A folding strip stacking integrated device and visual detection closed-loop control method

Abstract

The application belongs to the technical field of resistor manufacturing, and particularly relates to a folding and stacking integrated device, which comprises a rack, the top of the rack is provided with a piece suction mechanism, a folding mechanism, a strip suction mechanism, a vibration disc, a straight vibration feeder, a detection mechanism and a stacking mechanism arranged in sequence, wherein the piece suction mechanism is used for grabbing workpiece strips piece by piece and transferring the workpiece strips to a folding station; the folding mechanism is used for applying force to the joints of the workpiece strips to break the workpiece strips; and the strip suction mechanism is used for transferring the broken workpiece strips. The application constructs a full-automatic closed-loop production line for feeding, folding, quality inspection and stacking: closed-loop lifting and air blowing are used to prevent adhesion and ensure stable feeding; high-efficiency breaking is realized by combining double-side pinch feeding with longitudinal pressure applied by a pressure roller, visual monitoring is used to synchronously control the rhythm, three-level visual detection is used to close-loop correct the misalignment amount to adapt to the material quality, and automatic frame changing and vibration feeding are matched with layer-by-layer leveling to ensure continuous and stable operation.

Description

Technical Field

[0001] This invention relates to the field of resistor manufacturing technology, and in particular to an integrated equipment for folding and stacking strips and a closed-loop control method for visual inspection. Background Technology

[0002] In the manufacturing process of electronic components, the chip resistors used in electronic substrates are usually produced in an array strip form, with each chip resistor separated by fold lines. Subsequent folding processes are required to separate them into individual units. Traditional folding equipment often uses fixed-gap rolling or punching methods, and the relative position of the pressure roller and the base is difficult to adjust online once set. However, in actual production, different batches of strips to be processed often vary in material hardness, thickness, and residual joint strength. Folding with fixed parameters easily leads to quality problems such as under-folding (incomplete joint breakage), over-folding (cracks in the main body), or misalignment. Furthermore, after folding, traditional equipment typically relies on manual labor or simple suction cups for material transfer and collection, which is not only inefficient but also prone to scattering and mixing of broken components, making it difficult to meet the demands of high-precision, high-efficiency automated production. Especially for small-sized ceramic chip resistors (specifications: L0.40mm×W0.20mm×T0.20mm), due to the narrow folding lines and fragile wafers, existing equipment cannot achieve stable and precise breakage control, resulting in large fluctuations in yield. This requires manual intervention or subsequent sorting and remediation, which seriously restricts the company's production capacity and cost control.

[0003] To address the aforementioned issues, some automated strip folding equipment has emerged in the prior art, achieving a basic automated strip folding process through the cooperation of a feeding mechanism, a picking mechanism, a folding mechanism, and a stacking and receiving mechanism. However, these existing solutions still have significant shortcomings: First, the pressure adjustment of the folding mechanism relies on manual operation and is a static setting, unable to dynamically and adaptively adjust based on real-time feedback from the actual folding effect during continuous production. When the characteristics of incoming material batches fluctuate, the generation of batch defective products cannot be avoided. Second, the receiving stage uses a vacuum adsorption plate to directly place the folded sheets into a tray, and then stacks them by lifting the tray frame. This method has limited efficiency and lacks active leveling of the sheet posture during stacking, easily leading to uneven stacking due to sheet misalignment, affecting the retrieval of subsequent processes. Therefore, this application proposes an integrated strip folding and stacking equipment and a visual inspection closed-loop control method. Summary of the Invention

[0004] To address the shortcomings of existing technologies, this invention proposes an integrated folding and stacking device and a visual inspection closed-loop control method.

[0005] To achieve the above objectives, the present invention adopts the following technical solution: a strip folding and stacking integrated device, comprising a frame, wherein a suction mechanism, a strip folding mechanism, a strip suction mechanism, a vibrating plate, a linear vibrating feeder, a detection mechanism, and a stacking mechanism are sequentially arranged on the top of the frame, wherein: The suction mechanism is used to pick up workpiece strips one by one and transfer them to the folding station; A folding mechanism is used to apply force to break the joint of a workpiece strip. The suction strip mechanism is used to transfer the broken workpiece sheet. Vibratory feeders and linear vibratory feeders are used for screening, reversing, and directional conveying; Inspection agencies are used to perform multi-level visual inspections on sheet materials and provide feedback to adjust folding parameters; Stacking mechanism for automatically stacking and placing qualified sheets; The control system is electrically connected to each mechanism.

