Alumina ring defect detection method and system

Abstract

The application relates to an alumina ring defect detection method and system, and relates to the technical field of defect detection.The application comprises the following steps: collecting workpiece sizes in the current period and the number of workpieces in the current period; analyzing the workpiece sizes in the current period, the number of workpieces in the current period and historical reference workpiece sizes to obtain a corresponding relationship between a workpiece size proportion in the current period and a workpiece size proportion in the current period; determining whether the workpiece size proportion in the current period meets the requirement of a workpiece proportion without mixed sampling; if yes, determining a mixed sampling detection result at an inlet end as a mixed sampling detection result; determining the historical reference workpiece sizes and a historical conveying speed at the inlet end as actual reference workpiece sizes and an actual conveying speed at the inlet end respectively, and controlling an alumina ring defect detection device to detect alumina rings to obtain qualified alumina rings; if not, determining a mixed sampling result as the mixed sampling detection result at the inlet end, and controlling the alumina ring defect detection device to detect the alumina rings to obtain qualified alumina rings.The application has the effect of improving detection accuracy.

Description

Technical Field

[0001] This application relates to the technical field of defect detection, and in particular to a method and system for detecting defects in alumina rings. Background Technology

[0002] Alumina rings are industrial ceramic components widely used in electronics, chemicals, and machinery. They are characterized by a smooth, flat surface, absence of cracks, defects, or protrusions, and a regular ring shape. Alumina ring defect detection equipment refers to automated inspection equipment based on machine vision, consisting of an image acquisition module at the detection end, a mechanical conveying and sorting unit, and an image processing and control unit.

[0003] In related technologies, existing alumina ring defect detection technologies involve the following steps: after the alumina ring enters the sample inlet, the image acquisition module at the detection end acquires the current workpiece size, and the system determines the conveyor speed of the conveyor belt in the mechanical conveying and sorting unit based on this size. The alumina ring is then conveyed to the sorting component by the conveyor belt. The sorting component sends the alumina rings one by one into the detection area according to a preset frequency, allowing the image acquisition module at the detection end to acquire images of the alumina rings. The image processing and control unit then analyzes and processes the images to achieve defect detection of the alumina rings.

[0004] Regarding the aforementioned technologies, during the production of alumina rings, alumina rings of various sizes and specifications may be mixed together on the same production line. If a batch of alumina rings to be inspected contains mixed parts, and this mixed part happens to be used as a reference by the image acquisition module at the detection end to adjust the conveyor belt speed, the speed of the conveyor belt will be inconsistent with the suitable speed for the target alumina ring to be inspected. As a result, after the alumina ring enters the inspection area, the image acquired by the image acquisition module at the detection end will be blurry or miss images, which in turn affects the analysis and judgment of the image processing and control unit, reducing the accuracy of the alumina ring defect detection equipment's inspection results. There is still room for improvement. Summary of the Invention

[0005] To improve the accuracy of detection, this application provides a method and system for detecting defects in alumina rings.

[0006] Firstly, this application provides a method for detecting defects in alumina rings, employing the following technical solution: A method for detecting defects in alumina rings, comprising: The preset image acquisition module at the injection end is controlled to acquire the workpiece size and the number of workpieces in the current cycle on the preset injection end conveyor belt. The workpiece size, workpiece quantity, and preset historical benchmark workpiece size are analyzed to generate the corresponding relationship between the proportion of matching workpieces in this cycle and the proportion of workpiece size in this cycle. Determine whether the proportion of matched workpieces in this cycle meets the preset requirement for the proportion of workpieces without mixed samples; If the conditions are met, the preset no-mixing test result will be determined as the mixed-sample test result at the injection end. The historical reference workpiece size and the preset historical sample inlet conveying speed are respectively determined as the actual reference workpiece size and the actual sample inlet conveying speed. Based on the sample mixing test results at the sample inlet, the actual reference workpiece size and the actual sample inlet conveying speed, the preset alumina ring defect detection device is controlled to perform defect detection on the alumina ring in order to generate qualified alumina rings. If the conditions are not met, the preset mixed sample result will be determined as the mixed sample detection result at the injection end. Based on the corresponding relationship of the workpiece size ratio in this cycle and the mixed sample detection result at the injection end, the preset alumina ring defect detection device will be controlled to perform mixed sample rejection and defect detection on the preset alumina rings in order to generate qualified alumina rings.

[0007] Optionally, the steps of analyzing the workpiece size, workpiece quantity, and preset historical benchmark workpiece size in the current cycle to generate the correspondence between the workpiece proportion and workpiece size proportion in the current cycle include: The dimensions of the workpieces in this cycle are statistically counted to generate the quantity of workpieces of each size; Calculate the ratio between the number of workpieces of each size and the number of workpieces in this cycle to generate the proportion of workpieces of each size; The proportion of each size of workpiece is matched one-to-one with the size of the workpiece in this cycle to generate the corresponding relationship of the proportion of workpiece size in this cycle. The proportion of matching workpieces in the current period is found by referring to the historical benchmark workpiece size proportion relationship.

[0008] Optionally, the alumina ring defect detection device includes a sorting component, a mixed sample rejection component, and a defect detection end. The steps of controlling the preset alumina ring defect detection device to perform defect detection on the alumina rings based on the mixed sample detection results at the injection end, the actual reference workpiece size, and the actual injection end conveying speed, to generate qualified alumina rings, include: The movement of the sample inlet conveyor belt is controlled according to the actual sample inlet conveying speed. Find the outer diameter of the actual reference workpiece from the actual reference workpiece dimensions; Calculate the product between the actual reference workpiece outer diameter and the preset safety detection workpiece spacing parameter to generate the safety distance between workpieces; Calculate the product between the actual sample inlet conveying speed and the preset workpiece imaging and processing time to generate the workpiece imaging and processing reserved distance; Calculate the sum of the safe distance between workpieces and the reserved distance for workpiece shooting and processing to generate the workpiece conveying space; Calculate the quotient between the actual sample inlet conveying speed and the workpiece conveying space to generate the sorting frequency; Based on the mixed sample detection results at the injection end, the mixed sample rejection component is controlled to stop working, and based on the sorting frequency, the sorting component is controlled to allow the alumina rings to enter the defect detection end one by one for defect detection and defect rejection operations, so as to generate qualified alumina rings.

[0009] Optionally, the alumina ring defect detection device includes a sorting component, a mixed sample rejection component, and a defect detection end. The steps of rejecting preset alumina rings based on the workpiece size ratio in this cycle and the mixed sample detection results at the injection end, and controlling the preset alumina ring defect detection device to perform defect detection on the alumina rings to generate qualified alumina rings, include: Sort the proportions of workpieces of different sizes to generate the largest workpiece proportion; The reference workpiece size is determined based on the correspondence between the largest workpiece proportion and the workpiece size proportion in this cycle. The dimensions of the workpiece to be determined are set as the actual dimensions of the workpiece. The actual reference workpiece size and historical sample inlet conveyor speed are analyzed to generate the actual sample inlet conveyor speed. The movement of the sample inlet conveyor belt is controlled according to the actual sample inlet conveying speed, and the sorting component and the mixed sample rejection component are controlled according to the sample inlet mixed sample detection results, the actual sample inlet conveying speed and the actual reference workpiece size to perform mixed sample rejection and sorting of alumina rings, so as to generate actual alumina rings to be tested. The defect detection end controls the defect detection and rejection of the actual alumina ring to be tested, so as to generate qualified alumina rings.

[0010] Optionally, the step of analyzing actual reference workpiece dimensions and historical infeed conveyor speeds to generate actual infeed conveyor speeds includes: The actual reference workpiece dimensions are substituted into the preset workpiece volume calculation formula to generate the reference workpiece volume. Calculate the product between the volume of the reference workpiece and the preset alumina ring density to generate the mass of the reference workpiece; The quotient between the difference between the benchmark workpiece mass and the preset workpiece reference mass and the preset unit conversion factor is calculated to generate the quality deviation correction factor. The product of the quality deviation correction factor, the historical inlet conveyor speed, and the preset workpiece conveyor safety factor is calculated to generate the inlet conveyor speed adjustment value. The product of the historical inlet conveyor speed and the workpiece conveyor safety factor is calculated and summed with the inlet conveyor speed adjustment value to generate the actual inlet conveyor speed.

