tested based on the surface image; and a conveying mechanism disposed below the reflection mechanism and configured to convey the workpiece to be tested in a first direction orthogonal to the vertical direction, and to lift the workpiece to be tested into the detection space when the workpiece to be tested is conveyed to the area below the imaging mechanism; the conveying width of the conveying mechanism in a second direction orthogonal to the first direction is adjustable to accommodate workpieces to be tested with different sizes in the second direction.

[0005] According to an embodiment of this application, the conveying mechanism includes: a pair of conveying components extending in the first direction and spaced apart and opposite to each other in a second direction orthogonal to the first direction, suitable for jointly carrying the workpiece to be tested and moving the workpiece to be tested in the first direction; a lifting component disposed in the support mechanism and located between the two conveying components in the second direction, the lifting component being configured to move between a lifting position that lifts the workpiece to be tested to the detection space and a retracted position that places the workpiece to be tested between the two sets of conveying components; and an adjusting component disposed in the support mechanism and configured to drive the two conveying components to move closer to or further away from each other in the second direction to change the distance between the two conveying components, so that the conveying width is adapted to the workpiece to be tested having different sizes in the second direction.

[0006] According to an embodiment of this application, the conveying assembly includes: a support beam extending in the first direction; a conveyor belt disposed on the side of the support beam facing another conveying assembly, the outer surface of the conveyor belt forming a conveying surface for conveying the workpiece to be tested; and a first drive unit disposed on the support beam and configured to drive the conveyor belt to rotate cyclically.

[0007] According to an embodiment of this application, the support beam protrudes from the conveying surface to guide the workpiece to be tested, located between the two support beams, to translate along the first direction.

[0008] According to an embodiment of this application, the first driving unit includes: a first motor mounted on the support beam; a driving roller mounted on the support beam and configured to rotate under the drive of the first motor; and a driven roller mounted on the support beam at a distance from the driving roller. The conveyor belt surrounds the driving roller and the driven roller to form the conveying surface and rotates cyclically under the drive of the driving roller.

[0009] According to an embodiment of this application, the adjustment assembly includes: a support base; at least two bidirectional lead screws rotatably disposed on the support base, the at least two bidirectional lead screws being configured to extend in a second direction and spaced apart in a first direction, the at least two bidirectional lead screws each having two threaded segments with opposite directions of rotation, the two threaded segments of one bidirectional lead screw respectively threadedly engaging with two of the conveying assemblies; and a second drive unit adapted to drive the two bidirectional lead screws to rotate synchronously, so as to drive the two sets of the conveying assemblies to move relative to or opposite to each other in the second direction.

[0010] According to an embodiment of this application, the surface defect detection device further includes a limiting mechanism disposed below the reflection mechanism and on the support mechanism, and located between the two conveying components in the second direction. The limiting mechanism is configured to move between a first position that prevents the workpiece to be tested from further translating in the first direction and a second position that allows the workpiece to be tested to pass through.

[0011] According to an embodiment of this application, the limiting mechanism includes: at least two cylinders disposed on the support mechanism; and at least two blocking members configured to extend and retract along the height direction under the drive of the at least two cylinders, so as to move between the first position and the second position.

[0012] According to an embodiment of this application, the support mechanism includes a platform disposed in the height direction between the reflection mechanism and the conveying mechanism, the platform having an opening that allows the workpiece to be tested to pass through; the reflection mechanism includes: a plurality of prisms disposed around the opening on the platform and forming the detection space, a magnet being disposed at the bottom of the prisms, and a magnetic element being disposed on the platform that can be attracted by the magnet.

[0013] According to an embodiment of this application, the lifting assembly includes: a third drive unit disposed on the support mechanism; a support unit having a support surface for bearing the workpiece to be measured, wherein the support unit is configured to translate between the lifting position and the retracting position under the drive of the second drive unit; and when the support unit is in the lifting position, the support surface is configured to be flush with or protrude from the upper surface of the platform.

[0014] The surface defect detection device provided in this application, through the cooperation of an imaging mechanism and a reflection mechanism, forms a detection space below the imaging mechanism that matches the workpiece to be tested, and reflects light from the side of the workpiece into the field of view of the imaging mechanism. This allows the imaging mechanism to simultaneously image the top surface and at least one side of the workpiece, generating a single surface image containing multi-faceted topographic information. This design enables a single imaging mechanism to complete image acquisition of multiple surfaces of the workpiece, eliminating the need for multiple camera systems, significantly reducing equipment costs and system complexity, while completely eliminating the synchronization delay problem inherent in multi-camera shooting. A conveying mechanism is located below the reflection mechanism, automatically conveying the workpiece along a first direction to the area below the imaging mechanism and lifting it into the detection space. This achieves stable bearing and precise positioning of the workpiece during the imaging process, enabling the surface defect detection device to seamlessly connect with upstream and downstream production equipment, forming an online continuous detection capability. The conveying width of the conveying mechanism in a second direction orthogonal to the first direction is adjustable, accommodating workpieces of different widths. When the production line switches product models, there is no need to change equipment or adjust the production line layout, improving the equipment's versatility and changeover efficiency. Attached Figure Description

[0015] The above and other objects, features and advantages of this application will become clearer from the following description of embodiments with reference to the accompanying drawings, in which:

[0016] Figure 1 A perspective view of a surface defect detection apparatus according to an embodiment of this application is schematically shown;

[0017] Figure 2 Schematic illustration Figure 1 A three-dimensional view of the internal structure of the surface defect detection device shown.

[0018] Figure 3 A partial perspective view of a surface defect detection apparatus according to an embodiment of this application is schematically shown, illustrating the conveying mechanism;

[0019] Figure 4 Schematic illustration Figure 3 A magnified view of part A shown;

[0020] Figure 5A perspective view of a conveying mechanism according to an embodiment of this application is schematically shown;

[0021] Figure 6 A partial perspective view of a surface defect detection device according to an embodiment of this application is schematically shown, illustrating the reflection mechanism;

[0022] Figure 7 A schematic top view of a reflective mechanism according to an embodiment of this application is shown;

[0023] Figure 8 A schematic diagram of the prism reflection optical path according to an embodiment of this application is shown.

[0024] Figure 9 An optical path diagram of a reflection mechanism according to an embodiment of this application is schematically shown;

[0025] Figure 10 A partial perspective view of a surface defect detection device according to an embodiment of this application is schematically shown, illustrating a translation mechanism, a lifting mechanism, and an illumination mechanism;

[0026] Figure 11 Schematic illustration Figure 10 A magnified view of part B shown.

[0027] The annotations in the attached figures are explained as follows:

[0028] 1. Support mechanism; 11. Platform; 111. Opening; 12. Support frame; 13. Support plate; 131. First guide hole; 132. Second guide hole;

[0029] 2. Filming location;

[0030] 3. Reflection mechanism; 31. Prism;

[0031] 4. Conveying mechanism; 41. Conveying assembly; 411. Support beam; 412. Conveyor belt; 413. First drive unit; 4131. First motor; 4132. Drive roller; 4133. Driven roller; 42. Lifting assembly; 421. Third drive unit; 422. Support unit; 43. Adjusting assembly; 431. Support base; 432. Bidirectional lead screw; 4321. Transmission wheel; 433. Second drive unit; 4331. Transmission belt; 4332. Second motor;

[0032] 5. Limiting mechanism; 51. Cylinder body; 52. Blocking component;

[0033] 6. Translation mechanism; 61. Slide rail; 62. First slider;

[0034] 7. Lifting mechanism; 73. Second slider; 74. Third motor;

[0035] 8. Lighting mechanism; 81. Light source; 82. Mounting plate; 821. Through hole; 822. Arc-shaped hole;

[0036] 100. Workpiece. Detailed Implementation

[0037] To make the objectives, technical solutions, and advantages of this application clearer, the following detailed description is provided in conjunction with specific embodiments and the accompanying drawings.

[0038] The terminology used herein is for the purpose of describing particular embodiments only and is not intended to limit the scope of this application. The terms “comprising,” “including,” etc., as used herein indicate the presence of the stated features, steps, operations, and / or components, but do not exclude the presence or addition of one or more other features, steps, operations, or components.

[0039] All terms used herein, including technical and scientific terms, have the meanings commonly understood by those skilled in the art, unless otherwise defined. It should be noted that the terms used herein are to be interpreted in a manner consistent with the context of this specification, and not in an idealized or overly rigid way.

[0040] When using expressions such as "at least one of A, B, and C," the meaning should generally be interpreted according to the understanding of someone skilled in the art. For example, "a system having at least one of A, B, and C" should include, but is not limited to, systems having A alone, having B alone, having C alone, having A and B, having A and C, having B and C, and / or having A, B, and C. Similarly, when using expressions such as "at least one of A, B, or C," the meaning should generally be interpreted according to the understanding of someone skilled in the art. For example, "a system having at least one of A, B, or C" should include, but is not limited to, systems having A alone, having B alone, having C alone, having A and B, having A and C, having B and C, and / or having A, B, and C.

[0041] It should also be noted that the directional terms mentioned in the embodiments, such as "up," "down," "front," "back," "left," and "right," are only for reference to the directions in the accompanying drawings and are not intended to limit the scope of protection of this application. Throughout the drawings, the same elements are represented by the same or similar reference numerals. Conventional structures or constructions will be omitted where they may cause confusion in understanding this application.

[0042] In industrial production, comprehensive inspection of the appearance of rectangular objects such as laptops, mobile phones, and packaging boxes is a crucial step in ensuring product quality. Traditional inspection methods typically require multiple cameras positioned at different angles, or a robotic arm to rotate the camera or object to acquire multi-faceted images. These methods have the following drawbacks: high cost, requiring multiple cameras, lenses, and corresponding acquisition cards; complex calibration, requiring precise calibration of the positions and angles between multiple cameras, making system integration difficult; synchronization issues, as slight synchronization delays in multi-camera acquisition can affect the inspection of objects on dynamic production lines; and large space requirement, as multi-camera layouts require more installation space.

[0043] With the development of machine vision technology, various automated surface defect detection devices have emerged. Existing multi-faceted inspection solutions mainly include the following:

[0044] One approach is to use multiple cameras to simultaneously photograph multiple sides of the workpiece from different angles. While this method can achieve simultaneous multi-faceted inspection, it requires multiple sets of cameras, lenses, and corresponding image acquisition systems, resulting in high equipment costs, complex structures, and large space requirements. Furthermore, the synchronous calibration between multiple cameras is difficult, making it hard to achieve flexible integration with existing production lines within a limited space.

[0045] Secondly, a single camera combined with a mechanical rotation mechanism is used to sequentially photograph each surface of the workpiece by rotating the workpiece or by taking pictures of each surface of the workpiece in turn. Although this approach reduces camera costs, the inspection efficiency is low. The rotation action increases the inspection cycle time for a single piece, making it impossible to achieve truly synchronous imaging. Furthermore, the mechanical rotation mechanism increases the complexity and failure rate of the system, making it difficult to meet the requirements of high-speed online inspection.