[0006] Preferably, the suction mechanism includes a feeding trough, a carrier slidably installed in the feeding trough, an electric push rod two fixed to the bottom of the carrier, a vision sensor five fixed to the top of the feeding trough and a gas nozzle, an electric linear module one and a dual-axis cylinder one and a vacuum suction cup one installed on its slider; the folding mechanism includes a mounting frame one, a conveyor belt one and a conveyor belt two rotatably installed on the mounting frame one, a fixed seat fixed to the mounting frame one, an adjusting seat slidably installed at the bottom of the fixed seat, an electric push rod one fixed to the fixed seat and the piston rod end connected to the adjusting seat, a folding pressure roller rotatably installed on the wheel frame and a compression spring provided on the top of the wheel frame, and a shaft provided on the top of the adjusting seat. The mounting frame one is equipped with a waste tray one and a vision sensor six. The vision sensor six is ​​used to identify workpiece strips on the conveyor belt one whose seams are not broken or broken. The vacuum suction cup one does not grab them and makes them fall into the waste tray one.

[0007] Preferably, a vision sensor is fixed on the mounting frame, located on the side of the conveyor belt two near the suction mechanism and above the horizontal part of the conveyor belt one, for detecting whether there is a workpiece strip on the conveyor belt one, and the control system controls the feeding start and stop of the suction mechanism according to the detection result.

[0008] Preferably, the detection mechanism includes a mounting frame 2, a conveyor belt 3 rotatably mounted on the top of the mounting frame 2, and vision sensors 2, 3, and 4 arranged sequentially along the conveying direction to collect images of the fracture surface of the left seam, the main body area, and the fracture surface of the right seam of the workpiece sheet, respectively; a pneumatic telescopic rod and a waste tray 2 are also fixed on the mounting frame 2, and the pneumatic telescopic rod is used to push the workpiece sheet that is not qualified by the vision sensors 2, 3, and 4 to the waste tray 2.

[0009] Preferably, the stacking mechanism includes a mounting frame three, an electric linear module three fixed on the mounting frame three, a translation plate fixed on the slider of the electric linear module three, multiple placement slots opened on the translation plate, a material frame with a top opening movably installed in the placement slot, and a pneumatic telescopic gripper adapted to the material frame; the detection mechanism also includes a holding rack fixed on the top of the frame and a dual-axis cylinder three fixed on the mounting frame two, the ends of the two piston rods of the dual-axis cylinder three are fixed with pressure blocks adapted to the top opening of the material frame, used to periodically press and level the top layer of sheet material during the stacking process of workpiece sheets.

[0010] A visual inspection closed-loop control method, applied to the aforementioned integrated folding and stacking device, includes the following steps: S1: Image acquisition and pre-inspection are separated. Vision sensors 2, 3 and 4, arranged sequentially along the conveying direction, acquire images of the fracture surface of the left seam of the workpiece sheet, the main area, and the right seam fracture surface, respectively. Vision sensor 6 in the folding mechanism performs pre-inspection of the workpiece strips on conveyor belt 1, identifying strips with unbroken seams or broken pieces. Such strips are directly recycled by waste tray 1 and do not enter the subsequent inspection process. S2: Defect feature extraction and judgment. Defect features are extracted and judged for the three-level images respectively to obtain the state of the left fracture surface, the state of the main area and the state of the right fracture surface. S3: Comprehensive quality grade determination. Based on the three-level determination results of step S2, the folding quality grade of the single workpiece sheet is comprehensively determined. S4: Establish a sliding detection queue to store the quality grade judgment results of N consecutive workpiece sheets and perform trend analysis, where N≥5; S5: Closed-loop adjustment of folding parameters, which performs closed-loop adjustment of folding parameters based on trend analysis results; S6: Verification and Iterative Optimization of Adjustment Effect. After the adjustment action is executed, continue to monitor the detection results of the subsequent M workpiece sheets to verify the adjustment effect and iteratively optimize it, M≥3; unqualified sheets judged by the three-level visual inspection are pushed to the waste tray II by the pneumatic telescopic rod for centralized recycling.