[0011] Optionally, the steps of controlling the sorting component and the mixed sample rejection component to perform mixed sample rejection and sorting of alumina rings based on the mixed sample detection results at the injection end, the actual injection end conveying speed, and the actual reference workpiece size to generate the actual alumina ring to be tested include: Collect actual workpiece outer diameter, historical average mixed sample rejection time, and safe distance between workpieces at the inspection end; Calculate the quotient between the safe distance between the workpieces at the detection end and the actual sample delivery speed at the injection end to generate the safe time between the workpieces; Calculate the difference between the preset total workpiece ratio and the maximum workpiece ratio to generate the mixed workpiece ratio; Calculate the product between the percentage of mixed samples and the historical average mixed sample rejection time to generate the average mixed sample rejection time; Calculate the sum between the safety time between workpieces, the average mixed sample rejection time, and the preset workpiece shooting time to generate the average time spent on mixed workpieces; Calculate the reciprocal of the average time spent on mixed-sample workpieces to generate the mixed-sample sorting frequency; The alumina rings are sorted by the sorting component according to the mixed sample sorting frequency, and the alumina rings are rejected by the mixed sample rejection component according to the mixed sample detection results at the injection end and the actual reference workpiece size, so as to generate the actual alumina rings to be tested.

[0012] Optionally, the alumina ring defect detection device includes a detection end image acquisition module and an image processing module. The steps of controlling the defect detection end to perform defect detection and defect removal operations on the actual alumina ring to be detected to generate a qualified alumina ring include: The control detection end image acquisition module captures images of the actual alumina ring to be inspected, in order to generate workpiece inspection images; The workpiece inspection image is input into the image processing module for analysis to generate the workpiece inspection result; Based on the workpiece inspection results, the actual alumina rings to be inspected are rejected in order to generate qualified alumina rings.

[0013] Secondly, this application provides an alumina ring defect detection system, which adopts the following technical solution: An alumina ring defect detection system, comprising: The data acquisition module is used to acquire the dimensions and quantity of workpieces in the current cycle. A memory for storing a program for an alumina ring defect detection method as described in any of the preceding claims; The processor and the program in the memory can be loaded and executed by the processor to implement an alumina ring defect detection method as described in any of the above.

[0014] In summary, this application includes at least one of the following beneficial technical effects: 1. By analyzing the workpiece size, number of workpieces in the current cycle, and historical benchmark workpiece size, the corresponding relationship between the proportion of matching workpieces and the proportion of workpiece size in the current cycle is obtained. It is determined whether the proportion of matching workpieces in the current cycle meets the requirement of the proportion of workpieces without mixed samples. If it does, the result of no mixed sample detection is determined as the mixed sample detection result at the injection end. The historical benchmark workpiece size and the preset historical injection end conveying speed are determined as the actual benchmark workpiece size and the actual injection end conveying speed, respectively. Based on the mixed sample detection result at the injection end, the actual benchmark workpiece size, and the actual injection end conveying speed, the alumina ring defect detection device is controlled to perform defect detection on the alumina rings to obtain qualified alumina rings. If it does not meet the requirement, the result of mixed sample detection is determined as the mixed sample detection result at the injection end. Based on the corresponding relationship between the workpiece size proportion in the current cycle and the mixed sample detection result at the injection end, the alumina ring defect detection device is controlled to perform mixed sample rejection and defect detection on the alumina rings to obtain qualified alumina rings, thereby improving the accuracy of alumina ring defect detection. 2. By controlling the movement of the conveyor belt at the injection end according to the actual injection end conveying speed, the outer diameter of the actual reference workpiece is found in the actual reference workpiece size. The product between the outer diameter of the actual reference workpiece and the preset safety detection workpiece spacing parameter is calculated to obtain the safety distance between workpieces. The product between the actual injection end conveying speed and the workpiece shooting and processing time is calculated to obtain the workpiece shooting and processing reserved distance. The sum between the safety distance between workpieces and the workpiece shooting and processing reserved distance is calculated to obtain the workpiece conveying space. The quotient between the actual injection end conveying speed and the workpiece conveying space is calculated to obtain the sorting frequency. Thus, the mixed sample rejection component is controlled to stop working according to the mixed sample detection result at the injection end, and the sorting component is controlled according to the sorting frequency to make the alumina rings enter the defect detection end one by one for defect detection and defect rejection operation, thereby obtaining qualified alumina rings with high accuracy. 3. By sorting the proportions of workpieces of various sizes, the proportion of the largest workpiece is obtained. Based on the proportion of the largest workpiece, the size of the undetermined reference workpiece is found in the corresponding relationship of the workpiece size proportion in this cycle. The size of the undetermined reference workpiece is determined as the actual reference workpiece size. The actual sample inlet conveyor speed is obtained by analyzing the actual reference workpiece size and the historical sample inlet conveyor speed. The movement of the sample inlet conveyor belt is controlled according to the actual sample inlet conveyor speed. Based on the sample mixing detection results, the actual sample inlet conveyor speed and the actual reference workpiece size, the sorting component and the mixed sample rejection component are controlled to perform mixed sample rejection and sorting of alumina rings to obtain the actual alumina ring to be tested. Then, the defect detection end is controlled to perform defect detection and defect rejection operations on the actual alumina ring to be tested, to obtain qualified alumina rings with high accuracy. Attached Figure Description

[0015] Figure 1 This is a flowchart of an alumina ring defect detection method in an embodiment of this application.

[0016] Figure 2 This is a flowchart of the steps in this application embodiment to analyze the workpiece size, the number of workpieces in the current cycle, and the preset historical benchmark workpiece size to generate the corresponding relationship between the workpiece proportion and the workpiece size proportion in the current cycle.

[0017] Figure 3 This is a flowchart of the steps in this application embodiment to control a preset alumina ring defect detection device to perform defect detection on an alumina ring based on the mixed sample detection results at the injection end, the actual reference workpiece size, and the actual injection end conveying speed, so as to generate a qualified alumina ring.

[0018] Figure 4 This is a flowchart illustrating the steps in this application embodiment to perform mixed sample rejection of preset alumina rings based on the corresponding relationship of workpiece size proportion in this cycle and the mixed sample detection results at the injection end, and to control the preset alumina ring defect detection device to perform defect detection on the alumina rings in order to generate qualified alumina rings.

[0019] Figure 5 This is a flowchart of the steps in this application embodiment to analyze the actual reference workpiece size and historical sample inlet conveying speed to generate the actual sample inlet conveying speed.

[0020] Figure 6 This is a flowchart illustrating the steps in this application embodiment to control the sorting component and the mixed sample rejection component to perform mixed sample rejection and sorting of alumina rings based on the mixed sample detection results at the injection end, the actual injection end conveying speed, and the actual reference workpiece size, so as to generate the actual alumina ring to be tested.

[0021] Figure 7 This is a flowchart of the steps in this application embodiment to control the defect detection end to perform defect detection and defect removal operations on the actual alumina ring to be tested in order to generate a qualified alumina ring. Detailed Implementation

[0022] To make the purpose, technical solution, and advantages of this application clearer, the following description is provided in conjunction with the appendix. Figures 1 to 7 The present application will be further described in detail below with reference to embodiments. It should be understood that the specific embodiments described herein are for illustrative purposes only and are not intended to limit the scope of the application.