[0046] Thirdly, a single camera combined with multiple reflecting prisms is used to achieve multi-faceted imaging. This type of device uses several reflecting prisms surrounding the workpiece to capture reflected light from multiple prisms using a single camera, thus imaging each facet of the workpiece. This solution achieves single-image coverage of multiple surfaces at the optical level, reducing hardware costs to some extent. However, this type of device is typically a static inspection structure, requiring manual placement of the workpiece or fixation with simple positioning fixtures. It lacks an effective docking mechanism with automated conveyor lines, making continuous online inspection difficult. Furthermore, the inspection space of this type of device is determined by the fixed position of the prisms and cannot be adjusted according to workpiece size. When the production line switches to different product specifications, manual rearrangement of the prisms or replacement of the inspection module is often required, resulting in low flexibility and an inability to adapt to the production needs of multiple product lines.

[0047] Therefore, how to provide an online multi-faceted surface defect detection device that can seamlessly connect with automated production lines, realize automatic workpiece conveying and positioning, and be adaptable to workpieces of different sizes has become a technical problem that urgently needs to be solved by those skilled in the art.

[0048] In view of this, the present application provides a surface defect detection device that can improve the detection efficiency of the surface of the workpiece to be tested.

[0049] Figure 1 A perspective view of a surface defect detection apparatus according to an embodiment of this application is schematically shown. Figure 2 Schematic illustration Figure 1 A three-dimensional view of the internal structure of the surface defect detection device shown.

[0050] According to embodiments of this application, a surface defect detection device is provided. For example... Figure 1 and Figure 2 As shown, the surface defect detection device includes a support mechanism 1, an imaging mechanism 2, a reflection mechanism 3, a processor, and a conveying mechanism 4. The reflection mechanism 3 is disposed on the support mechanism 1 and configured to form a detection space matching the workpiece 100 to be tested. The imaging mechanism 2 is disposed above the workpiece 100. The reflection mechanism 3 reflects light from at least one side of the workpiece 100 located within the detection space into the field of view of the imaging mechanism 2. The imaging mechanism 2 simultaneously images the top surface and at least one side of the workpiece 100 located within the detection space, generating a surface image containing morphological information of the top surface and at least one side of the workpiece 100. The processor is configured to identify surface defects of the workpiece 100 based on the surface image. The conveying mechanism 4 is disposed below the reflection mechanism 3 and configured to convey the workpiece 100 in a first direction orthogonal to the vertical direction, and, while the workpiece 100 is conveyed below the imaging mechanism 2, lift the workpiece 100 into the detection space. The conveying width of the conveying mechanism 4 in the second direction orthogonal to the first direction is adjustable to accommodate workpieces 100 of different sizes in the second direction.

[0051] The surface defect detection device provided in this application, through the cooperation of the imaging mechanism 2 and the reflection mechanism 3, forms a detection space below the imaging mechanism 2 that matches the workpiece 100 to be tested, and reflects the light from the side of the workpiece 100 into the field of view of the imaging mechanism 2, enabling the imaging mechanism 2 to simultaneously image the top surface and at least one side of the workpiece 100, generating a single surface image containing multi-faceted topographic information. This design allows a single imaging mechanism 2 to complete image acquisition of multiple surfaces of the workpiece 100, eliminating the need for multiple camera systems, significantly reducing equipment costs and system complexity, while completely eliminating the synchronization delay problem inherent in multi-camera shooting. The conveying mechanism 4 is located below the reflection mechanism 3, automatically conveying the workpiece 100 along a first direction to the area below the imaging mechanism 2 and lifting it into the detection space, achieving stable bearing and precise positioning of the workpiece 100 during the imaging process, enabling the surface defect detection device to seamlessly connect with upstream and downstream production equipment, forming an online continuous detection capability. The conveying mechanism 4 has an adjustable conveying width in the second direction orthogonal to the first direction, which can adapt to workpieces 100 of different widths. When the production line switches product models, there is no need to replace equipment or adjust the production line layout, which improves the equipment's versatility and changeover efficiency.

[0052] Therefore, the surface defect detection device can acquire complete surface information of the top and side surfaces of a workpiece in a single imaging, greatly improving detection efficiency and automation. At the same time, it has flexible production capabilities, providing a comprehensive solution for multi-faceted appearance defect detection in industrial production lines that is simple in structure, cost-controllable, and can be operated online.

[0053] The support mechanism 1 may include a support frame, wall panels, and a door. The support frame may form a roughly rectangular structure, and the wall panels and door are respectively installed on each side of the support frame, forming an installation space.

[0054] The general concept of a cuboid can be understood as follows: the support mechanism 1 and the defined installation space visually resemble a cuboid, but do not conform to the strict geometric definition of a cuboid. For example, two opposite faces of the support mechanism 1 are hollowed out to expose the input and output ends of the conveying mechanism 4 to the support mechanism 1; the extension directions of opposite sets of wall panels of the support mechanism 1 have angular deviations; the four corners of the support mechanism 1 are rounded to distribute stress and for aesthetic purposes, etc.

[0055] In some embodiments, the first direction can be understood as the width direction of the support mechanism 1, and the second direction can be understood as the length direction of the support mechanism 1.

[0056] The first direction can be the width direction of the workpiece 100 being measured, and the second direction can be the length direction of the workpiece 100 being measured. Alternatively, the first direction can be the length direction of the workpiece 100 being measured, and the second direction can be the width direction of the workpiece 100 being measured.

[0057] The support structure may also include multiple partitions, which divide the installation space into multiple sub-spaces. The imaging mechanism 2 and the reflection mechanism 3 are located in the upper sub-space, while the processor can be located in the lower sub-space. This facilitates heat dissipation and cable management, while also isolating the components from the optical parts to reduce electromagnetic interference. The partitions have cable routing holes and are equipped with seals to ensure unobstructed electrical connections and dust protection between the upper and lower sub-spaces.

[0058] The conveying mechanism 4 extends at least partially into the installation space along the first direction and extends below the detection space to convey the workpiece 100 to be tested to the area below the shooting mechanism 2 and to lift the workpiece 100 to be tested into the detection space.

[0059] The imaging mechanism 2 can be an imaging unit used to acquire optical images of the surface of the workpiece 100 under test. As an example, the imaging mechanism 2 can include a camera and an optical lens. The industrial camera and the optical lens work together to convert the optical information of the top surface of the workpiece 100 under test and the side optical information transmitted through the reflection mechanism 3 into digital image signals for the processor to perform defect identification.

[0060] Processors can include central processing units (CPUs), graphics processing units (GPUs), and so on.

[0061] The surface defect detection device also includes a display screen, which is mounted on the door or front wall panel of the support mechanism 1 and is communicatively connected to the processor. The display screen can be used to display detection results, system status, and a human-machine interface in real time, facilitating operator monitoring and operation of the equipment. The display screen can be a touchscreen, supporting parameter setting and manual control functions.

[0062] The display screen can include a real-time image display area, a test result display area, an equipment status display area, and a statistical data display area. The real-time image display area is used to display the surface image currently acquired by the imaging mechanism 2 or the various corrected views; the test result display area is used to display the test results (pass / fail, defect type, defect location) of the current workpiece 100; the equipment status display area is used to display the working status of each mechanism (run / stop, current position parameters, alarm information); and the statistical data display area is used to display production data such as the cumulative number of tests, pass rate, and defective product classification statistics.

[0063] The processor can provide data export functionality, allowing operators to export test data via USB interface or network for quality traceability and statistical analysis.

[0064] In some embodiments of this application, the surface defect detection device is further provided with safety protection devices to ensure the safety of operators. These safety protection devices may include an emergency stop button, a safety door lock, and a warning light.

[0065] The emergency stop button is located in a prominent and easily accessible position on the support mechanism 1, such as on the front of the door or on the control panel, so that the operator can press it quickly in an emergency to cut off the power to the equipment and stop all moving parts immediately.

[0066] The safety lock is located between the door and the frame. When the door is opened, the safety lock trigger signal is transmitted to the processor, which immediately stops the operation of all moving parts to prevent operators from contacting hazardous areas while the equipment is running. The equipment can only resume normal operation after the door is closed and locked.

[0067] Warning lights (such as tri-color lights) are located on the top of support mechanism 1 and are connected to the processor to visually display the current status of the equipment: a green light indicates normal operation, a yellow light indicates standby or switching status, and a red light indicates a fault or alarm status. When a fault occurs, the processor can simultaneously issue an alarm signal through the warning lights and the display screen to prompt the operator to handle the situation promptly.

[0068] After receiving the surface image sent by the imaging mechanism 2, the processor first performs image preprocessing on the surface image, including noise reduction, brightness correction, and geometric correction, to eliminate distortions caused by optical system and environmental factors. Subsequently, the processor performs region segmentation on the preprocessed image, extracting sub-image regions corresponding to the top surface and each side surface of the workpiece 100 under test. For the segmented sub-images, the processor runs a preset defect detection algorithm, such as threshold segmentation, feature extraction, and classifier discrimination based on traditional machine vision, or a convolutional neural network model based on deep learning, to identify and locate defects such as surface scratches, dents, stains, and imprints. The processor can display the detection results on the screen in real time and transmit them to the production management system via a network interface. Simultaneously, based on the detection conclusions, it sends control signals to the conveying mechanism 4 or downstream equipment to achieve defective product rejection or diversion. The processor's storage module (such as a solid-state drive or embedded storage chip) is used to save detection images, log data, and algorithm models for easy subsequent traceability and model updates.

[0069] Figure 3 A partial perspective view of a surface defect detection apparatus according to an embodiment of this application is schematically shown, illustrating the conveying mechanism. Figure 4 Schematic illustration Figure 3 A magnified view of part A shown. Figure 5 A perspective view of a conveying mechanism according to an embodiment of this application is shown schematically.

[0070] According to embodiments of this application, such as Figures 2 to 5As shown, the conveying mechanism 4 includes a pair of conveying components 41, a lifting component 42, and an adjusting component 43. The pair of conveying components 41 extend in a first direction and are spaced apart and opposite to each other in a second direction orthogonal to the first direction, suitable for jointly carrying the workpiece 100 to be tested and moving it in the first direction. The lifting component 42 is disposed on the support mechanism 1 and located between the two conveying components 41 in the second direction. The lifting component 42 is configured to move between a lifting position that lifts the workpiece 100 to the detection space and a retracted position that places the workpiece 100 between the two sets of conveying components 41. The adjusting component 43 is disposed on the support mechanism 1 and configured to drive the two conveying components 41 closer together or further apart in the second direction to change the distance between the two conveying components 41, so that the conveying width adapts to the workpiece 100 with different dimensions in the second direction.

[0071] As an example, the two conveying components 41 can be controlled independently or driven synchronously, providing a structural basis for the subsequent adaptive adjustment of workpieces 100 with different widths.

[0072] In this embodiment, the workpiece 100 to be tested is carried by paired conveying components 41 and moved along the first direction, realizing the automatic conveying of the workpiece 100 within the testing device, providing a foundation for online continuous testing. The lifting component 42 moves between a lifting position and a retracted position, achieving a smooth switch between the conveying state and the testing state for the workpiece 100: when the lifting component 42 is in the retracted position, the workpiece 100 is carried by the conveying component 41 and passes normally without affecting the conveying cycle; when the lifting component 42 is in the lifting position, the workpiece 100 is lifted into the testing space, detached from the conveying component 41, avoiding the impact of conveying vibration on the imaging quality, while ensuring the positional accuracy of the workpiece 100 relative to the reflecting mechanism 3 and the imaging mechanism 2 during each imaging. By adjusting the component 43 to drive the two conveying components 41 closer to or further away from each other in the second direction, the conveying width can be adapted to workpieces 100 of different sizes. When the production line changes product specifications, there is no need to replace the conveying components or adjust the production line layout, allowing for rapid changeover and improving the equipment's versatility and flexible production capabilities. The conveying component 41, the lifting component 42, and the adjusting component 43 work together to enable the device to automatically convey, accurately position, and stably detect workpieces 100 of different widths, providing a complete conveying solution for online multi-faceted defect detection.