[0011] Preferably, the fracture surface state determination in step S2 includes: extracting the fracture surface contour and calculating the straightness deviation, counting the number and size of residual connection points, and detecting the edge burr height, and determining them as intact, under-folded, over-folded, or burr exceeding the standard, respectively; the quality level in step S3 includes: qualified, under-folded, skewed, over-folded, and seriously unqualified; wherein, the unbroken joints or the whole broken material strips identified by the visual sensor six pre-inspection are directly classified into the seriously unqualified category, recycled by the waste tray one, and do not participate in the sliding detection queue statistics in step S4.

[0012] Preferably, the closed-loop adjustment in step S5 includes: Under-folding trend adjustment: When the proportion of "under-folding" in the sliding detection queue exceeds the first preset threshold T1, the first control signal C1 is sent to the electric push rod of the folding mechanism to drive the adjustment seat to translate in the direction of increasing the misalignment between the folding pressure roller and the shaft. Deflection or over-fracture trend adjustment: When the proportion of "deflection" or "over-fracture" in the sliding detection queue exceeds the second preset threshold T2, a second control signal C2 is sent to the electric push rod of the folding mechanism to drive the adjustment seat to translate in the direction of reducing the misalignment between the folding pressure roller and the shaft. Emergency handling for serious non-conformities: When any workpiece sheet is determined to be "seriously non-conforming", an audible and visual alarm is immediately triggered and the feeding action of the sheet suction mechanism is suspended; at the same time, the seriously non-conforming sheet is pushed to the waste tray two by the pneumatic telescopic rod, and the control system records the event and marks the corresponding adjustment cycle; Hybrid trend coordinated adjustment: When both "under-fracture" and "over-fracture" exist in the sliding detection queue and neither exceeds its respective threshold, if the two types of defects appear alternately, the current parameters are maintained; if they show a unilateral increasing trend, the adjustment is performed according to the type with the larger proportion.

[0013] Preferably, in the under-bending trend adjustment, the single adjustment step size is a preset δ1; in the deflection or over-bending trend adjustment, the single adjustment step size is a preset δ2, and δ1 > δ2.

[0014] Preferably, the adjustment effect verification in step S6 includes: if the defect ratio drops below the preset qualified threshold T0, then the current parameter is locked; If the defect percentage does not improve or continues to worsen, continue adjusting in the same direction until the adjustment stroke limit of electric actuator one is reached. At this point, the system alarm will be triggered, indicating that the mechanical parameters need to be recalibrated. During the verification of the adjustment effect, the pneumatic telescopic rod continuously pushes the defective sheets into the second waste tray. The fullness status of the first and second waste trays is monitored by the control system, and the system issues a tray replacement prompt when either is full.

[0015] Compared with the prior art, the beneficial effects of the present invention are: This invention achieves precise positioning and piece-by-piece separation of workpiece strips through the cooperation of vision sensor five and electric push rod two in the suction mechanism. Combined with the anti-sticking design of the gas nozzle, it effectively avoids the simultaneous adsorption of multiple layers of strips, improving feeding stability. In the folding mechanism, the clamping conveyor belts one and two, along with the longitudinal reverse force structure of the folding pressure roller and shaft, ensure concentrated and uniform force at the joint. The compression spring allows the folding pressure roller to adapt to fluctuations in strip thickness, ensuring dynamic stability of the folding pressure. Vision sensor six on mounting frame one performs pre-inspection of the workpiece strips on conveyor belt one, identifying severely defective strips with unbroken joints or overall breakage in advance and causing them to fall into waste tray one, preventing invalid strips from entering subsequent processes and saving process resources. Vision sensor one provides real-time detection of the status of the workpiece strips on conveyor belt one, forming a closed-loop cycle with the feeding action of the suction mechanism, achieving self-consistent connection between the feeding and folding processes.

[0016] This invention utilizes a vibratory feeder and a linear vibratory feeder to screen and redirect the irregularly shaped workpiece sheets after breakage, ensuring consistent sheet posture during subsequent visual inspection and reducing false detection rates caused by sheet angle deviations. Visual sensors two, three, and four, arranged sequentially along the conveying direction in the inspection mechanism, perform three-level image acquisition and analysis of the left-side seam fracture surface, the main body area, and the right-side seam fracture surface of the workpiece sheet, achieving comprehensive and refined inspection of the folding quality. Based on the three-level inspection results, the control system sends a closed-loop adjustment signal to the electric actuator, adjusting the relative position of the adjusting seat and the folding pressure roller in real time to achieve dynamic adaptive optimization of the folding parameters.