[0023] This application discloses a method for detecting alumina ring defects. This method primarily addresses the issue of improving the accuracy of alumina ring defect detection. Specifically, it discloses an alumina ring defect detection device, a sample inlet image acquisition module, an alumina ring, and a processing terminal. The processing terminal is communicatively connected to the alumina ring defect detection device and the sample inlet image acquisition module to achieve data interaction and control. After the sample inlet image acquisition module sends the acquired workpiece size and quantity for the current cycle to the processing terminal, the processing terminal analyzes the workpiece size and quantity for the current cycle to obtain the corresponding relationship between the proportion of matching workpieces and the proportion of workpiece size for the current cycle. When the processing terminal determines that the proportion of matching workpieces for the current cycle meets the requirement of a proportion of workpieces without mixing, it then determines the historical baseline workpiece size and the historical sample inlet conveying speed. The system uses the actual reference workpiece size and actual sample inlet conveying speed as a reference. Based on the mixed sample detection results at the sample inlet, the actual reference workpiece size, and the actual sample inlet conveying speed, the system controls the alumina ring defect detection device to perform defect detection on the alumina rings, thereby obtaining qualified alumina rings. When the processing terminal determines that the proportion of matched workpieces in this cycle does not meet the requirement of the proportion of workpieces without mixed samples, the processing terminal determines the mixed sample result as the mixed sample detection result at the sample inlet. Based on the corresponding relationship of the workpiece size proportion in this cycle and the mixed sample detection result at the sample inlet, the alumina rings are mixed and rejected. The system then controls the alumina ring defect detection device to perform defect detection on the alumina rings, thereby obtaining qualified alumina rings. The aim is to quickly and reasonably control the alumina ring defect detection device to perform defect detection on the alumina rings, thereby obtaining qualified alumina rings and improving the accuracy of defect detection.

[0024] Reference Figure 1 This application discloses a method for detecting alumina ring defects, comprising the following steps: Step S100: Control the preset sample inlet end image acquisition module to acquire the workpiece size and the number of workpieces in this cycle on the preset sample inlet end conveyor belt.

[0025] The workpiece size in this cycle refers to the size of the alumina ring captured by the image acquisition module at the injection end within one shooting cycle, including the outer diameter, inner diameter, roundness, and thickness of each alumina ring. The number of workpieces in this cycle refers to the total number of alumina rings captured by the image acquisition module at the injection end within one shooting cycle. By controlling the image acquisition module at the injection end to acquire images of the conveyor belt at the injection end within one cycle through the processing terminal, and inputting the acquired images into the image processing module for processing and analysis through the processing terminal, the workpiece size and the number of workpieces in this cycle can be obtained.

[0026] The cycle refers to the time required for the image acquisition module at the sample inlet to complete one full image acquisition, transmit the image to the image processing module, and process and analyze the image through the image processing module. In one embodiment, the operator finds the camera's frame rate in the technical manual based on the camera model in the image acquisition module at the detection end. The reciprocal of the frame rate is then used to calculate the image acquisition time of the image acquisition module at the detection end. For example, if the camera's frame rate is 80fps, the image acquisition time of the image acquisition module at the detection end is approximately 12.5ms. Then, by selecting a typical alumina ring image sample, the image processing algorithm is run N times (N ≥ 1000), and the execution time is recorded each time. The average value is taken as the time required for the image processing module to process and analyze the image. Finally, the two calculated times are added together to obtain the workpiece imaging and processing time.

[0027] The alumina ring defect detection device is an automated inspection equipment based on machine vision. It consists of an image acquisition module at the sample inlet, a conveyor belt at the sample inlet, a sorting component, a mixed sample rejection component, a defect detection end, an image acquisition module at the detection end, an image processing module, a waste recycling area, a normal workpiece recycling area, and a communication module. After the alumina ring defect detection device is started, the image acquisition module at the sample inlet acquires images of the alumina rings on the conveyor belt and transmits these images to the processing terminal for analysis. This analysis determines the operating speed of the conveyor belt and controls it to transport the alumina rings to the sorting component. Simultaneously, when a defect ring enters the conveyor belt... When there is mixing of alumina rings, the mixing rejection component located at the sorting assembly starts working. The image acquisition module in the sorting assembly screens the alumina rings of this cycle one by one according to the determined size of the reference alumina ring. Alumina rings whose size is inconsistent with the reference alumina ring are sorted to the waste recycling area by the rejection module. The sorting assembly is controlled to sort the alumina rings without mixing at a determined frequency, so that the alumina rings enter the defect detection end one by one. The image acquisition module at the detection end detects the alumina rings and sorts the defective alumina rings to the waste recycling area according to the detection results, while the normal alumina rings are sorted to the normal workpiece recycling area.

[0028] The sample inlet image acquisition module is a module installed directly above the midpoint of the sample inlet conveyor belt in the alumina ring defect detection device. It is used to acquire images of the alumina rings entering the sample inlet to determine the size of the alumina rings within a cycle. It mainly consists of an industrial camera and a communication module. After the alumina ring defect detection device starts working, the sample inlet image acquisition module takes pictures of the sample inlet conveyor belt according to the set shooting cycle and sends the captured pictures to the processing terminal. The processing terminal then analyzes and processes the images to obtain the size and quantity of the workpieces in the current cycle.

[0029] The sample inlet conveyor belt is an adjustable speed component used to carry alumina rings and sequentially pass them through the sample inlet image acquisition module, sorting component, mixed sample rejection component, and defect detection end. It mainly consists of the conveyor belt body, drive motor, and communication module. After the processing terminal determines the conveying speed of the sample inlet conveyor belt, the processing terminal controls the drive motor to operate according to the conveying speed, so that the sample inlet conveyor belt runs at the set speed. This avoids blurry or missed images in the image acquisition module of the detection end due to speed mismatch after the alumina ring enters the detection area, thereby improving the accuracy of the alumina ring defect detection device in detecting alumina rings.

[0030] The sorting assembly is a module used to feed alumina rings one by one into the defect detection end at a calculated frequency, ensuring that the alumina rings enter the defect detection end at a fixed interval, thus preventing workpiece charging or accumulation. It mainly consists of a sorting fork, a stepper motor, a position sensor, and a communication module. After receiving the calculated frequency and start-up command from the processing terminal, it controls the sorting fork to perform periodic movements at the calculated frequency, so that only one alumina ring passes through in one operation cycle, thereby ensuring that the two alumina rings maintain a fixed interval and avoiding overlapping or accumulation.

[0031] The mixed sample rejection component is a module used to remove alumina rings that do not conform to the determined target size from the workpiece during the sorting process. It consists of an image acquisition module, a pneumatic pusher, a recovery channel, and a communication module. While the sorting component is working, if the mixed sample rejection component receives a work instruction from the processing terminal, it controls the image acquisition module to take real-time pictures of each alumina ring. The image processing module then analyzes and processes the acquired images to obtain the actual size of the current workpiece and compares the actual size with the determined target size to obtain the size detection result of the alumina ring. Based on the size detection result, the processing terminal pushes the alumina rings that do not conform to the target size into the recovery channel via the pneumatic pusher. The alumina rings then enter the waste recycling area for recycling, while the alumina rings that conform to the target size continue to move forward with the conveyor belt and enter the defect detection end through the sorting component.

[0032] The defect detection end refers to the area used for defect detection of the sorted alumina rings. It mainly consists of an image acquisition module, a position sensor, a multi-angle light source module, a waste recycling area, a normal workpiece recycling area, and a communication module. When the position sensor acquires the signal of the arrival of the alumina ring, it sends the signal to the image acquisition module and the multi-angle light source module through the communication module. The image acquisition module then takes pictures of the alumina ring from different angles, and controls the multi-angle light source module to start illumination, thereby providing lighting conditions for the image acquisition module so that various defects of the alumina ring can be clearly displayed. The captured images are then input into the image processing module for image processing to obtain the defect detection results of the alumina ring. Based on the defect detection results, the alumina rings are then sorted into the normal workpiece recycling area or the waste recycling area to realize defect detection of alumina rings in this cycle and to remove unqualified alumina rings.

[0033] The image acquisition module at the inspection end is used to detect linear defects such as notches, chipped corners, scratches, cracks, and wear on alumina rings. It mainly consists of a high-resolution industrial camera, an area array industrial camera, and a communication module. After the alumina ring enters the defect detection end, the high-resolution industrial camera and the area array industrial camera installed above and on the side of the conveyor belt acquire images of the alumina ring. The image processing module then analyzes and processes the acquired images to obtain the defect detection results. Based on the defect detection results, each alumina ring is judged as qualified or unqualified, thereby realizing the defect detection of alumina rings.