[0073] According to embodiments of this application, such as Figures 2 to 5As shown, the conveying assembly 41 includes a support beam 411, a conveyor belt 412, and a first drive unit 413. The support beam 411 extends in a first direction. The conveyor belt 412 is disposed on the side of the support beam 411 facing the other conveying assembly 41, and the outer surface of the conveyor belt 412 forms a conveying surface for conveying the workpiece 100 to be tested. The first drive unit 413 is disposed on the support beam 411 and is configured to drive the conveyor belt 412 to rotate cyclically.

[0074] In this embodiment, the support beam 411 extends along a first direction, serving as the load-bearing skeleton of the conveying assembly 41 and providing a mounting base for the conveyor belt 412 and the drive unit. The conveyor belt 412 is positioned on the side of the support beam 411 facing the other conveying assembly 41, with the conveyor belts 412 of the two conveying assemblies 41 facing each other, jointly forming double-sided support for the workpiece 100, ensuring the stability and centering of the workpiece 100 during the conveying process. The cyclic rotation of the two conveyor belts 412 in the same direction provides continuous and stable conveying power for the workpiece 100, avoiding the impact and positional deviation that may be caused by intermittent conveying. At the same time, the friction drive between the conveyor belt 412 and the workpiece 100 has a certain degree of flexibility, which can adapt to the unevenness or slight deformation that may exist at the bottom of the workpiece 100, reducing damage to the surface of the workpiece 100.

[0075] According to embodiments of this application, such as Figure 4 and Figure 5 As shown, the support beam 411 protrudes from the conveying surface to guide the workpiece 100 to be tested, located between the two support beams 411, to translate along the first direction.

[0076] In this embodiment, since the two conveying components 41 are spaced apart and opposite to each other in the second direction, the support beams 411 are located on both sides of the workpiece 100. When the upper surface of the support beam 411 protrudes from the conveying surface of the conveyor belt 412, the two support beams 411 together form a guide channel extending in the first direction, restricting the workpiece 100 to move within this channel. This prevents the workpiece 100 from shifting laterally or slipping off the conveying surface due to vibration, off-center loading, or speed differences of the conveyor belt 412 during conveying, ensuring that the workpiece 100 always remains on the predetermined conveying trajectory. When the workpiece 100 experiences lateral displacement due to external disturbances, the side of the workpiece 100 will first contact the protruding support beam 411 and be pushed back to the normal position by the obstruction of the support beam 411. The centering of the workpiece 100 can be maintained without additional sensors or active correction mechanisms, simplifying the design of the control system and improving the reliability of the conveying.

[0077] During the conveying process, the workpiece 100 maintains a precise lateral position, so that when the workpiece 100 is conveyed to the inspection station, its center can be accurately aligned with the lifting component 42, the inspection space and the optical axis of the imaging mechanism 2 in the second direction, ensuring that the imaging mechanism 2 can obtain a clear, complete, distortion-free or minimally distorted side image.

[0078] The support beam 411 serves as both the mounting base for the conveyor belt 412 and a guide side plate. This eliminates the need for additional guide rails or baffles to guide the workpiece 100, making the structure of the conveying assembly 41 more compact and reducing its width in the second direction. This allows for greater adjustment space for the width of the conveying mechanism 4, which helps to expand the range of workpiece 100 sizes that the device can accommodate.

[0079] According to embodiments of this application, such as Figures 2 to 5 As shown, the first drive unit 413 includes a first motor 4131, a drive roller 4132, and a driven roller 4133. The first motor 4131 is mounted on a support beam 411. The drive roller 4132 is mounted on the support beam 411 and configured to rotate under the drive of the first motor 4131. The driven roller 4133 is spaced apart from the drive roller 4132 and mounted on the support beam 411. A conveyor belt 412 surrounds the drive roller 4132 and the driven roller 4133 to form a conveying surface and rotates cyclically under the drive of the drive roller 4132.

[0080] As an example, the number of driven rollers 4133 in each first drive unit 413 can be multiple. For example, the number of driven rollers 4133 can include any number of 1, 2, 3, 4, 5, 6, 7, etc.

[0081] In this implementation, the active roller 4132 rotates under the drive of the first motor 4131, and the power is transmitted to the driven roller 4133 via the conveyor belt 412, so that the entire conveyor belt 412 achieves uniform and continuous cyclic rotation, thereby enabling the workpiece 100 placed on the conveyor surface to obtain a stable driving force for movement. The active roller 4132 and driven roller 4133 are spaced apart on the support beam 411, and the conveyor belt 412 is wrapped around them, forming a stable support structure. This ensures that the conveyor surface remains flat when carrying the workpiece 100, preventing changes in the workpiece 100's posture due to local depressions. Furthermore, by precisely controlling the start, stop, and speed of the active roller 4132 through the first motor 4131, the workpiece 100 can accurately reach the detection station according to a preset rhythm, providing precise positional assurance for subsequent lifting and synchronous imaging.

[0082] According to embodiments of this application, such as Figures 2 to 5As shown, the surface defect detection device also includes a limiting mechanism 5. The limiting mechanism 5 is disposed below the reflection mechanism 3 on the support mechanism 1 and is located between the two conveying components 41 in the second direction. The limiting mechanism 5 is configured to move between a first position that prevents the workpiece 100 to be tested from further translating in the first direction and a second position that allows the workpiece 100 to be tested to pass through.

[0083] like Figure 5 As shown, along the conveying direction of the conveying assembly 41, the limiting mechanism 5 is located downstream of the lifting assembly 42. When the workpiece 100 to be tested is conveyed to the inspection station (i.e., the position below the inspection space), the limiting assembly is in a first position to prevent the workpiece 100 to be tested from further translating in the first direction. After the workpiece 100 to be tested is inspected, the limiting assembly is in a second position, allowing the workpiece 100 to further translate in the first direction and move out of the inspection station.

[0084] According to embodiments of this application, such as Figure 5 As shown, the conveying mechanism 4 can convey multiple workpieces 100 to be tested along the first direction. There is a preset interval between two adjacent workpieces 100 to be tested. The conveying time corresponding to this interval is greater than or equal to the time required for the lifting component 42 to complete one lifting test and retract to the retracted position, so as to ensure that the next workpiece 100 will not enter the test area and cause interference during the test of the previous workpiece 100.

[0085] When the first workpiece 100 to be tested is conveyed to the inspection station (i.e., the position below the inspection space), the limiting mechanism 5 switches to the first position, physically blocking the movement path of the workpiece 100 through the blocking member 52, so that the workpiece 100 is precisely intercepted at the inspection station. Subsequently, the conveying assembly 41 stops operating, and the lifting assembly 42 lifts the workpiece 100 to be tested into the inspection space for imaging inspection. After imaging is completed, the lifting assembly 42 returns to the retracted position, and the workpiece 100, after inspection, falls back onto the conveying assembly 41. At this time, the limiting mechanism 5 switches to the second position, exiting the conveying path, so that the inspected workpiece 100 can pass unimpeded through the area where the limiting mechanism 5 is located and continue to be conveyed downstream in the first direction.

[0086] After the workpiece 100 leaves the detection area, the limiting mechanism 5 switches back to the first position, ready to intercept the next workpiece 100 to be tested. Through the timing coordination between the limiting mechanism 5 and the lifting component 42, the surface defect detection device can orderly control the entry, detection, and release of the workpiece 100 according to the preset detection rhythm, ensuring that each detection is completed when the workpiece 100 is stationary and accurately positioned. At the same time, by controlling the interval between adjacent workpieces 100, the device avoids stacking or interference caused by multiple workpieces 100 entering the detection area at the same time, thus achieving a balance between detection efficiency and accuracy.

[0087] According to embodiments of this application, such as Figures 3 to 5 As shown, the limiting mechanism 5 includes at least two cylinder bodies 51 and at least two blocking members 52. The at least two cylinder bodies 51 are disposed on the support mechanism 1. The at least two blocking members 52 are respectively configured to extend and retract in the height direction under the drive of the at least two cylinder bodies 51, so as to move between a first position and a second position.

[0088] In some alternative embodiments, at least two cylinder blocks 51 can be mounted on the support beam 411 via L-shaped mounting brackets.

[0089] As an example, the output shaft of the cylinder block 51 extends in the height direction, and a stopper 52 is installed at the end of the output shaft (the end near the shooting mechanism 2).

[0090] The blocking element 52 can be a rod-shaped, block-shaped, or plate-shaped structure.

[0091] In the initial state, the output shaft of the cylinder body 51 is retracted, and the upper end of the blocking member 52 is lower than the conveying surface of the conveying assembly 41. At this time, the limiting mechanism 5 is in the second position that allows the workpiece 100 to pass through. When it is necessary to intercept the workpiece 100, the cylinder body 51 drives the output shaft to extend, causing the blocking member 52 to rise to a first position higher than the conveying surface. The blocking member 52 contacts the front end of the workpiece 100 moving along the first direction, preventing the workpiece 100 from continuing to move forward.

[0092] In this embodiment, at least two cylinders 51 are spaced apart between two conveying assemblies 41 along a second direction, so that the at least two blocking members 52 form multi-point supports in the second direction adapted to the width of the workpiece 100 to be tested. When the blocking members 52 extend to the first position, at least two blocking members 52 contact the front end of the workpiece 100 to be tested together. By applying intercepting force at multiple points simultaneously, the workpiece 100 to be tested is subjected to uniform force, preventing the workpiece 100 from deflecting or tilting due to single-point force, thus ensuring the stability and positional accuracy of the workpiece 100 after interception. By synchronously driving the blocking members 52 to extend and retract by at least two cylinders 51, the blocking members 52 can move precisely between the first and second positions along the height direction.

[0093] The synchronized action of at least two blocking components 52 ensures the consistency of force on both sides of the workpiece 100 during interception and release, preventing workpiece 100 from tilting or jamming due to asynchronous action of the blocking components 52. Furthermore, the method of driving the blocking components 52 to extend and retract via cylinder 51 features a simple structure, fast response speed, large driving force, and convenient maintenance. It can meet the requirements of rapid interception and release of workpiece 100 in online inspection scenarios, and forms a complete inspection cycle control system in conjunction with the conveying assembly 41 and the lifting assembly 42.

[0094] In some alternative embodiments, the limiting mechanism 5 can be a lead screw and nut mechanism. The lead screw extends along the height direction and is rotatably mounted on the support mechanism 1. One end of the lead screw is directly connected to the output shaft of the motor or connected via a coupling. The nut is threaded into the lead screw and is slidably mounted in the guide structure. The telescopic rod blocking member 52 is fixedly connected to the nut. When the motor drives the lead screw to rotate, the nut drives the telescopic rod blocking member 52 to rise and fall along the height direction. It should be understood that the embodiments of this application are not limited to this. For example, the blocking member 52 can also be driven by a linear motor to achieve displacement.