[0017] This invention overcomes the problem of erroneous adjustment caused by fluctuations in single-piece inspection results by establishing a sliding detection queue and using a trend analysis mechanism to statistically analyze and judge the quality grades of N consecutive workpiece sheets. The differentiated design of four closed-loop adjustment strategies (under-folding trend adjustment, deflection or over-folding trend adjustment, emergency handling of serious non-conformities, and mixed trend collaborative adjustment) enables the system to perform precise parameter correction for different defect types and combination patterns. The differentiated step size design of δ1>δ2 allows under-folding adjustment to use a larger step size to quickly eliminate residual connection points, while deflection or over-folding adjustment uses a smaller step size to avoid over-adjustment. The adjustment effect verification and iterative optimization mechanism in step S6 ensures that each adjustment action is confirmed by the effect, and the stroke limit alarm function enhances the system's self-diagnosis and maintainability.

[0018] This invention utilizes the coordinated design of multiple placement slots and material frames on a translation plate in a stacking mechanism, combined with the automatic displacement of the electric linear module three and the clamping and transfer of pneumatic telescopic grippers, to achieve continuous stacking of qualified sheets and automatic replacement of material frames. The periodic pressing and leveling action of the dual-axis cylinder three and the pressure block effectively eliminates interlayer misalignment or tilting caused by gravity-induced posture deviations during sheet stacking, ensuring neat stacking. The pneumatic telescopic rod pushes visually inspected defective sheets to waste tray two, while waste tray one collects pre-inspected defective strips. This dual waste tray design achieves continuous stacking of qualified sheets and automatic replacement of material frames. The system features a qualified product diversion and recycling mechanism. Real-time monitoring of the full status of the two waste pans and a pan-changing prompt function ensure the reliability of the equipment's long-term continuous operation. The image processing algorithm employs specialized detection schemes for fracture surface contours, residual connection points, edge burrs, and cracks. It combines multiple image processing techniques, including Canny edge detection, morphological closing operations, adaptive threshold binarization, and Gabor filter banks, providing targeted algorithmic support for each detection item. This results in high detection accuracy and strong anti-interference capabilities, providing an accurate data foundation for closed-loop control. Attached Figure Description

[0019] Figure 1 This is a schematic diagram of the overall structure of an integrated folding and stacking device proposed in this invention; Figure 2 This is a schematic diagram of the folding mechanism, the sheet suction mechanism, and the strip suction mechanism in the folding and stacking integrated device proposed in this invention; Figure 3 for Figure 2 Enlarged diagram of part A in the middle; Figure 4 for Figure 2 Enlarged diagram of section B; Figure 5 This is a schematic diagram of the detection mechanism and stacking mechanism in an integrated folding and stacking device proposed in this invention. Figure 1 ; Figure 6 This is a schematic diagram of the detection mechanism and stacking mechanism in an integrated folding and stacking device proposed in this invention. Figure 2 Figure 7 This is a schematic diagram illustrating the steps of a visual detection closed-loop control method proposed in this invention.

[0020] In the diagram: 1. Frame; 2. Folding mechanism; 3. Sheet suction mechanism; 4. Strip suction mechanism; 5. Vibratory feeder; 6. Straight vibratory feeder; 7. Detection mechanism; 8. Stacking mechanism; 21. Mounting frame one; 22. Conveyor belt one; 23. Conveyor belt two; 24. Fixed seat; 25. Adjusting seat; 251. Shaft; 26. Electric actuator one; 27. Wheel frame; 28. Folding strip pressure roller; 29. ​​Compression spring; 210. Vision sensor one; 211. Waste tray one; 212. Vision sensor six; 31. Feeding trough; 32. Carrier; 33. Electric actuator II; 34. Vision sensor V; 35. Gas nozzle; 36. Electric linear module I; 37. Dual-axis cylinder I; 38. Vacuum suction cup I; 41. Electric linear module II; 42. Dual-axis cylinder II; 43. Vacuum suction cup II; 71. Mounting frame two; 72. Conveyor belt three; 73. Press block; 74. Container rack; 75. Dual-axis cylinder three; 76. Vision sensor two; 77. Vision sensor three; 78. Vision sensor four; 79. Pneumatic telescopic rod; 710. Waste tray two; 81. Mounting frame three; 82. Electric linear module three; 83. Translation plate; 831. Placement slot; 84. Material frame; 85. Pneumatic telescopic gripper. Detailed Implementation

[0021] The technical solution of the present invention will now be clearly and completely described with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.