[0034] The image processing module is used to process and analyze acquired images. It mainly consists of various image processing functions. When processing and analyzing images acquired by the sample acquisition module or the mixed sample rejection component, the image preprocessing module first converts color images to grayscale to reduce data volume, uses Gaussian filtering to remove image noise, adjusts contrast and brightness to highlight workpiece edges and defect features, and corrects image distortion caused by lens distortion or workpiece position offset. Then, the station positioning and segmentation module uses the Canny function to detect the edges of the alumina rings and separate them from the background. The sample acquisition dimension measurement and statistics module extracts the outer contour and inner hole contour of the alumina rings, calculates the outer diameter, inner diameter, roundness, and thickness of the alumina rings using geometric parameter calculation functions, and statistically counts the alumina rings present in the image. Finally, the outer diameter, inner diameter, roundness, thickness of the alumina rings, and the number of workpieces in this cycle are output and processed through the processing terminal. The outer diameter, inner diameter, roundness, and thickness of the alumina ring are summarized to obtain the workpiece dimensions for this cycle. When processing the images acquired by the image acquisition module at the detection end, the image preprocessing module in the image processing module converts the color image into a grayscale image, uses a median filter function to remove image noise, adjusts contrast and brightness to highlight the edge and defect features of the alumina ring, and corrects image distortion caused by lens distortion or workpiece position offset. Then, the station positioning and segmentation module uses the Canny function to detect the edge of the alumina ring and separate the alumina ring from the background. The defect recognition module uses grayscale gradient analysis, filtering enhancement, and other functions to identify linear defects, uses morphological processing, edge tracking, and other methods to identify fine cracks, and analyzes edge continuity to identify edge missing areas. Finally, the analyzed defect recognition results are output to the processing terminal to obtain the defect detection results for each alumina ring, and then the alumina rings are classified according to the defect detection results.

[0035] The waste recycling area is used to collect mixed workpieces rejected by the mixed sample rejection component and defective workpieces rejected by the defect detection end. It mainly consists of a recycling bin and a guide slide. The waste recycling area is connected to the workpiece scratch detection component and the defect detection end. The mixed workpieces rejected by the mixed sample rejection component are slid into the recycling bin through the guide slide to collect the mixed alumina rings in this cycle. The unqualified alumina rings detected by the image acquisition module at the detection end are slid into the recycling bin through the guide slide to collect the defective alumina rings in this cycle.

[0036] The normal workpiece recycling area is a module used to collect alumina rings that have passed the inspection of the image acquisition module at the detection end. It mainly consists of a recycling bin and a guide slide. The normal workpiece recycling area is connected to the end of the defect detection end. The qualified alumina rings detected by the image acquisition module at the detection end are slid into the recycling bin through the guide slide to complete the defect detection of the alumina rings in that cycle.

[0037] Alumina rings are industrial ceramic components widely used in electronics, chemical industry, machinery and other fields. They have smooth and flat surfaces, are free of cracks, defects or protrusions, and have regular ring shapes.

[0038] Step S101: Analyze the workpiece size, workpiece quantity, and preset historical benchmark workpiece size in this cycle to generate the corresponding relationship between the proportion of matching workpieces in this cycle and the proportion of workpiece size in this cycle.

[0039] The "matching workpiece ratio in this cycle" refers to the proportion of alumina rings whose dimensions match the historical benchmark workpiece size within the total number of workpieces in this cycle. The "workpiece size ratio correspondence in this cycle" refers to the correspondence between the proportion of alumina rings of each size within the total number of workpieces in this cycle and the size of the alumina rings present in this cycle. By analyzing the workpiece size, the total number of workpieces in this cycle, and the historical benchmark workpiece size through the processing terminal, the matching workpiece ratio and the workpiece size ratio correspondence in this cycle can be obtained, thus providing data support for subsequently determining the benchmark workpiece size for this cycle.

[0040] The historical reference workpiece size refers to the size of the alumina ring used as a reference in the previous cycle, which is obtained by searching the historical data through the processing terminal.

[0041] Historical data refers to the data set used to store the relevant setting parameters of each module of the alumina ring defect detection device during the defect detection process.

[0042] Step S102: Determine whether the proportion of matched workpieces in this cycle meets the preset requirement of the proportion of workpieces without mixing.

[0043] Among them, the proportion of no mixed samples refers to the proportion when the proportion of matched workpieces in this cycle is 100%. The requirement for the proportion of no mixed samples means that when there is no mixing of alumina rings entering the sample feeding end conveyor belt, the proportion of matched workpieces in this cycle is 100%.

[0044] By processing the terminal to determine whether the proportion of matched workpieces in this cycle meets the requirement of no mixed workpieces, it can be determined whether there is a mixed sample situation in the alumina rings entering the sample feeding end conveyor belt in this cycle.

[0045] Step S1021: If satisfied, the preset no-mixing test result is determined as the mixed-sample test result at the injection end.

[0046] If the processing terminal determines that the proportion of matched workpieces in this cycle meets the requirement of the proportion of workpieces without mixing, it means that there is no mixing of alumina rings entering the sample feeding end conveyor belt in this cycle. Therefore, the processing terminal determines the no-mixing detection result, thereby providing data support for the subsequent control of the mixing rejection component in the alumina ring defect detection device to perform mixing rejection.

[0047] The sample mixing detection result at the injection end refers to the signal that reflects whether there is a mixture of samples in the alumina rings put in during this cycle, that is, whether there are alumina rings of other sizes in the alumina rings. The no-mixing detection result is determined by the processing terminal as the sample mixing detection result at the injection end, and then used as a command signal to control the mixing rejection component in the alumina ring defect detection device.

[0048] The no-mixing test result refers to a signal that indicates there is no mixing of samples in the alumina rings placed in this cycle.

[0049] The alumina ring defect detection device and mixed sample rejection assembly in this step are the same as those in step S100 above, and will not be described again here.

[0050] Step S10211: Determine the historical reference workpiece size and the preset historical sample inlet conveying speed as the actual reference workpiece size and the actual sample inlet conveying speed, respectively. Based on the sample mixing test results at the sample inlet, the actual reference workpiece size, and the actual sample inlet conveying speed, control the preset alumina ring defect detection device to perform defect detection on the alumina ring, so as to generate a qualified alumina ring.

[0051] Among them, a qualified alumina ring refers to an alumina ring that has no defects after being inspected by an alumina ring defect detection device. The actual reference workpiece size and the actual sample inlet conveying speed are determined by the processing terminal. Based on the mixed sample detection results at the sample inlet, the actual reference workpiece size, and the actual sample inlet conveying speed, the alumina ring defect detection device is controlled to perform defect detection on the alumina ring, thus obtaining a qualified alumina ring. The specific method is described in [reference needed]. Figure 3 This process improves the accuracy of detecting defects in alumina rings.

[0052] Historical sample inlet conveyor speed refers to the conveyor speed of the sample inlet conveyor belt in the previous cycle, which can be obtained by searching the historical data through the processing terminal.

[0053] The actual reference workpiece size refers to the size of the alumina ring used as a reference in this cycle; the actual sample inlet conveyor speed refers to the conveyor speed of the sample inlet conveyor belt in this cycle. The actual reference workpiece size is determined by the processing terminal, and the actual sample inlet conveyor speed is determined by the historical sample inlet conveyor speed.

[0054] The alumina ring defect detection device in this step is the same as the alumina ring defect detection device in step S100 above, and will not be described again here.

[0055] Step S1022: If not satisfied, the preset mixed sample result is determined as the mixed sample detection result at the injection end. Based on the workpiece size ratio correspondence in this cycle and the mixed sample detection result at the injection end, the preset alumina ring defect detection device is controlled to perform mixed sample rejection and defect detection on the preset alumina ring to generate a qualified alumina ring.

[0056] If the processing terminal determines that the proportion of matched workpieces in this cycle meets the requirement of the proportion of workpieces without mixing, it means that there is no mixing of alumina rings entering the conveyor belt at the injection end in this cycle. Therefore, the mixing result is determined by the processing terminal as the mixing detection result at the injection end.