[0095] According to embodiments of this application, such as Figures 2 to 5 As shown, the adjusting assembly 43 includes a support base 431, at least two bidirectional lead screws 432, and a second drive unit 433. The at least two bidirectional lead screws 432 are rotatably mounted on the support base 431. The at least two bidirectional lead screws 432 are configured to extend in a second direction and be spaced apart in a first direction. Each of the at least two bidirectional lead screws 432 has two threaded segments with opposite directions of rotation. The two threaded segments of one bidirectional lead screw 432 are threadedly engaged with two conveying assemblies 41, respectively. The second drive unit 433 is adapted to drive the two bidirectional lead screws 432 to rotate synchronously, thereby driving the two sets of conveying assemblies 41 to move relative to or opposite to each other in the second direction.

[0096] In this embodiment, at least two bidirectional lead screws 432 extend in the second direction and are spaced apart in the first direction, such that two threaded segments on each bidirectional lead screw 432 are threadedly engaged with two conveying assemblies 41 respectively. When the bidirectional lead screw 432 rotates, since the two threaded segments rotate in opposite directions, the two conveying assemblies 41 produce linear movements in opposite directions in the second direction, thereby precisely changing the distance between the two conveying assemblies 41. By using at least two bidirectional lead screws 432 spaced apart in the first direction, multiple positions of the two conveying assemblies 41 are simultaneously driven in the first direction, ensuring that the conveying assemblies 41 remain parallel during adjustment and preventing skewing or jamming caused by single-point drive.

[0097] The second drive unit 433 drives at least two bidirectional lead screws 432 to rotate synchronously, so that the two conveying components 41 on all bidirectional lead screws 432 move at the same speed and direction, ensuring the synchronicity and centering of the two conveying components 41 during the adjustment process, and ensuring that the two conveying components 41 always move symmetrically with the center line of the support mechanism 1 as the reference, and the center line position between the two conveying components 41 remains unchanged.

[0098] The second drive unit 433 enables a single power source to drive multiple lead screws to rotate synchronously, which simplifies the structure of the drive system, reduces costs, and ensures synchronization accuracy.

[0099] The spacing adjustment is achieved through threaded transmission, which has a self-locking characteristic. When the second drive unit 433 stops driving, the threaded engagement between the bidirectional lead screw 432 and the conveying component 41 maintains a stable position, preventing the conveying component 41 from shifting due to vibration or external force, thus ensuring the stability of the conveying width during the testing process. Furthermore, the precise spacing adjustment function achieved through the adjusting component 43 allows the conveying mechanism 4 to automatically adjust its width according to the actual dimensions of the workpiece 100 in the second direction. When the production line switches to different product specifications, the changeover can be completed automatically without manual intervention, providing a fundamental guarantee for flexible online production.

[0100] According to embodiments of this application, such as Figures 2 to 5 As shown, the adjustment assembly 43 includes two bidirectional lead screws 432, each with a drive wheel 4321 at one end. The second drive unit 433 includes a drive belt 4331 and a second motor 4332. The drive belt 4331 wraps around the two drive wheels 4321. The second motor 4332 is coupled to one of the bidirectional lead screws 432 to drive the two bidirectional lead screws 432 to rotate synchronously via the drive belt 4331.

[0101] As an example, the transmission belt 4331 can be a synchronous belt, and the transmission pulley 4321 can be a synchronous belt pulley. The synchronous belt ring, according to an embodiment of this application, such as... Figures 2 to 5 As shown, the inner tooth surface of the synchronous belt meshes with the outer tooth surface of the transmission wheel 4321, which is wound around two transmission pulleys 4321. The second motor 4332 is coupled to one of the bidirectional lead screws 432, that is, the output shaft of the second motor 4332 is directly connected to one end of the bidirectional lead screw 432 or connected through a coupling.

[0102] When the second motor 4332 starts, it drives the bidirectional lead screw 432 connected to the second motor 4332 to rotate. The transmission wheel 4321 on the bidirectional lead screw 432 rotates synchronously with the bidirectional lead screw 432, and transmits the rotational motion to the transmission wheel 4321 on the other bidirectional lead screw 432 through a synchronous belt, thereby driving the other bidirectional lead screw 432 to rotate at the same speed and direction. The relative slippage during the transmission process is eliminated by the meshing of the synchronous belt with the transmission wheel 4321, ensuring a precise transmission ratio and synchronization accuracy between the two bidirectional lead screws 432. When the two transmission wheels 4321 have the same number of teeth, the two bidirectional lead screws 432 rotate at exactly the same speed, thereby causing the two conveying components 41 to move closer to or further away from each other in the second direction with the same speed and displacement.

[0103] In this implementation, the second motor 4332 is directly coupled to one of the bidirectional lead screws 432, allowing the rotational power of the second motor 4332 to be directly transmitted to the bidirectional lead screw 432. This reduces intermediate transmission links and improves transmission efficiency and response speed. A transmission belt 4331 is wrapped around the two transmission pulleys 4321, creating a flexible connection between them. When the second motor 4332 drives one bidirectional lead screw 432 to rotate, the transmission pulley 4321 on that bidirectional lead screw 432 transmits torque to the transmission pulley 4321 on the other bidirectional lead screw 432 via the transmission belt 4331, thus achieving synchronous rotation of the two bidirectional lead screws 432.

[0104] By having two transmission wheels 4321 with the same number of teeth, the two bidirectional lead screws 432 rotate at exactly the same speed. This, in turn, causes the two conveying components 41 on the two bidirectional lead screws 432 to move closer to or further away from each other in the second direction with the same speed and displacement, ensuring the synchronicity and alignment of the two conveying components 41 during the adjustment process. Driving the two bidirectional lead screws 432 with a single second motor 4332 simplifies the drive system structure and reduces equipment cost and control system complexity.

[0105] It should be understood that the embodiments of this application are not limited thereto. For example, the second drive unit 433 may include a plurality of second motors 4332, and the plurality of second motors 4332 respectively drive a plurality of bidirectional lead screws 432 to rotate synchronously.

[0106] Figure 6 A partial perspective view of a surface defect detection apparatus according to an embodiment of this application is schematically shown, illustrating the reflection mechanism.

[0107] According to embodiments of this application, such as Figure 2 and Figure 6 As shown, the support mechanism 1 includes a platform 11 disposed in the height direction between the reflecting mechanism 3 and the conveying mechanism 4. The platform 11 has an opening 111 that allows the workpiece 100 to be measured to pass through. The reflecting mechanism 3 includes multiple prisms. Multiple prisms 31 are disposed around the opening 111 on the platform 11 and form a detection space. A magnet is disposed at the bottom of the prisms 31, and the platform 11 is provided with magnetic components that can be attracted by the magnet.

[0108] As an example, the magnet at the bottom of the prism 31 can be a permanent magnet embedded at the bottom of the prism 31, and the magnetic component on the platform 11 can be a ferromagnetic metal plate embedded inside the platform 11.

[0109] Alternatively, the magnet at the bottom of the prism 31 can be a magnetic sheet bonded to the bottom of the prism 31, and the magnetic component on the platform 11 can be a thin ferromagnetic metal plate laid on the upper surface of the platform 11.

[0110] Alternatively, the magnet at the bottom of the prism 31 can be a magnetic block fixed by screws or adhesive, and the magnetic components on the platform 11 can be made of a ferromagnetic metal material that is integral with the platform 11, that is, the platform 11 as a whole is made of a material that can be attracted by magnets.

[0111] In some alternative embodiments, the configuration of the magnet and the magnetic element can be interchanged, that is, the bottom of the prism 31 is provided with a magnetic element that can be attracted by the magnet, while the platform 11 is provided with a magnet at a position corresponding to the prism 31.

[0112] Multiple prisms 31 are releasably fixed to predetermined positions on the upper surface of the platform 11 by magnetic attraction between magnets and magnetic components. When it is necessary to adjust the size or shape of the detection space to accommodate workpieces 100 of different specifications, the prisms 31 can be manually removed from the platform 11 and placed in a new position by overcoming the magnetic force.

[0113] In some embodiments, the upper surface of the platform 11 may be provided with scale markings to indicate the placement position of the prism 31, facilitating the operator to quickly and accurately adjust the position of the prism 31 when changing the specifications of the workpiece 100. The scale markings may be grid lines and numerical marks formed by laser engraving, printing, or etching.

[0114] As an example, with the center of platform 11 (i.e., the center of opening 111) as the origin, mutually perpendicular grid lines are engraved on the upper surface of platform 11 along the first and second directions. The spacing of the grid lines can be 1 mm, 5 mm, or 10 mm. Numerical marks are engraved at the intersections of the grid lines or along the edges of the grid lines, indicating the coordinate values ​​of that location from the origin. The operator can place the prism 31 at the corresponding position on platform 11 according to the preset coordinate values ​​based on the dimensions of the workpiece 100 to be measured.

[0115] A magnet is provided at the bottom of the prism 31, and the platform 11 is made of a magnetic material that can be attracted by the magnet. When the prism 31 is placed in the predetermined position on the platform 11, the magnetic attraction between the magnet and the platform 11 fixes the prism 31 in place, keeping its position stable. When it is necessary to adjust the position of the prism 31, the operator manually overcomes the magnetic force to lift the prism 31, moves it to the new coordinate position, and then releases it, at which point the prism 31 is attracted and fixed in the new position.

[0116] In some embodiments, the control system can store the position parameters of the prism 31 corresponding to different workpiece 100 specifications, and display the coordinate position of the prism 31 to the operator through the display screen during the changeover, so as to guide the operator to perform a quick changeover.

[0117] As an example, the number of prisms 31 can include any number of 1, 2, 3, 4, 6, etc.

[0118] In this embodiment, the platform 11 is positioned between the reflecting mechanism 3 and the conveying mechanism 4, with an opening 111 at its center. This allows the workpiece 100 to pass through the opening 111 and enter the detection space above the platform 11 after being lifted by the lifting assembly 42, while also providing a stable mounting base for the prism 31. Multiple prisms 31 are arranged around the opening 111 on the platform 11, forming the detection space. The reflecting surfaces of the multiple prisms 31 face different sides of the workpiece 100, reflecting light from each side of the workpiece 100 into the field of view of the imaging mechanism 2. A magnet is provided at the bottom of the prism 31, and the platform 11 is equipped with magnetic components that can be attracted by the magnet. The magnetic attraction between the magnet and the magnetic components allows the prism 31 to be releasably fixed to the platform 11, ensuring that the prism 31 remains stable under normal operating conditions and will not shift due to equipment vibration or external disturbances, thus guaranteeing the stability of the imaging optical path.

[0119] Figure 7 A top view of a reflective mechanism according to an embodiment of this application is shown schematically.

[0120] like Figure 7 As shown in (a), (b), and (c), when different sizes of workpieces 100 need to be inspected, the prism 31 is manually removed from the platform 11 by overcoming the magnetic force and repositioned to a position suitable for the size of the workpiece 100. This allows for rapid adjustment of the inspection space without the need for tools or disassembling fasteners, improving changeover efficiency. The magnetic adsorption method avoids the need for complex mounting holes or grooves on the platform 11, simplifying its structure. It also allows the position of the prism 31 on the platform 11 to be continuously adjustable around the opening 111, without being limited by pre-set hole positions, thus improving adjustment flexibility. Furthermore, by matching the inspection space formed by multiple prisms 31 with the workpiece 100, it ensures that after the workpiece 100 is lifted into the inspection space, each side maintains an appropriate working distance and angle relationship with the corresponding prism 31, ensuring that light from each side is accurately reflected by the prism 31 to the imaging mechanism 2.