[0022] Example 1 A strip folding and stacking integrated equipment includes a frame 1 and a sheet suction mechanism 3, a strip folding mechanism 2, a strip suction mechanism 4, a vibratory feeder 5, a linear vibratory feeder 6, a detection mechanism 7, a stacking mechanism 8, and a control system, all of which are mounted on the frame 1.

[0023] like Figure 2 and Figure 3 As shown, the suction mechanism 3 includes a loading trough 31 fixed to the top of the frame 1 and an electric linear module 36 fixed to the frame 1. A carrier 32 is slidably installed in the loading trough 31, and an electric push rod 33 is fixedly installed in the loading trough 31. The piston rod end of the electric push rod 33 is fixedly connected to the bottom of the carrier 32. A vision sensor 34 and a gas nozzle 35 are fixedly installed on the top of the loading trough 31. The electric linear module 36 is fixedly installed on the frame 1. A dual-axis cylinder 37 is fixedly installed on the slider of the electric linear module 36, and vacuum suction cups 38 are fixedly installed on the two piston rod ends of the dual-axis cylinder 37. The workpiece strips to be broken are stacked inside the feeding trough 31 and fall above the carrier 32. The electric push rod 33 extends and retracts, driving the carrier 32 to move up and down. The vision sensor 34 detects the position of the top layer of workpiece strips to ensure that the top layer of workpieces is always at the same picking height. The gas nozzle 35 is connected to an external compressed air source to spray air between the top layer of workpiece strips and the lower layer to prevent sticking. The dual-axis cylinder 37 drives the vacuum suction cup 38 to lift and pick up the material. The electric linear module 36 drives it to move horizontally to the top horizontal part of the conveyor belt 22 to complete the unloading.

[0024] like Figures 2 to 4 As shown, the folding mechanism 2 includes a mounting frame 21 fixed to the top of the frame 1. Conveyor belts 22 and 23 are rotatably mounted on the mounting frame 21, with their sides horizontally parallel to each other for clamping and conveying the workpiece. A fixed seat 24 is fixedly mounted on the mounting frame 21, and an adjusting seat 25 is slidably mounted on the bottom of the fixed seat 24. An electric push rod 26 is fixedly mounted through the fixed seat 24, and the piston rod end of the electric push rod 26 is fixedly connected to the adjusting seat 25. A wheel frame 27 is rotatably mounted on the folding pressure roller 28, and the wheel frame 27 is rotatably connected to the mounting frame 21. A height-adjustable compression spring 29 is fixedly mounted on the top of the wheel frame 27, and the top of the compression spring 29 is connected to the mounting frame 21. Conveyor belt 22 transfers the workpiece strips between conveyor belt 23 and conveyor belt 22. The horizontal sections of both belts clamp and convey the workpiece strips. When the seam of the workpiece strip passes the folding roller 28 and the shaft 251 at the top of the adjusting seat 25, the folding roller 28 and the shaft 251 apply longitudinal pressure in opposite directions to the workpiece sheets on both sides of the seam, causing the seam to break and achieving single-piece breakage. The mounting frame 21 is equipped with a waste tray 211 and a vision sensor 212. The vision sensor 212 is used to identify workpiece strips on conveyor belt 22 whose seams are not broken or broken. The vacuum suction cup 38 does not grab them, allowing them to fall into the waste tray 211. A vision sensor 210 is fixedly installed on the mounting frame 21. It is located on the side of the conveyor belt 23 near the suction mechanism 3 and above the horizontal part of the conveyor belt 22. It is used to detect whether there is a workpiece strip on the conveyor belt 22. If a workpiece strip is detected, the suction mechanism 3 stops transferring new material to the conveyor belt 22. If there is no material, the suction mechanism 3 feeds material again, thus achieving self-synchronization of cycle time.