[0057] A mixed sample result indicates that there is a mixed sample situation in the alumina rings put in during this cycle, that is, there is a signal that there are alumina rings of other sizes in the alumina rings.

[0058] The sample mixing test results at the injection end in this step are consistent with the sample mixing test results at the injection end in step S1021 above. The alumina ring and alumina ring defect detection device in this step are consistent with the alumina ring and alumina ring defect detection device in step S100 above, and will not be described again here.

[0059] Reference Figure 2 The steps for analyzing the workpiece size, workpiece quantity, and preset historical baseline workpiece size in this cycle to generate the corresponding relationship between the workpiece proportion and workpiece size proportion in this cycle include: Step S200: Statistically count the dimensions of the workpieces in this cycle to generate the quantity of workpieces of each size.

[0060] The quantity of workpieces of each size refers to the number of alumina rings in the workpiece size of this cycle that have the same outer diameter, inner diameter, roundness, and thickness. The processing terminal compares the outer diameter, inner diameter, roundness, and thickness of each alumina ring in the workpiece size of this cycle with the outer diameter, inner diameter, roundness, and thickness of all other alumina rings. Workpiece sizes of alumina rings with corresponding parameter errors not exceeding ±0.05mm are grouped into one category. After all alumina rings in this cycle have been compared, the workpiece sizes of alumina rings in each category are statistically counted to obtain the quantity of workpieces of each size.

[0061] Step S201: Calculate the ratio between the number of workpieces of each size and the number of workpieces in this cycle to generate the proportion of workpieces of each size.

[0062] The percentage of workpieces of each size refers to the proportion of each size of alumina ring in the total number of workpieces in this cycle. The percentage of workpieces of each size is obtained by dividing the number of workpieces of each size by the total number of workpieces in this cycle through the processing terminal, and then summing up all the calculated proportions.

[0063] Step S202: Match the proportion of each size of workpiece with the size of the workpiece in this cycle to generate the corresponding relationship of the proportion of workpiece size in this cycle.

[0064] In this step, the corresponding relationship of the workpiece size ratio in this cycle is consistent with the corresponding relationship of the workpiece size ratio in this cycle in step S101 above. By processing the terminal to form a mapping table by matching the proportion of each size of workpiece with the corresponding workpiece size in this cycle, the corresponding relationship of the workpiece size ratio in this cycle can be obtained.

[0065] Step S203: Find the proportion of matching workpieces in the current cycle based on the historical benchmark workpiece size proportion relationship.

[0066] In this step, the proportion of matching workpieces in this cycle is consistent with the proportion of matching workpieces in this cycle in step S101 above. The processing terminal searches according to the historical reference workpiece size and the corresponding relationship of workpiece size proportion in this cycle, and determines the proportion of each size of workpiece corresponding to the workpiece size in this cycle that is consistent with the historical reference workpiece size as the proportion of matching workpieces in this cycle.

[0067] Reference Figure 3 The steps for generating qualified alumina rings by controlling a preset alumina ring defect detection device to perform defect detection on the alumina rings based on the mixed sample detection results at the injection end, the actual reference workpiece size, and the actual injection end conveying speed include: Step S300: Control the movement of the sample inlet conveyor belt according to the actual sample inlet conveying speed.

[0068] In this process, after the processing terminal determines the actual sample inlet conveyor speed, it controls the conveyor speed of the sample inlet conveyor belt based on the actual sample inlet conveyor speed. This allows the alumina rings to be conveyed to the sorting component, and in conjunction with the sorting component, the alumina rings enter the defect detection end one by one for defect detection. This avoids situations where two adjacent alumina rings are too close or too far apart, resulting in unclear images or empty detections by the image acquisition module at the detection end, thereby improving the accuracy of the detection results.

[0069] Step S301: Locate the outer diameter of the actual reference workpiece in the actual reference workpiece dimensions.

[0070] The actual reference workpiece outer diameter refers to the maximum diameter of the actual reference alumina ring. The actual reference workpiece outer diameter can be obtained by searching for it in the actual reference workpiece dimensions through the processing terminal.

[0071] Step S302: Calculate the product between the actual reference workpiece outer diameter and the preset safety detection workpiece spacing parameter to generate the safety distance between workpieces.

[0072] The safe distance between workpieces refers to the distance that two adjacent alumina rings need to maintain when entering the defect detection end for defect detection, in order to avoid the situation where the distance between two adjacent alumina rings is too close or too far, resulting in unclear images or missed images captured by the image acquisition module of the detection end. The safe distance between workpieces can be obtained by multiplying the actual outer diameter of the reference workpiece by the safe detection workpiece spacing parameter through the processing terminal.

[0073] The safety inspection workpiece spacing parameter refers to the parameter set to avoid collisions or contact between two adjacent alumina rings, which could cause damage to the alumina rings, and to allow time for image acquisition and processing by the image acquisition module at the detection end, so as to avoid missed shots or unclear images. In one embodiment, the safety inspection workpiece spacing is 1.3.

[0074] Step S303: Calculate the product between the actual sample inlet conveying speed and the preset workpiece imaging and processing time to generate the workpiece imaging and processing reserved distance.

[0075] The workpiece imaging processing reserved distance refers to the distance the alumina ring moves at a constant speed during the workpiece imaging processing time when it enters the defect detection end for defect detection. The workpiece imaging processing reserved distance can be obtained by multiplying the actual sample inlet conveying speed by the workpiece imaging processing time through the processing terminal.

[0076] The workpiece imaging and processing time refers to the time required for the image acquisition module at the detection end to acquire an image, transmit the image to the image processing module, and process and analyze the image. In one embodiment, the operator finds the camera's frame rate in the technical manual based on the camera model in the image acquisition module at the detection end, and calculates the reciprocal of the frame rate to obtain the image acquisition time of the image acquisition module at the detection end. For example, if the camera's frame rate is 70fps, the image acquisition time of the image acquisition module at the detection end is approximately 14.3ms. Then, by selecting a typical alumina ring image sample, the image processing algorithm is run N times (N ≥ 1000), and the execution time is recorded each time. The average value is taken as the time required for the image processing module to process and analyze the image. Finally, the two calculated times are added together to obtain the workpiece imaging and processing time.

[0077] Step S304: Calculate the sum between the safe distance between workpieces and the reserved distance for workpiece shooting and processing to generate the workpiece conveying space.

[0078] The workpiece conveying space refers to the distance that two adjacent alumina rings need to maintain to avoid unclear images or empty inspections caused by two adjacent alumina rings being too close or too far apart, and to reserve space for image acquisition and processing by the image acquisition module and image processing module at the detection end. The workpiece conveying space can be obtained by adding the safe distance between the workpieces to the reserved distance for workpiece imaging and processing through the processing terminal.

[0079] Step S305: Calculate the quotient between the actual sample inlet conveying speed and the workpiece conveying space to generate the sorting frequency.

[0080] The sorting frequency refers to the number of sorting cycles per unit time of the sorting component. By adjusting the sorting frequency, the number of alumina rings entering the defect detection end per unit time can be adjusted, thereby avoiding the situation where two adjacent alumina rings are too close or too far apart, resulting in unclear images or empty detection by the image acquisition module at the detection end. The sorting frequency can be obtained by dividing the actual sample feeding end conveying speed by the workpiece conveying space through the processing terminal.

[0081] Step S306: Control the mixed sample rejection component to stop working according to the mixed sample detection result at the injection end, and control the sorting component according to the sorting frequency to make the alumina rings enter the defect detection end one by one for defect detection and defect rejection operations, so as to generate qualified alumina rings.

[0082] In this step, the qualified alumina rings are the same as those in step S10211 above. The processing terminal controls the mixed sample rejection component to stop working based on the mixed sample detection results at the sample inlet, and controls the sorting component to allow the alumina rings to enter the defect detection end one by one according to the sorting frequency. Then, the image acquisition module at the detection end acquires images of each alumina ring, and processes the acquired images to obtain the defect detection results. When the defect detection result is a qualified result, the processing terminal sends the alumina ring to the normal workpiece recycling area according to the defect detection result; when the defect detection result is a failed result, the processing terminal sends the alumina ring to the waste recycling area according to the defect detection result, thereby realizing the defect detection and defect rejection functions. Finally, the alumina rings collected at the normal workpiece recycling area are qualified alumina rings. The specific process is the same as the steps in step S100, and will not be repeated here.