[0121] According to embodiments of this application, the prism 31 is a solid glass optical material, a polyhedron made of transparent material (such as glass, crystal, etc.) through frosting and polishing, and is widely used in optical instruments. The prism 31, which deflects the path of light or shifts the image from its original axis, is very helpful in many imaging systems.

[0122] Figure 8 The schematic diagram illustrates the prism reflection optical path according to an embodiment of this application. Figure 9 An optical path diagram of a reflective mechanism according to an embodiment of this application is illustrated schematically.

[0123] As an example, such as Figure 8 and Figure 9 As shown, prism 31 can be a right-angle prism 31. The right-angle prism 31 is designed using a 90° concept and can produce a left-handed rotating image that can be flipped or rotated. Multiple prisms 31 combined can be used to rotate the image 90° around multiple sides of the object being inspected, enabling a single camera to image the product from all four sides.

[0124] Multiple right-angle prisms 31 surround the workpiece 100 (e.g., rectangular) to form a complete image covering all four sides. This allows a surface defect detection device that originally required five or more cameras to acquire multi-faceted images of the workpiece 100 with just one camera by designing multiple right-angle prism modules 31.

[0125] According to embodiments of this application, such as Figures 3 to 6 As shown, the lifting assembly 42 includes a third drive unit 421 and a support unit 422. The third drive unit 421 is disposed on the support mechanism 1, and the support unit 422 has a support surface for supporting the workpiece 100 being measured. The support unit 422 is configured to translate between a lifting position and a retracted position under the drive of the second drive unit 433. When the support unit 422 is in the lifting position, the support surface is configured to be flush with or protrude from the upper surface of the platform 11.

[0126] In some embodiments of this application, the support portion 422 of the lifting assembly 42 forms at least one vacuum suction hole. The at least one vacuum suction hole is used to adsorb and fix the workpiece 100 to be tested in the lifting state, so as to prevent the workpiece 100 from being displaced due to vibration or external force during the imaging process.

[0127] The number and distribution of vacuum suction holes can be designed according to the shape and size of the workpiece 100. For example, for a rectangular workpiece 100, a suction hole can be set near each of the four corners of the support surface.

[0128] The vacuum suction port is connected to a negative pressure source via an air passage. The negative pressure source can be a vacuum generator or a vacuum pump. A vacuum generator uses compressed air to generate negative pressure and is characterized by its simple structure and fast response; a vacuum pump can provide continuous negative pressure and is suitable for scenarios requiring long-term adsorption. A solenoid valve is installed on the air passage, and the processor controls the on / off state of the negative pressure.

[0129] After the lifting assembly 42 lifts the workpiece 100 to be tested into the detection space, the processor controls the solenoid valve to open, and the negative pressure source generates negative pressure at the vacuum suction port through the air passage, adsorbing and fixing the workpiece 100 onto the support surface. After imaging is completed, the processor controls the solenoid valve to close, the negative pressure at the vacuum suction port disappears, the workpiece 100 is released, and then the lifting assembly 42 returns to the retracted position, and the workpiece 100 falls back onto the conveying assembly 41.

[0130] The support surface of the support part 422 can be provided with an anti-slip pad or a soft material layer to prevent damage to the surface of the workpiece 100 during the adsorption process, while increasing the reliability of adsorption.

[0131] As an example, the third drive unit 421 can be a cylinder, with the cylinder body fixed to the support mechanism 1 and the piston rod of the cylinder connected to the support unit 422.

[0132] In some alternative embodiments, the third drive unit 421 may be an electric cylinder or a linear motor, and the lifting position of the support unit 422 may be precisely controlled by a control system.

[0133] As an example, the support 422 can adopt a plate-like or block-like structure, and the size of the support surface is adapted to or meets the shape of the bottom of the workpiece 100 to ensure the stability of the workpiece 100 during the lifting process.

[0134] In this implementation, the third drive unit 421 drives the support unit 422 to translate between the lifting position and the retracting position, so that the support unit 422 can lift the workpiece 100 to be tested from the conveying assembly 41 when needed according to the detection rhythm, and put the workpiece 100 back into the conveying assembly 41 after imaging is completed, realizing a smooth switch between the conveying state and the detection state of the workpiece 100. When the support unit 422 is in the lifting position, its support surface is flush with or protrudes from the upper surface of the platform 11, so that the side of the workpiece 100 to be tested can be fully exposed in the detection space enclosed by the multiple prisms 31 of the reflection mechanism 3 after being lifted, ensuring that the light from each side can be effectively reflected by the prisms 31 to the imaging mechanism 2.

[0135] Meanwhile, the height relationship between the support surface and the platform 11 surface ensures that the bottom of the workpiece 100 to be tested will not interfere with the edge of the opening 111 of the platform 11 after it is lifted, and the workpiece 100 can accurately enter the preset detection position. When the support part 422 is in the retracted position, its support surface is lower than the conveying surface, so that the workpiece 100 to be tested can be carried through by the conveying assembly 41 without obstruction, without affecting the normal conveying rhythm of the workpiece 100.

[0136] Furthermore, by having the support surface of the support part 422 contact the bottom of the workpiece 100 to be tested, a stable support is formed for the workpiece 100 during the lifting process, preventing the workpiece 100 from tilting or shifting during the lifting process. This ensures the relative positional accuracy between the various sides of the workpiece 100 and the prism 31 after it enters the detection space, providing a basic guarantee for obtaining a clear and complete side image. Through the cooperation of the lifting component 42 and the adjusting component 43, when the conveying component 41 moves in the second direction to adapt to workpieces 100 of different widths, the lifting component 42 always remains in the center position between the two conveying components 41, so that workpieces 100 of different widths can accurately enter the central area of ​​the detection space after being lifted.

[0137] In some embodiments of this application, the conveying mechanism 4 is equipped with multiple position sensors to detect the position of the workpiece 100 on the conveying path. The sensors can be photoelectric sensors, proximity switches, or limit switches. The detection signals from the sensors are transmitted to the processor as trigger signals to control the operation of the conveying assembly 41, the limiting mechanism 5, and the lifting assembly 42.

[0138] As an example, a first sensor is installed at the entrance of the conveying mechanism 4 to detect when the workpiece 100 to be tested enters the conveying mechanism 4, and the processor starts the conveying assembly 41 accordingly. A second sensor is installed in front of the detection station to detect when the workpiece 100 to be tested approaches the limiting mechanism 5, and the processor controls the limiting mechanism 5 to switch to the first position (blocking position) to precisely intercept the workpiece 100 at the predetermined position. A third sensor is installed below the detection station to detect whether the workpiece 100 has reached directly above the lifting assembly 42, and the processor controls the conveying assembly 41 to stop running and starts the lifting assembly 42 to lift the workpiece 100 into the detection space.

[0139] The signal connection between the sensor and the processor can be wired or wireless. The sensor signal is input to the processor's input port after passing through a conditioning circuit. The processor judges and processes the sensor signal according to a preset logic program and outputs corresponding control commands.

[0140] Figure 10 A partial perspective view of a surface defect detection apparatus according to an embodiment of this application is schematically shown, illustrating a translation mechanism, a lifting mechanism, and an illumination mechanism.

[0141] According to an embodiment of this application, the surface defect detection device further includes a translation mechanism 6. The translation mechanism 6 is configured to drive the imaging mechanism 2 to translate along a first direction to adjust the relative position of the imaging mechanism 2 and the workpiece 100 to be tested in the first direction, so that the optical axis of the imaging mechanism 2 is aligned with the geometric center of the workpiece 100 to be tested in the first direction.

[0142] In this implementation, when the geometric center of the workpiece 100 under test in the first direction coincides with the optical axis of the imaging mechanism 2, the top image of the workpiece 100 is centered on the sensor, and the distribution of the side images on the sensor after reflection by the prism 31 is also symmetrical, which is beneficial for region segmentation and feature extraction in subsequent image processing. When the conveying mechanism 4 is adapted to workpieces 100 of different lengths, the geometric center of the workpiece 100 under test in the first direction may shift with the length of the workpiece 100. By adjusting the position of the imaging mechanism 2 through the translation mechanism 6, the optical axis of the imaging mechanism 2 can always be aligned with the geometric center of workpieces 100 of different lengths, ensuring the symmetry and consistency of the imaging.

[0143] According to embodiments of this application, such as Figure 10 As shown, the translation mechanism 6 includes a slide rail 61, a first slider 62, and a fourth drive unit. The slide rail 61 extends along a first direction and is disposed on the support mechanism 1. The first slider 62 is slidably disposed on the slide rail 61, and the imaging mechanism 2 is disposed on the first slider 62. The fourth drive unit (not shown) is adapted to drive the first slider 62 to translate along the slide rail 61 to adjust the position of the imaging mechanism 2 relative to the workpiece 100 to be measured in the first direction.

[0144] As an example, the translation mechanism 6 can adopt a structure of servo motor and ball screw. The servo motor is fixed to the support mechanism 1, and the ball screw is rotatably set on the support mechanism 1 and parallel to the slide rail 61. The nut of the ball screw is fixedly connected to the first slider 62. The servo motor drives the ball screw to rotate, thereby driving the first slider 62 and the shooting mechanism 2 to move along the first direction.

[0145] In some other illustrative embodiments of this application, the fourth drive unit may be a linear motor. The mover of the linear motor is fixedly connected to the first slider 62, and the stator is laid on the support mechanism 1 along the first direction. The first slider 62 is directly driven to move linearly by electromagnetic force to achieve contactless transmission.

[0146] In some illustrative embodiments of this application, the fourth driving unit may be driven by a cylinder. The cylinder body is fixed to the support mechanism 1, and the piston rod of the cylinder is connected to the first slider 62. The shooting mechanism 2 can be quickly adjusted in the first direction by air pressure drive.

[0147] In some further illustrative embodiments of this application, the fourth drive unit can be manually adjusted, and the operator can adjust the position of the shooting mechanism 2 by manually adjusting the position of the first slider 62 relative to the slide rail 61.

[0148] In this embodiment, the slide rail 61 extends along the first direction and is fixed to the support mechanism 1, providing precise motion guidance for the movement of the first slider 62. The first slider 62 is slidably mounted on the slide rail 61, enabling the imaging mechanism 2 to move stably along the first direction, ensuring straightness and repeatability during movement. The first slider 62 is driven to move along the slide rail 61 by the fourth drive unit, allowing the imaging mechanism 2 to automatically or manually adjust its position according to the actual position of the workpiece 100 under test in the first direction, achieving alignment between the optical axis of the imaging mechanism 2 and the geometric center of the workpiece 100 under test.

[0149] By setting the shooting mechanism 2 on the first slider 62, a rigid connection is formed between the shooting mechanism 2 and the first slider 62. The shooting mechanism 2 moves synchronously with the movement of the first slider 62, ensuring the stability of the shooting mechanism 2's posture during the adjustment process.