[0083] Reference Figure 4 The steps for generating qualified alumina rings include: Based on the corresponding ratio of workpiece size in this cycle and the mixed sample detection results at the injection end, pre-set alumina rings are mixed and rejected; and a pre-set alumina ring defect detection device is controlled to perform defect detection on the alumina rings. Step S400: Sort the proportions of workpieces of each size to generate the maximum workpiece proportion.

[0084] The maximum workpiece percentage refers to the proportion of alumina rings of each size that accounts for the largest share of the total number of workpieces in this cycle and is greater than 50%. The processing terminal sorts the workpiece percentages of each size from largest to smallest, extracts the largest percentage, and compares it with 50%. When it is greater than 50%, the largest percentage is determined as the maximum workpiece percentage. Determining the maximum workpiece percentage provides data support for subsequently determining the actual reference workpiece size. When it is greater than 50%, it indicates that there are too many alumina rings of different sizes mixed in this cycle, and it is impossible to determine the actual alumina ring that needs to be detected. Therefore, the processing terminal sends a signal to stop the alumina ring defect detection device from working. The device will only start working again after the operator determines the actual reference workpiece size.

[0085] Step S401: Find the undetermined reference workpiece size in the workpiece size ratio correspondence relationship in this cycle based on the maximum workpiece ratio.

[0086] Among them, the size of the workpiece to be determined refers to the size of the alumina ring with the largest proportion among the proportions of workpieces of various sizes. The size of the workpiece to be determined can be obtained by searching the corresponding relationship of the proportion of the largest workpiece in the current cycle by the processing terminal.

[0087] Step S402: Determine the size of the workpiece to be referenced as the actual size of the workpiece.

[0088] In this step, the actual reference workpiece size is consistent with the actual reference workpiece size in step S10211 above. The size of the workpiece to be determined is determined as the actual reference workpiece size by the processing terminal, thereby providing data support for determining the actual sample inlet conveying speed based on the actual reference workpiece size.

[0089] Step S403: Analyze the actual reference workpiece size and historical sample inlet conveying speed to generate the actual sample inlet conveying speed.

[0090] In this step, the actual sample inlet conveyor speed is consistent with the actual sample inlet conveyor speed in step S10211 above. The actual sample inlet conveyor speed can be obtained by analyzing the actual reference workpiece size and historical sample inlet conveyor speeds using a processing terminal. For specific methods, refer to [reference needed]. Figure 5 This process provides data support for controlling the movement of the sample inlet conveyor belt based on the actual sample inlet conveyor speed.

[0091] Step S404: Control the movement of the sample inlet conveyor belt according to the actual sample inlet conveying speed, and control the sorting component and the mixed sample rejection component to perform mixed sample rejection and sorting of the alumina ring according to the sample inlet mixed sample detection results, the actual sample inlet conveying speed and the actual reference workpiece size, so as to generate the actual alumina ring to be tested.

[0092] In this process, after the processing terminal determines the actual sample inlet conveyor speed, it controls the movement of the sample inlet conveyor belt according to the actual sample inlet conveyor speed and determines the actual alumina ring to be tested. This provides support for the subsequent processing terminal to control the defect detection end to perform defect detection and defect removal operations on the actual alumina ring to be tested to obtain a qualified alumina ring.

[0093] The actual alumina ring to be tested refers to the alumina ring after other sizes of alumina rings have been removed by the mixed sample rejection component. The processing terminal controls the sorting and mixed sample rejection components to perform mixed sample rejection and sorting based on the mixed sample detection results at the sample inlet, the actual sample inlet conveying speed, and the actual reference workpiece size. The actual alumina ring to be tested is then obtained. For specific methods, please refer to [link to relevant documentation]. Figure 6 This process provides support for subsequently transmitting the actual alumina ring to be tested to the defect detection end for defect detection.

[0094] Step S405: Control the defect detection end to perform defect detection and defect removal operations on the actual alumina ring to be tested, so as to generate a qualified alumina ring.

[0095] In this step, the qualified alumina ring is the same as the qualified alumina ring in step S10211 above. The qualified alumina ring is obtained by controlling the defect detection end of the processing terminal to perform defect detection and defect removal operations on the actual alumina ring to be tested. The specific method is as follows: Figure 7 This process involves several steps to detect defects in alumina rings.

[0096] Reference Figure 5 The steps for generating the actual sample inlet conveyor speed by analyzing the actual reference workpiece dimensions and historical sample inlet conveyor speeds include: Step S500: Substitute the actual reference workpiece dimensions into the preset workpiece volume calculation formula to generate the reference workpiece volume.

[0097] The reference workpiece volume refers to the standard volume of the alumina ring that actually needs to be inspected for defects. The processing terminal finds the workpiece's inner diameter, outer diameter, and thickness from the actual reference workpiece dimensions, and then substitutes these dimensions into the workpiece volume calculation formula. By performing calculations, the volume of the reference workpiece can be obtained, where, This refers to the volume of the reference workpiece. This refers to the thickness of the workpiece. It refers to pi, in For example, =3.14, This refers to the outer diameter of the workpiece. This refers to the inner diameter of the workpiece. The formula for calculating the volume of the workpiece in this step is the same as the formula for calculating the volume of a ring, which is common knowledge in this field and will not be elaborated here.

[0098] Step S501: Calculate the product between the volume of the reference workpiece and the preset alumina ring density to generate the mass of the reference workpiece.

[0099] The reference workpiece mass refers to the standard mass of the alumina ring that actually needs to be inspected for defects. The reference workpiece mass can be obtained by multiplying the volume of the reference workpiece by the density of the alumina ring through the processing terminal.

[0100] The density of alumina rings refers to the mass of alumina rings per unit volume. In one embodiment, it is determined by the operator from the alumina ring material handbook based on the actual reference workpiece dimensions, with an alumina ring density of 3.8 g / cm³. 3 For example.

[0101] Step S502: Calculate the quotient between the difference between the reference workpiece mass and the preset workpiece reference mass and the preset unit conversion factor to generate a quality deviation correction factor.

[0102] The mass deviation correction coefficient is used to dynamically compensate the speed of the conveyor belt at the injection end based on the difference between the mass of the reference workpiece and the reference mass of the workpiece, so as to adapt to the conveying stability requirements of alumina rings of different masses. The mass deviation correction coefficient can be obtained by subtracting the reference mass of the workpiece from the mass of the reference workpiece at the processing terminal and dividing the difference by the unit conversion factor.

[0103] The workpiece reference mass refers to a physical quantity used to measure whether the speed of the sample inlet conveyor belt needs to be increased. When the reference workpiece mass is greater than the workpiece reference mass, it indicates that the speed of the sample inlet conveyor belt needs to be increased; when the reference workpiece mass is greater than the workpiece reference mass, it indicates that the speed of the sample inlet conveyor belt needs to be decreased. In one embodiment, the workpiece reference mass is the mass corresponding to the size of the main alumina ring detected by the alumina ring defect detection device. The processing terminal finds the reference workpiece mass corresponding to the actual reference workpiece size of each cycle in the historical data, and classifies and statistically analyzes the reference workpiece mass of each cycle. The most frequently used reference workpiece mass is taken as the workpiece reference mass of this cycle, taking a workpiece reference mass of 50g as an example.

[0104] The unit conversion factor is the conversion factor used to convert the mass unit of alumina rings, grams, to kilograms. Since 1000 grams = 1 kilogram, the unit conversion factor is 1000.

[0105] Step S503: Calculate the product between the quality deviation correction coefficient, the historical sample inlet conveying speed, and the preset workpiece conveying safety factor to generate the sample inlet conveying speed adjustment value.

[0106] The sample inlet conveyor speed adjustment value refers to the speed that the sample inlet conveyor belt needs to be adjusted. The sample inlet conveyor speed adjustment value can be obtained by multiplying the quality deviation correction coefficient, the historical sample inlet conveyor speed, and the workpiece conveying safety factor by the processing terminal.