[0150] When the conveying mechanism 4 is adapted to workpieces 100 of different lengths, the geometric center position of the workpiece 100 in the first direction may change. By adjusting the position of the imaging mechanism 2 through the translation mechanism 6, the optical axis of the imaging mechanism 2 can always be aligned with the geometric center of the workpieces 100 of different lengths, ensuring the symmetry and consistency of the imaging and providing standardized image input for subsequent image processing.

[0151] According to embodiments of this application, such as Figure 10 As shown, the surface defect detection device also includes a lifting mechanism 7. The lifting mechanism 7 is disposed on the first slider 62, and the imaging mechanism 2 is disposed on the lifting mechanism 7. The lifting mechanism 7 is configured to drive the imaging mechanism 2 to translate along the height direction, so as to adjust the distance between the imaging mechanism 2 and the workpiece 100 to be tested in the height direction.

[0152] In this implementation, the lifting mechanism 7 drives the imaging mechanism 2 to translate along the height direction, allowing the distance between the imaging mechanism 2 and the workpiece 100 under test to be adjusted as needed. This distance directly determines the object distance and field of view of the imaging. By adjusting the height of the imaging mechanism 2, it can accommodate workpieces 100 of different thicknesses. When the workpiece 100 is thick, the object distance between the imaging mechanism 2 and the workpiece 100 is appropriately increased to ensure that the entire top and side surfaces of the workpiece 100 are completely within the depth of field of the imaging mechanism 2. When the workpiece 100 is thin, the object distance is appropriately decreased to improve imaging resolution and detail clarity.

[0153] According to embodiments of this application, such as Figure 10As shown, the lifting mechanism 7 includes a lead screw (not shown), a guide rail (not shown), a second slider 73, and a third motor 74. The lead screw extends vertically and is disposed on the first slider 62. The guide rail is disposed parallel to the lead screw on the first slider 62. The second slider 73 is threadedly engaged with the lead screw, and the shooting mechanism 2 is disposed on the second slider 73. The third motor 74 is disposed on the first slider 62 and is used to drive the lead screw to rotate, so that the second slider 73, guided by the guide rail, drives the shooting mechanism 2 to move vertically.

[0154] When the third motor 74 starts, it drives the lead screw to rotate. Through the threaded engagement between the lead screw and the second slider 73, the rotational motion of the lead screw is converted into the linear motion of the second slider 73. The second slider 73 moves vertically under the guidance of the guide rail, thereby driving the shooting mechanism 2 to rise and fall.

[0155] In this implementation, a lead screw extends vertically and is rotatably mounted on the first slider 62, allowing the lead screw to convert rotational motion into linear motion as a driving element. A guide rail, parallel to the lead screw and mounted on the first slider 62, provides precise motion guidance for the second slider 73, ensuring the straightness and stability of the second slider 73 and the imaging mechanism 2 during lifting and lowering, preventing jamming or positioning errors caused by skew. The second slider 73 is threadedly engaged with the lead screw and slidably mounted on the guide rail, allowing the lead screw to precisely drive the second slider 73 to rise and fall along the guide rail when rotating. The threaded drive has a self-locking characteristic; when the third motor 74 stops driving, the second slider 73 maintains a stable position, preventing positional shifts in the imaging mechanism 2 due to gravity or vibration. The third motor 74, mounted on the first slider 62 and driving the lead screw rotation, achieves automated control of the lifting and lowering motion, allowing the height of the imaging mechanism 2 to be automatically adjusted according to the actual dimensions of the workpiece 100 being measured.

[0156] By integrating the lifting mechanism 7 into the first slider 62, the imaging mechanism 2 can move both along the first direction via the translation mechanism 6 and along the vertical direction via the lifting mechanism 7, achieving independent adjustment and precise positioning of the imaging mechanism 2 in both directions. When the thickness of the workpiece 100 to be measured changes, the third motor 74 drives the lead screw to rotate, causing the second slider 73 to lift the imaging mechanism 2, adjusting the distance between the imaging mechanism 2 and the workpiece 100 in the height direction, i.e., the object distance. This ensures that the top and side surfaces of the workpiece 100 can be completely and clearly imaged on the sensor of the imaging mechanism 2, guaranteeing the acquisition of high-quality inspection images.

[0157] It should be understood that the embodiments of this application are not limited thereto. For example, the lifting mechanism 7 can be replaced by a linear motor, with the mover of the linear motor directly connected to the second slider 73 and the stator vertically disposed on the first slider 62, directly driving the second slider 73 to rise and fall via electromagnetic force. Alternatively, the lifting mechanism 7 can be driven by a cylinder, suitable for applications requiring switching between two fixed heights. The cylinder body is fixed to the first slider 62, and the piston rod of the cylinder is connected to the second slider 73, achieving rapid lifting and lowering of the shooting mechanism 2 via pneumatic drive.

[0158] Figure 11 Schematic illustration Figure 10 A magnified view of part B shown.

[0159] According to embodiments of this application, such as Figure 10 and Figure 11 As shown, the surface defect detection device also includes an illumination mechanism 8. The illumination mechanism 8 is disposed above the reflection mechanism 3 and is configured to provide illumination to the workpiece 100 to be tested.

[0160] In some embodiments of this application, the wall panel and door of the support mechanism 1 together form a closed installation space to reduce the interference of dust and stray light from the external environment on optical imaging. To further improve the dustproof effect, a sealing strip is provided at the contact edge between the door and the frame, and a sealing ring or sealing cover is provided for the wire passage hole on the wall panel. A positive pressure dustproof system can be installed inside the installation space, which supplies clean air into the interior through a small fan and filter, making the internal air pressure slightly higher than the external pressure to prevent dust from entering through gaps.

[0161] To improve heat dissipation, the wall panel of the support mechanism 1 can be made of a metal material with good thermal conductivity, such as aluminum alloy or galvanized steel sheet. The wall panel has ventilation holes covered with dustproof mesh to prevent dust from entering while ensuring air circulation. For components that generate a large amount of heat, such as the processor, power module, and lighting source 81, independent cooling fans or heat sinks can be installed for forced air cooling.

[0162] As an example, the lighting mechanism 8 can use a ring light source 81, which is fitted around the lens of the imaging mechanism 2. The light emitted from the ring light source 81 is directed downwards, directly illuminating the top surface of the workpiece 100 to be tested and the area where the reflecting mechanism 3 is located.

[0163] Alternatively, the lighting mechanism 8 can employ multiple strip light sources 81, arranged at intervals around the upper perimeter of the reflecting mechanism 3. The illumination angle of each strip light source 81 is adjustable to provide illumination to the workpiece 100 under test from different directions. By arranging multiple strip light sources 81 around the upper perimeter of the reflecting mechanism 3, illumination to the workpiece 100 under test can be provided from multiple directions. By adjusting the brightness and on / off state of the light sources 81 in different directions, bright field illumination, dark field illumination, or a combination of light fields can be formed to adapt to the detection needs of different material surfaces and different types of defects. For example, low-angle dark field illumination can enhance the contrast of scratch defects, while high-angle bright field illumination can clearly present the surface morphology of pit defects.

[0164] Alternatively, the lighting mechanism 8 can adopt a dome light source 81, which is a hemispherical or arc-shaped cover above the reflection mechanism 3. The light is evenly projected onto each surface of the workpiece 100 under test through diffuse reflection from the inner wall, reducing shadows and reflection interference.

[0165] The type of light source 81 of the lighting mechanism 8 can be selected according to the testing requirements, such as LED light source 81, fiber optic halogen light source 81 or laser light source 81, etc. The color temperature, brightness and flicker characteristics of the light source 81 can be configured according to the material and defect type of the workpiece 100 to be tested.

[0166] In this implementation, the illumination mechanism 8 is arranged above the reflection mechanism 3, allowing the illumination light to directly illuminate the top surface of the workpiece 100 under test. Simultaneously, some light indirectly illuminates the sides of the workpiece 100 through the area where the reflection mechanism 3 is located, ensuring that all surfaces of the workpiece 100 under test receive sufficient illumination after entering the testing space. By using a ring light source 81 surrounding the lens of the imaging mechanism 2, the illumination light and the imaging optical path are coaxial, effectively eliminating shadows and ensuring the uniformity of the top surface image. Furthermore, the emitted light from the ring light source 81 covers the area where the reflection mechanism 3 is located, providing sufficient light to the side prisms 31.

[0167] According to embodiments of this application, such as Figure 10 and Figure 11As shown, the support mechanism 1 includes a support frame 12 and an elongated support plate 13. The support frame 12 is disposed above the reflection mechanism 3. The elongated support plate 13 extends obliquely downward from the support frame 12 to the periphery of the reflection mechanism 3, and the support plate 13 has a first guide hole 131 extending along the length direction of the support plate 13. The illumination mechanism 8 includes a light source 81, a mounting plate 82, and a first fastener (not shown). The mounting plate 82 is mounted on the backlight side of the light source 81 and has a through hole 821. The first fastener passes through the through hole 821 and the first guide hole 131 and is configured to move along the first guide hole 131 in a first loose state to adjust the height between the light source 81 and the workpiece 100 to be measured; and in a first fastened state, to mount the mounting plate 82 onto the support plate 13 to lock the height between the light source 81 and the workpiece 100 to be measured.

[0168] Mounting plate 82 is fixedly mounted on the backlight side of light source 81, that is, the opposite side of the light-emitting surface of light source 81. Mounting plate 82 has a through hole 821. A first fastener passes through the through hole 821 of mounting plate 82 and the first guide hole 131 of support plate 13 to connect mounting plate 82 and support plate 13.

[0169] As an example, the first fastener can be a combination of a bolt and a nut, with the bolt passing through the through hole 821 and the first guide hole 131 and then tightened with the nut. The length direction of the first guide hole 131 extends along the length direction of the support plate 13, that is, along the inclined direction of the support plate 13. When the first fastener is in the loose state, the connection between the mounting plate 82 and the support plate 13 is loose, and the mounting plate 82 can move along the first guide hole 131, thereby driving the light source 81 to move along the length direction of the support plate 13, adjusting the height of the light source 81 relative to the workpiece 100 to be measured. When the light source 81 moves to the required height, the first fastener is switched to the tightened state, so that sufficient friction or pressure is generated between the mounting plate 82 and the support plate 13, fixing the mounting plate 82 in the predetermined position of the support plate 13, thereby locking the height of the light source 81.

[0170] In some alternative embodiments, the mounting plate 82 may be provided with two or more through holes 821, and the support plate 13 may be provided with two or more first guide holes 131, which are connected simultaneously by multiple first fasteners to improve the stability and load-bearing capacity of the connection.

[0171] As an example, the mounting plate 82 and the light source 81 can be connected in a detachable manner to facilitate the replacement and maintenance of the light source 81.

[0172] In this embodiment, the support plate 13 extends obliquely downward from the support frame 12 to the periphery of the reflecting mechanism 3, allowing the light source 81 mounted on the support plate 13 to illuminate the workpiece 100 at an oblique angle, providing a suitable illumination direction. A first guide hole 131 extending along the length of the support plate 13 provides a guiding path for the movement of the mounting plate 82, enabling the mounting plate 82 and the light source 81 to move along the length direction (oblique direction) of the support plate 13, thereby changing the vertical distance and relative angle between the light source 81 and the workpiece 100. The mounting plate 82 is positioned on the backlight side of the light source 81 and has a through hole 821, ensuring that when the first fastener passes through the through hole 821 and connects to the first guide hole 131, the fastening force acts on the mounting plate 82 rather than the light source 81 itself, avoiding direct compression and damage to the structure of the light source 81.

[0173] With the first fastener in the loosened state, the mounting plate 82 is allowed to move along the first guide hole 131, enabling the operator to manually adjust the light source 81 to a suitable height position according to the size, material, and testing requirements of the workpiece 100 to meet the lighting needs under different working conditions. With the first fastener in the tightened state, the mounting plate 82 is fixed to the support plate 13. The friction or pressure between the fastener and the guide hole ensures that the light source 81 remains stable after adjustment and will not shift due to equipment vibration or external disturbances, thus guaranteeing the stability of the lighting conditions during imaging.

[0174] With this adjustable height mounting structure, when inspecting workpieces 100 of different thicknesses, the illumination effect can be optimized by adjusting the height of the light source 81, ensuring that the top and sides of the workpiece 100 receive uniform and sufficient illumination, thus guaranteeing high-quality image acquisition by the imaging mechanism 2. At the same time, this adjustment structure is simple and reliable, requiring no complex transmission mechanisms or control systems, reducing equipment costs and maintenance difficulty, and facilitating quick adjustment of the light source 81 height by operators during model changes.

[0175] In some embodiments of this application, the lighting mechanism 8 includes at least two different colored light sources 81. The different colored light sources 81 can be installed independently on the support plate 13, or they can be integrated into the same light source 81 module.

[0176] The brightness and on / off status of the light source 81 can be independently controlled by the processor through the control system. Specifically, each light source 81 is connected to an independent drive circuit. The processor adjusts the brightness of the light source 81 through pulse width modulation (PWM) signals or analog voltage signals, and controls the lighting and extinguishing of the light source 81 through switching signals. The processor can automatically switch the combination mode and brightness parameters of the light sources 81 according to the preset detection program, targeting different materials and types of defects, to form various light field environments.

[0177] As an example, for scratch detection on metal surfaces, low-angle dark-field illumination can be used, i.e., illuminating the tilted light source 81 so that the light illuminates the surface of the workpiece 100 at a grazing angle, enhancing the contrast of the shadows at the edges of the scratches. For pit detection on plastic surfaces, high-angle bright-field illumination can be used, i.e., illuminating the near-vertical light source 81 so that the light illuminates the surface of the workpiece 100 perpendicularly, clearly showing the light and shadow variations in the pitted areas. For multi-colored workpieces 100 or printed patterns, different colored light sources 81 can be illuminated sequentially, and images can be acquired separately and then differentially processed to highlight defects of specific colors.

[0178] The processor can sequentially activate multiple light field combinations during the inspection of the same workpiece 100 according to the inspection requirements, acquire multiple sets of images for comprehensive judgment, and improve the accuracy of defect detection.

[0179] As an example, the support frame 12 is mounted above the reflector 3, providing a stable mounting base for the lighting mechanism 8. The support plate 13 is a long strip-shaped structure that extends downwards from the support frame 12 to the periphery of the reflector 3. The tilt angle of the support plate 13 can be preset according to lighting requirements, such as 30 degrees, 45 degrees, or 60 degrees.

[0180] According to the disclosed embodiments, such as Figure 10 and Figure 11 As shown, the support plate 13 also has a second guide hole 132 extending parallel to the first guide hole 131. The mounting plate 82 forms an arcuate hole 822 spaced from the through hole 821. The illumination mechanism 8 also includes a second fastener (not shown) passing through the arcuate hole 822 and the second guide hole 132, and is configured to allow the mounting plate 82 to rotate about the first fastener in a second loosened state to adjust the illumination angle of the light source 81 relative to the workpiece 100 under test; and to mount the mounting plate 82 to the support plate 13 in a second locked state to lock the illumination angle.

[0181] As a specific configuration, the first and second fasteners can be a combination of bolts and nuts, with the bolts passing through corresponding holes and tightened with the nuts. The through hole 821 through which the first fastener passes is a circular hole, serving as a fulcrum for the rotation of the mounting plate 82; the arc-shaped hole 822 through which the second fastener passes is an arc-shaped through hole 821, the arc length of which corresponds to the required adjustment angle range. When both the first and second fasteners are in the loose state, the mounting plate 82 can rotate around the first fastener as its axis, and the second fastener moves relative to it within the arc-shaped hole 822, thereby changing the illumination angle of the light source 81 relative to the workpiece 100 to be measured. When the light source 81 rotates to the required angle, the second fastener is switched to the locked state, generating sufficient friction or pressure between the mounting plate 82 and the support plate 13, fixing the mounting plate 82 to the predetermined position of the support plate 13, thereby locking the illumination angle.

[0182] As an example, the center angle of the arc-shaped hole 822 can be set according to the required adjustment range, such as 45 degrees, 60 degrees or 90 degrees.

[0183] In this embodiment, a second guide hole 132 parallel to the first guide hole 131 is provided by the support plate 13, providing a movement path for the second fastener, allowing the second fastener to move within the guide hole as the mounting plate 82 rotates. An arc-shaped hole 822 spaced from the through hole 821 is formed on the mounting plate 82, and the arc-shaped hole 822 extends in an arc shape with the through hole 821 as its center. This allows the second fastener to slide relative to the first fastener within the arc-shaped hole 822 when the mounting plate 82 rotates around the first fastener. The shape of the arc-shaped hole 822 matches the rotation trajectory, ensuring smooth rotation.

[0184] The second fastener passes sequentially through the arc-shaped hole 822 and the second guide hole 132, allowing the mounting plate 82 to rotate around the first fastener in the loosened state and fixing the mounting plate 82 to the support plate 13 in the locked state, thus achieving the dual functions of angle adjustment and locking. With the first fastener as a rotation fulcrum and the second fastener as an angle positioning point, their coordinated operation allows the light source 81 to be continuously adjustable within a predetermined angle range. The operator can adjust the light source 81 to the optimal illumination angle according to the material, surface characteristics, and defect type of the workpiece 100 under test, thereby enhancing the contrast between the defect and the background. For example, low-angle grazing illumination can highlight the edge shadows of scratches, while vertical illumination can clearly present the light and dark variations in the recessed area for pitted defects.

[0185] The mounting plate 82 is fixed to the support plate 13 in the locked state by the second fastener. The friction or pressure between the fastener and the arc-shaped hole 822 and the guide hole ensures that the light source 81 maintains a stable angle after adjustment, preventing deflection due to equipment vibration or external disturbances, thus guaranteeing the stability and repeatability of illumination conditions during imaging. This adjustable angle mounting structure allows for optimization of the illumination effect by adjusting the illumination angle of the light source 81 when detecting workpieces 100 with different characteristics or different types of defects. This ensures high-quality image acquisition by the imaging mechanism 2, thereby improving the accuracy and reliability of defect identification.

[0186] The support plate 13 has a first guide hole 131 and a second guide hole 132 along its length. The two guide holes are parallel and spaced apart. The length of the guide hole determines the adjustment range of the height of the light source 81, and the width of the guide hole matches the diameter of the fastener to ensure the guiding accuracy of the fastener when it moves within the guide hole.

[0187] The first fastener passes through the through hole 821 of the mounting plate 82 and the first guide hole 131 of the support plate 13, and the second fastener passes through the arc-shaped hole 822 of the mounting plate 82 and the second guide hole 132 of the support plate 13. The fasteners can be a combination of bolts and nuts, or quick-locking screws with handles for easy manual adjustment and tightening.

[0188] In some embodiments of this application, the processor is also configured to record and recall the position parameters of each key mechanism to achieve intelligent model switching. Key mechanisms include the adjustment component 43 of the conveying mechanism 4, the translation mechanism 6 of the shooting mechanism 2, the lifting mechanism 7, and the position of the mounting plate 82 of the lighting mechanism 8.

[0189] Specifically, for each specification of the workpiece 100 to be tested (such as 13-inch, 15-inch, and 17-inch laptop casings), during the initial debugging, the operator manually or automatically adjusts each mechanism to the optimal position to suit that specification. The processor records the positional parameters of each mechanism at this time, including the distance between the two conveying components 41 of the adjustment component 43, the position of the first slider 62 of the translation mechanism 6, the position of the second slider 73 of the lifting mechanism 7, the coordinate positions of each prism 31 on the platform 11, and the height and angle positions of the mounting plates 82 of each light source 81. These positional parameters are associated with the identification information of the workpiece 100 specification (such as model code and size parameters) and stored in the processor's memory.

[0190] When the production line needs to switch to a different specification of workpiece 100, the operator can select the target workpiece 100 specification through the human-machine interface, or read the identification code on the workpiece 100 through a barcode scanner. The processor automatically retrieves the corresponding position parameters and controls the drive components of each mechanism (such as motors and cylinders) to adjust each mechanism to the preset position. During the changeover process, the processor can also prompt the operator through the display screen for parts that need to be manually adjusted (such as the repositioning of prism 31), and confirm the changeover is complete after all mechanisms are in place.

[0191] Operators can input or select detection parameters via the touchscreen, such as the brightness of the light source 81, detection sensitivity, defect judgment threshold, and changeover parameters. The manual control interface allows operators to manually control the actions of various mechanisms, such as starting and stopping the conveyor assembly 41, raising and lowering the lifting assembly 42, moving the limit mechanism 5, and triggering the shooting mechanism 2, facilitating debugging and maintenance. Operators can also select workpiece specification 100 to trigger the automatic changeover program and view the changeover progress and prompts.

[0192] This function of recording and automatically recalling position parameters shortens changeover time, reduces the workload of manual adjustments and the probability of errors, and enables flexible online production.

[0193] In some embodiments of this application, the surface defect detection device is also provided with an interface for communicating with upstream and downstream equipment to achieve seamless integration with the production line.

[0194] The processor interacts with upstream equipment (such as upstream processing equipment and feeding equipment) and downstream equipment (such as downstream processing equipment, sorting equipment, and rejection devices) through a communication interface. The interaction signals include, but are not limited to: ready signal (indicating that the device can receive workpiece 100), request to feed signal, feed completion confirmation signal, detection completion signal, detection result signal, and defective product rejection trigger signal.

[0195] As an example, when the device is idle and can receive workpiece 100, the processor sends a ready signal to the upstream device via the communication interface. Upon receiving the signal, the upstream device releases the workpiece 100 to be tested onto the conveyor mechanism 4. After workpiece 100 enters the device, the processor sends an occupied signal to the downstream device, indicating that the inspection station is occupied. After inspection, the processor sends a pass or fail signal to the downstream device based on the inspection result. For fail-conforming workpiece 100, the downstream device performs a rejection action. After workpiece 100 leaves the device, the processor sends a ready signal to the upstream device again to begin the next cycle.

[0196] Through standardized communication interfaces and protocols, this device can be easily integrated into various automated production lines to achieve collaborative work with upstream and downstream equipment.

[0197] The surface defect detection device provided in this application is not only suitable for the appearance inspection of notebook casings, but can also be extended to the multi-faceted surface defect detection of various types of products.

[0198] As an example, by adjusting the number, layout, and size of the prisms 31 in the reflection mechanism 3, and by adjusting the width range of the conveying mechanism 4, this device can be adapted to products of different shapes and sizes, such as mobile phone cases, tablet back covers, packaging boxes, gift boxes, and automotive parts.