[0107] The workpiece conveying safety factor refers to the additional compensation ratio for the speed of the conveyor belt at the sample inlet, in order to ensure that the alumina ring does not slip during the conveying process, thereby improving operational stability. In one embodiment, the workpiece conveying safety factor is 1.05.

[0108] Step S504: Calculate the sum between the product of the historical injection end conveying speed and the workpiece conveying safety factor and the injection end conveying speed adjustment value to generate the actual injection end conveying speed.

[0109] In this step, the actual sample inlet conveying speed is the same as that in step S10211 above. The actual sample inlet conveying speed can be obtained by multiplying the historical sample inlet conveying speed and the workpiece conveying safety factor by the processing terminal and then adding it to the sample inlet conveying speed adjustment value.

[0110] Reference Figure 6 The steps for controlling the sorting and mixing rejection components to perform mixing rejection and sorting of alumina rings based on the mixed sample detection results at the injection end, the actual injection end conveying speed, and the actual reference workpiece size, to generate the actual alumina rings to be tested, include: Step S600: Collect the actual workpiece outer diameter, historical average mixed sample rejection time, and safe distance between workpieces at the detection end.

[0111] In this step, the actual workpiece outer diameter is consistent with the actual reference workpiece outer diameter in step S301 above, and the safe distance between the workpieces at the detection end in this step is consistent with the workpiece conveying space in step S304 above, which will not be elaborated here.

[0112] The historical average mixed sample rejection time refers to the average time required for the mixed sample rejection component to reject one alumina ring in the previous cycle. In one embodiment, the historical average mixed sample rejection time can be obtained by processing the terminal to find the total time of a single rejection action recorded in the previous detection cycle with mixed sample conditions in the historical data and calculating the average of all the times.

[0113] Step S601: Calculate the quotient between the safe distance between the workpieces at the detection end and the actual sample feeding end conveying speed to generate the safe time between the workpieces.

[0114] The safe time between workpieces refers to the time interval between the entry of one alumina ring into the defect detection end and the entry of the next alumina ring into the defect detection end when only the sorting component is performing the sorting operation, in order to avoid the situation where two adjacent alumina rings are too close or too far apart, resulting in unclear images or empty detections by the image acquisition module at the detection end.

[0115] Step S602: Calculate the difference between the preset total workpiece ratio and the maximum workpiece ratio to generate the mixed workpiece ratio.

[0116] The mixed sample workpiece ratio refers to the proportion of alumina rings in the current cycle whose size is inconsistent with the actual reference workpiece in the current cycle. The mixed sample workpiece ratio can be obtained by subtracting the maximum workpiece ratio from the total workpiece ratio through the processing terminal.

[0117] The total workpiece percentage refers to the percentage of the number of alumina rings corresponding to the actual reference workpiece size in the total number of workpieces in this cycle when there is no mixing of alumina rings. In one embodiment, the total workpiece percentage is 100%.

[0118] Step S603: Calculate the product between the proportion of mixed workpieces and the historical average mixed rejection time to generate the average mixed rejection time.

[0119] The average mixed sample rejection time refers to the average time required for the mixed sample rejection component to reject one alumina ring in this cycle. The average mixed sample rejection time can be obtained by multiplying the proportion of mixed sample workpieces by the historical average mixed sample rejection time through the processing terminal.

[0120] Step S604: Calculate the sum between the safety time between workpieces, the average mixed sample rejection time, and the preset workpiece shooting time to generate the average time consumed for mixed sample workpieces.

[0121] The average time for mixed-sample workpieces refers to the total time required to complete one sorting and mixed-sample rejection operation. The average time for mixed-sample workpieces can be obtained by adding the safety time between workpieces, the average mixed-sample rejection time, and the workpiece photography time through the processing terminal.

[0122] The workpiece photography time in this step is the same as the workpiece photography processing time in step S303 above, and will not be repeated here.

[0123] Step S605: Calculate the reciprocal of the average time consumed by the mixed sample workpieces to generate the mixed sample sorting frequency.

[0124] The mixed sample sorting frequency refers to the number of sorting times per unit time when there is a mixed sample situation in the alumina rings in the current cycle and the mixed sample rejection component needs to be activated to reject the mixed sample. The mixed sample sorting frequency can reflect the number of alumina rings that can enter the defect detection end per unit time. The mixed sample sorting frequency can be obtained by calculating the reciprocal of the average time spent on mixed sample workpieces by the processing terminal.

[0125] Step S606: Control the sorting component to sort the alumina rings according to the mixed sample sorting frequency, and control the mixed sample rejection component to reject the alumina rings according to the mixed sample detection results at the injection end and the actual reference workpiece size, so as to generate the actual alumina ring to be tested.

[0126] In this step, the actual alumina ring to be tested is the same as the actual alumina ring to be tested in step S404 above. The processing terminal controls the sorting component to sort the alumina ring according to the mixed sample sorting frequency, and controls the mixed sample rejection component to reject the alumina ring according to the mixed sample detection results at the sample inlet and the actual reference workpiece size, so as to obtain the actual alumina ring to be tested. The specific method is the same as that in step S100 above, and will not be repeated here.

[0127] Reference Figure 7 The steps for controlling the defect detection end to perform defect detection and defect removal operations on the actual alumina ring to be tested in order to generate qualified alumina rings include: Step S700: Control the image acquisition module at the detection end to capture images of the actual alumina ring to be detected, so as to generate a workpiece detection image.

[0128] Among them, the workpiece inspection image refers to the image of the alumina ring acquired by the image acquisition module of the detection end. The workpiece inspection image can be obtained by controlling the image acquisition module of the detection end to take a picture of the actual alumina ring to be inspected through the processing terminal.

[0129] Step S701: Input the workpiece inspection image into the image processing module for analysis to generate workpiece inspection results.

[0130] The workpiece inspection result refers to the signal used to reflect whether there are defects in the alumina ring, thereby determining whether the alumina ring needs to be removed. The workpiece inspection image is input into the image processing module through the processing terminal for processing and analysis to obtain the workpiece inspection result. The specific method is the same as in step S100 above, and will not be repeated here.

[0131] Step S702: Based on the workpiece inspection results, the actual alumina rings to be inspected are rejected to generate qualified alumina rings.

[0132] In this step, the qualified alumina ring is the same as the qualified alumina ring in step S10211 above. The actual alumina ring to be tested is removed by the processing terminal according to the workpiece detection result, and the qualified alumina ring can be obtained. The specific method is the same as that in step S100 above, and will not be repeated here.

[0133] Based on the same inventive concept, embodiments of this application provide an alumina ring defect detection system, comprising: The data acquisition module is used to collect data on the workpiece size, number of workpieces in the current cycle, actual workpiece outer diameter, historical average mixed sample rejection time, and safe distance between workpieces at the detection end. A memory for storing a program for detecting alumina ring defects; The processor and memory can load and execute programs to implement a method for detecting defects in alumina rings.

[0134] Those skilled in the art will clearly understand that, for the sake of convenience and brevity, the above-described division of functional modules is used as an example. In practical applications, the above functions can be assigned to different functional modules as needed, that is, the internal structure of the device can be divided into different functional modules to complete all or part of the functions described above. The specific working process of the system, device, and unit described above can be referred to the corresponding process in the foregoing method embodiments, and will not be repeated here.

[0135] This application provides a computer-readable storage medium storing a computer program that can be loaded by a processor and executed as a method for detecting alumina ring defects.

[0136] Computer storage media include, for example, USB flash drives, portable hard drives, read-only memory (ROM), random access memory (RAM), magnetic disks, optical disks, and other media that can store program code.

[0137] Based on the same inventive concept, embodiments of this application provide a smart terminal, including a memory and a processor, wherein the memory stores a computer program that can be loaded and executed by the processor to perform a method for detecting alumina ring defects.

[0138] Those skilled in the art will clearly understand that, for the sake of convenience and brevity, the above-described division of functional modules is used as an example. In practical applications, the above functions can be assigned to different functional modules as needed, that is, the internal structure of the device can be divided into different functional modules to complete all or part of the functions described above. The specific working process of the system, device, and unit described above can be referred to the corresponding process in the foregoing method embodiments, and will not be repeated here.

[0139] The above are all preferred embodiments of this application and are not intended to limit the scope of protection of this application. Any feature disclosed in this specification (including the abstract and drawings) may be replaced by other equivalent or similar features unless specifically stated otherwise. That is, unless specifically stated otherwise, each feature is only one example of a series of equivalent or similar features.

Claims

1. A method for detecting defects in alumina rings, characterized in that, include: The preset image acquisition module at the injection end is controlled to acquire the workpiece size and the number of workpieces in the current cycle on the preset injection end conveyor belt. The workpiece size, workpiece quantity, and preset historical benchmark workpiece size are analyzed to generate the corresponding relationship between the proportion of matching workpieces in this cycle and the proportion of workpiece size in this cycle. Determine whether the proportion of matched workpieces in this cycle meets the preset requirement for the proportion of workpieces without mixed samples; If the conditions are met, the preset no-mixing test result will be determined as the mixed-sample test result at the injection end. The historical reference workpiece size and the preset historical sample inlet conveying speed are respectively determined as the actual reference workpiece size and the actual sample inlet conveying speed. Based on the sample mixing test results at the sample inlet, the actual reference workpiece size and the actual sample inlet conveying speed, the preset alumina ring defect detection device is controlled to perform defect detection on the alumina ring in order to generate qualified alumina rings. If the conditions are not met, the preset mixed sample result will be determined as the mixed sample detection result at the injection end. Based on the corresponding relationship of the workpiece size ratio in this cycle and the mixed sample detection result at the injection end, the preset alumina ring defect detection device will be controlled to perform mixed sample rejection and defect detection on the preset alumina ring in order to generate qualified alumina ring. The alumina ring defect detection device includes a sorting component, a mixed sample rejection component, and a defect detection end. The steps of rejecting preset alumina rings based on the workpiece size ratio in the current cycle and the mixed sample detection results at the injection end, and controlling the preset alumina ring defect detection device to perform defect detection on the alumina rings to generate qualified alumina rings, include: Sort the proportions of workpieces of different sizes to generate the largest workpiece proportion; The reference workpiece size is determined based on the correspondence between the largest workpiece proportion and the workpiece size proportion in this cycle. The dimensions of the workpiece to be determined are set as the actual dimensions of the workpiece. The actual reference workpiece size and historical sample inlet conveyor speed are analyzed to generate the actual sample inlet conveyor speed. The movement of the sample inlet conveyor belt is controlled according to the actual sample inlet conveying speed, and the sorting component and the mixed sample rejection component are controlled according to the sample inlet mixed sample detection results, the actual sample inlet conveying speed and the actual reference workpiece size to perform mixed sample rejection and sorting of alumina rings, so as to generate actual alumina rings to be tested. The defect detection end controls the actual alumina ring to be tested to perform defect detection and defect removal operations to generate qualified alumina rings; The steps for controlling the sorting and mixing rejection components to perform mixed sample rejection and sorting of alumina rings based on the mixed sample detection results at the injection end, the actual injection end conveying speed, and the actual reference workpiece size, to generate the actual alumina rings to be tested, include: Collect actual workpiece outer diameter, historical average mixed sample rejection time, and safe distance between workpieces at the inspection end; Calculate the quotient between the safe distance between the workpieces at the detection end and the actual sample delivery speed at the injection end to generate the safe time between the workpieces; Calculate the difference between the preset total workpiece ratio and the maximum workpiece ratio to generate the mixed workpiece ratio; Calculate the product between the percentage of mixed samples and the historical average mixed sample rejection time to generate the average mixed sample rejection time; Calculate the sum between the safety time between workpieces, the average mixed sample rejection time, and the preset workpiece shooting time to generate the average time spent on mixed workpieces; Calculate the reciprocal of the average time spent on mixed-sample workpieces to generate the mixed-sample sorting frequency; The alumina rings are sorted by the sorting component according to the mixed sample sorting frequency, and the alumina rings are rejected by the mixed sample rejection component according to the mixed sample detection results at the injection end and the actual reference workpiece size, so as to generate the actual alumina rings to be tested.

2. The method for detecting alumina ring defects according to claim 1, characterized in that, The steps for analyzing the workpiece size, workpiece quantity, and preset historical baseline workpiece size in this cycle to generate the corresponding relationship between the workpiece proportion and workpiece size proportion in this cycle include: The dimensions of the workpieces in this cycle are statistically counted to generate the quantity of workpieces of each size; Calculate the ratio between the number of workpieces of each size and the number of workpieces in this cycle to generate the proportion of workpieces of each size; The proportion of each size of workpiece is matched one-to-one with the size of the workpiece in this cycle to generate the corresponding relationship of the proportion of workpiece size in this cycle. The proportion of matching workpieces in the current period is found by referring to the historical benchmark workpiece size proportion relationship.

3. The method for detecting alumina ring defects according to claim 1, characterized in that, The alumina ring defect detection device includes a sorting component, a mixed sample rejection component, and a defect detection end. The steps for controlling the preset alumina ring defect detection device to perform defect detection on the alumina rings to generate qualified alumina rings, based on the mixed sample detection results at the injection end, the actual reference workpiece size, and the actual injection end conveying speed, include: The movement of the sample inlet conveyor belt is controlled according to the actual sample inlet conveying speed. Find the outer diameter of the actual reference workpiece from the actual reference workpiece dimensions; Calculate the product between the actual reference workpiece outer diameter and the preset safety detection workpiece spacing parameter to generate the safety distance between workpieces; Calculate the product between the actual sample inlet conveying speed and the preset workpiece imaging and processing time to generate the workpiece imaging and processing reserved distance; Calculate the sum of the safe distance between workpieces and the reserved distance for workpiece shooting and processing to generate the workpiece conveying space; Calculate the quotient between the actual sample inlet conveying speed and the workpiece conveying space to generate the sorting frequency; Based on the mixed sample detection results at the injection end, the mixed sample rejection component is controlled to stop working, and based on the sorting frequency, the sorting component is controlled to allow the alumina rings to enter the defect detection end one by one for defect detection and defect rejection operations, so as to generate qualified alumina rings.

4. The method for detecting alumina ring defects according to claim 1, characterized in that, The steps for generating the actual infeed end conveyor speed by analyzing the actual reference workpiece dimensions and historical infeed end conveyor speeds include: The actual reference workpiece dimensions are substituted into the preset workpiece volume calculation formula to generate the reference workpiece volume. Calculate the product between the volume of the reference workpiece and the preset alumina ring density to generate the mass of the reference workpiece; The quotient between the difference between the benchmark workpiece mass and the preset workpiece reference mass and the preset unit conversion factor is calculated to generate the quality deviation correction factor. The product of the quality deviation correction factor, the historical inlet conveyor speed, and the preset workpiece conveyor safety factor is calculated to generate the inlet conveyor speed adjustment value. The product of the historical inlet conveyor speed and the workpiece conveyor safety factor is calculated and summed with the inlet conveyor speed adjustment value to generate the actual inlet conveyor speed.

5. The method for detecting alumina ring defects according to claim 1, characterized in that, The alumina ring defect detection device includes a detection end image acquisition module and an image processing module. The steps of controlling the defect detection end to perform defect detection and defect removal operations on the actual alumina ring to be detected, so as to generate a qualified alumina ring, include: The control detection end image acquisition module captures images of the actual alumina ring to be inspected, in order to generate workpiece inspection images; The workpiece inspection image is input into the image processing module for analysis to generate the workpiece inspection result; Based on the workpiece inspection results, the actual alumina rings to be inspected are rejected in order to generate qualified alumina rings.

6. A system for detecting defects in alumina rings, characterized in that, include: The data acquisition module is used to acquire the dimensions and quantity of workpieces in the current cycle. A memory for storing a program for an alumina ring defect detection method as described in any one of claims 1 to 5; The processor and the program in the memory can be loaded and executed by the processor to implement the aforementioned method for detecting alumina ring defects.

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