[0199] For products made of different materials, the lighting mechanism 8 can be optimized by combining the color, angle and light field of the light source 81. For example, coaxial light source 81 or dome light source 81 can be used for highly reflective metal surfaces, backlighting can be used for transparent or semi-transparent plastic parts, and multi-color light source 81 can be used for packaging boxes with rich printed patterns.

[0200] The processor's defect detection algorithm can be configured and trained according to the detection standards of different products. By changing the algorithm model or adjusting the detection parameters, it can accurately identify different products and different defect types.

[0201] In some embodiments of this application, in order to accurately establish the mapping relationship between the points on the side of the workpiece 100 to be tested and the imaging points on the sensor of the imaging mechanism 2, rigorous geometric optical modeling is required.

[0202] Define the world coordinate system The origin O is the center of the top surface of the workpiece 100 to be tested. w The Zw axis points vertically upwards towards the shooting mechanism 2.

[0203] Define the camera coordinate system With the shooting location 2 as the origin point O c Z c The axis coincides with the optical axis and points towards the workpiece to be measured at 100.

[0204] Define the image pixel coordinate system The origin is the top left corner of the image.

[0205] The reflection model of prism 31 is illustrated using the right-side prism 31 as an example. Assume a point on the right side face of the workpiece 100 to be measured... ,in, Y w and Z w Describe the specific location of this point on the side. The emitted light travels in a straight line to the incident surface of prism 31. Since prism 31 is parallel to the side of workpiece 100, the spatial transformation between them is a translation transformation. Define the local coordinate system of prism 31. The origin is located at the right-angle vertex of prism 31. Coordinates in this coordinate system The result is obtained through translation transformation:

[0206] (1);

[0207] Where R is the rotation matrix (for the right prism 31, it is mainly a 180-degree rotation around the Zw axis), and T is the translation vector.

[0208] For an isosceles right-angle prism 31, light undergoes total internal reflection on the inclined plane, which is equivalent to a plane mirror at a 45-degree angle to the coordinate axes. Let the normal vector of the reflecting surface be n, and the exit point P after reflection be... p The coordinates are calculated using the mirror reflection matrix:

[0209] (2);

[0210] This formula expands the light path, ignoring the internal light path of prism 31, and treats it as a virtual periscope system.

[0211] After being equivalently processed by prism 31, point Pw on the side of workpiece 100 is mapped to the corresponding point Pv on the virtual object, which is located directly in front of the shooting mechanism 2. Using the classic pinhole imaging model, points in the camera coordinate system... Image pixel coordinates The relationship is:

[0212] (3);

[0213] Where s is the scale factor, and K is the intrinsic parameter matrix of the imaging mechanism 2, including the focal length. , and principal point coordinates , :

[0214] (4);

[0215] The external parameter matrix of the shooting mechanism 2 relative to the coordinate system of the virtual object.

[0216] Because the side light rays from the workpiece 100 are reflected by the prism 31 and enter the imaging mechanism 2, there is perspective distortion between the imaging position and shape of the side sub-image on the sensor and the actual geometry of the workpiece 100. To obtain a distortion-free side view, perspective transformation correction is required for the side sub-image.

[0217] The correction process is based on the homography transformation. For each side profile sub-image, there exists a 3×3 homography matrix H such that:

[0218] (5);

[0219] in, These are the pixel coordinates of the side sub-image region in the original captured image. These are the pixel coordinates of the corrected standard side view.

[0220] The homography matrix H is obtained through pre-calibration.

[0221] The calibration process includes: placing a standard calibration plate of known dimensions on the side of the workpiece 100 to be measured, ensuring its surface is coplanar with the side of the workpiece 100; acquiring a reflected image containing the calibration plate image through the imaging mechanism 2; extracting the coordinates of feature points (such as checkerboard corner points) in the calibration plate image; and solving the homography matrix H based on the theoretical coordinates and actual image coordinates of the feature points. After calibration, the H matrix is ​​stored in the processor.

[0222] In the actual inspection process, the processor performs region segmentation on each frame of the acquired global surface image, extracting peripheral sub-images corresponding to each side of the workpiece 100 under test. Then, it applies the corresponding homography matrix H to each peripheral sub-image for perspective transformation, generating a distortion-free side view. The corrected side view and the top image are then input into the defect detection algorithm for surface defect identification.

[0223] In some embodiments of this application, the processor performs region segmentation on the global surface image to extract sub-images corresponding to the top surface and various side surfaces of the workpiece 100 under test. The segmentation method can be implemented in various ways:

[0224] As an example, since the mounting positions of the multiple prisms 31 in the reflecting mechanism 3 relative to the imaging mechanism 2 are fixed, the imaging areas of each side sub-image on the sensor of the imaging mechanism 2 are also relatively fixed. Therefore, the coordinate range of each sub-image area can be preset in the processor, and the top surface sub-image and each side sub-image can be directly extracted by image cropping.

[0225] As another example, the processor can use image feature recognition methods for dynamic segmentation. For instance, it can identify the boundary between the top and side images using an edge detection algorithm, or locate pre-stored prism 31 contour features in the image using a template matching method, thereby determining the region boundaries of each sub-image.

[0226] The segmented top surface sub-image and each side surface sub-image are stored in the processor's memory and assigned corresponding identification information for subsequent independent defect detection processing.

[0227] In some embodiments of this application, the processor performs defect identification on the segmented top surface sub-image and the corrected side surface sub-image, respectively. The defect detection algorithm can be implemented using traditional machine vision methods or deep learning methods.

[0228] As an example, when using traditional machine vision algorithms, the processor first preprocesses each sub-image, including grayscale conversion, filtering and denoising, brightness normalization, etc.; then, it extracts candidate defect regions in the image through methods such as threshold segmentation, edge detection, and morphological processing; next, it calculates the geometric features (such as area, length, aspect ratio, grayscale mean, etc.) and texture features of the candidate regions; finally, it inputs the extracted features into a preset classifier (such as support vector machine, decision tree, etc.) to determine the defect type.

[0229] As another example, when using deep learning algorithms, the processor can load a pre-trained convolutional neural network model and directly input each sub-image into the network for end-to-end defect detection. The network model can be an object detection network used to locate and classify defect regions in the image, or an image classification network used to determine whether the entire sub-image contains a defect. For different types of defects, dedicated detection models can be trained, such as separate classifiers for scratches, imprints, dents, and stains.

[0230] The processor combines the detection results from the top surface and all sides. If any surface has a defect, the workpiece 100 is determined to be defective and a rejection signal is sent to the downstream equipment through the output interface.

[0231] The embodiments of this application have been described above. However, these embodiments are merely illustrative and not intended to limit the scope of this application. Although various embodiments have been described above, this does not mean that the measures in the various embodiments cannot be used advantageously in combination. The scope of this application is defined by the appended claims and their equivalents. Various substitutions and modifications can be made by those skilled in the art without departing from the scope of this application, and all such substitutions and modifications should fall within the scope of this application.

Claims

1. A surface defect detection device, characterized in that, include: Supporting institutions; A reflection mechanism, disposed on the support mechanism, is configured to form a detection space that matches the workpiece to be tested; The imaging mechanism is positioned above the detection space and is suitable for simultaneously imaging the top surface and at least one side surface of the workpiece to be tested located within the detection space to generate a surface image. The processor is configured to identify surface defects of the workpiece under test based on the surface image; A conveying mechanism is disposed below the reflecting mechanism and is configured to convey the workpiece to be tested in a first direction orthogonal to the vertical direction, and to lift the workpiece to be tested into the detection space when the workpiece to be tested is conveyed to the bottom of the imaging mechanism; the conveying width of the conveying mechanism in a second direction orthogonal to the first direction is adjustable to accommodate workpieces to be tested with different sizes in the second direction.

2. The surface defect detection device according to claim 1, characterized in that, The conveying mechanism includes: The paired conveying components extend in the first direction and are spaced apart and opposite to each other in a second direction orthogonal to the first direction, and are suitable for jointly carrying the workpiece to be tested and moving the workpiece to be tested in the first direction; A lifting assembly is disposed on the support mechanism and located between the two conveying assemblies in the second direction. The lifting assembly is configured to move between a lifting position that lifts the workpiece to be tested to the detection space and a retracted position that places the workpiece to be tested between the two sets of conveying assemblies. An adjustment component, disposed on the support mechanism, is configured to drive the two conveying components closer to or further apart in the second direction to change the distance between the two conveying components, so that the conveying width is adapted to the workpiece to be tested having different dimensions in the second direction.

3. The surface defect detection device according to claim 2, characterized in that, The conveying assembly includes: A support beam extends in the first direction; A conveyor belt is disposed on the side of the support beam facing another conveying assembly, and the outer surface of the conveyor belt forms a conveying surface for conveying the workpiece to be tested; A first drive unit is disposed on the support beam and is configured to drive the conveyor belt to rotate cyclically.

4. The surface defect detection device according to claim 3, characterized in that, The support beam protrudes from the conveying surface to guide the workpiece to be tested, located between the two support beams, to translate along the first direction.

5. The surface defect detection device according to claim 3, characterized in that, The first driving unit includes: The first motor is mounted on the support beam; An active roller is mounted on the support beam and configured to rotate under the drive of the first motor; The driven roller is installed at a distance from the driving roller on the support beam. The conveyor belt is wrapped around the driving roller and the driven roller to form the conveying surface and rotates cyclically under the drive of the driving roller.

6. The surface defect detection device according to claim 2, characterized in that, The adjustment component includes: Support base; At least two bidirectional lead screws are rotatably disposed on the support base. The at least two bidirectional lead screws are configured to extend in a second direction and are spaced apart in a first direction. The at least two bidirectional lead screws each have two threaded segments with opposite directions of rotation. The two threaded segments of one bidirectional lead screw are respectively threadedly engaged with the two conveying components. The second drive unit is adapted to drive the two bidirectional lead screws to rotate synchronously, so as to drive the two sets of conveying components to move relative to or opposite to each other in the second direction.

7. The surface defect detection device according to claim 2, characterized in that, Also includes: A limiting mechanism is disposed below the reflective mechanism and on the support mechanism, and located between the two conveying components in the second direction. The limiting mechanism is configured to move between a first position that prevents the workpiece to be tested from further translating in the first direction and a second position that allows the workpiece to be tested to pass through.

8. The surface defect detection device according to claim 7, characterized in that, The limiting mechanism includes: At least two cylinder blocks are disposed in the support mechanism; At least two blocking elements are configured to extend and retract in the height direction under the drive of at least two of the cylinder bodies to move between the first position and the second position.

9. The surface defect detection device according to claim 2, characterized in that, The support mechanism includes a platform disposed in the height direction between the reflective mechanism and the conveying mechanism, the platform having an opening allowing the workpiece to be measured to pass through; the reflective mechanism includes: Multiple prisms are arranged around the opening on the platform to form the detection space. A magnet is provided at the bottom of each prism, and a magnetic component that can be attracted by the magnet is provided on the platform.

10. The surface defect detection device according to claim 9, characterized in that, The lifting assembly includes: The third drive unit is disposed in the support mechanism; The support portion has a support surface for supporting the workpiece to be measured. The support portion is configured to translate between the lifting position and the retracting position under the drive of the second drive portion. When the support portion is in the lifting position, the support surface is configured to be flush with or protrude from the upper surface of the platform.

Images