[0025] like Figure 1 , Figures 4 to 6 As shown, the suction strip mechanism 4 includes an electric linear module 41 fixedly connected to the frame 1. A dual-axis cylinder 42 is fixedly mounted on its slider, and vacuum suction cups 43 are fixedly mounted on the ends of the two piston rods of the dual-axis cylinder 42. The output end of the conveyor belt 22 of the folding strip mechanism 2 is connected to the input end of the suction strip mechanism 4. The suction strip mechanism 4 transfers the folded workpiece sheet to the inlet of the vibratory plate 5 through the vacuum suction cups 43. The outlet of the vibratory plate 5 is connected to the inlet of the linear vibratory feeder 6. The outlet of the linear vibratory feeder 6 is connected to the inlet of the conveyor belt 72 of the detection mechanism 7. The vibratory plate 5 screens and reverses the workpiece sheet, so that the complete workpiece sheet enters the linear vibratory feeder 6 in the same direction. The linear vibratory feeder 6 continuously conveys the workpiece sheet to the conveyor belt 72 of the detection mechanism 7.

[0026] like Figure 5 and Figure 6As shown, the detection mechanism 7 includes a mounting frame 2 71 fixed to the top of the frame 1. A conveyor belt 3 72 is rotatably mounted on the top of the mounting frame 2 71. Vision sensors 2 76, 3 77, and 4 78 are sequentially arranged on the mounting frame 2 71 along the workpiece movement direction on the conveyor belt 3 72. Vision sensor 2 76 acquires and analyzes images of the left seam of the workpiece sheet, vision sensor 3 77 acquires and analyzes images of the central main area of ​​the workpiece sheet, and vision sensor 4 78 acquires and analyzes images of the right seam of the workpiece sheet. Vision sensors 2 76 and 4 78 focus on detecting the flatness and residual connection points of the fracture surfaces on both sides of the workpiece sheet, while vision sensor 3 77 detects whether cracks or deformations have occurred in the main area of ​​the workpiece sheet. Vision sensors 2 76, 3 77, and 4 78 sequentially detect the broken workpiece sheet. The control system sends a control signal to the electric push rod 26 based on the detection results to adjust the position of the adjusting seat 25 below the folding pressure roller 28. The mounting bracket 2 71 is also fixedly mounted with a pneumatic telescopic rod 79 and a waste tray 2 710. The pneumatic telescopic rod 79 is used to push the workpiece sheet that is not qualified by vision sensor 2 76, vision sensor 3 77 and vision sensor 4 78 into the waste tray 2 710.

[0027] like Figure 5 and Figure 6 As shown, the inspection mechanism 7 also includes a holding rack 74 fixed to the top of the frame 1 and a dual-axis cylinder 75 fixed to the mounting frame 71. The ends of the two piston rods of the dual-axis cylinder 75 are fixedly fitted with pressure blocks 73 that are compatible with the top opening of the material frame 84. Workpiece sheets that pass inspection by the inspection mechanism 7 are discharged from the discharge end of the conveyor belt 72 and fall into the top opening of the material frame 84 placed on the holding rack 74 in the stacking mechanism 8. The stacking mechanism 8 includes a mounting frame 81 fixed to the top of the frame 1. An electric linear module 82 is fixedly mounted on the mounting frame 81, and a translation plate 83 is fixedly mounted on its slider. Multiple equally spaced placement slots 831 are opened on the translation plate 83. A material frame 84 is movably installed in each placement slot 831. The top of the material frame 84 is open. A pneumatic telescopic gripper 85 is fixedly mounted on the side of the mounting frame 81 away from the inspection mechanism 7, compatible with the material frame 84, for clamping and transferring the material frame 84. Under the influence of gravity, the workpiece sheet gradually moves down and stacks in the material frame 84. The dual-axis cylinder 75 drives the pressure block 73 to move up and down. During the stacking process, the top layer of workpiece sheet is periodically pressed and leveled. The electric linear module 82 grabs the full material frame 84 into the empty placement slot 831 in the translation plate 83, and grabs the empty material frame 84 into the holding rack 74 for use, realizing the automatic replacement and transfer of the material frame 84, and ensuring the continuous operation of the stacking process.

[0028] Example 2 A visual inspection closed-loop control method includes the following steps: Step S1: Image Acquisition and Pre-detection Triage Vision sensors 2 76, 3 77, and 4 78, arranged sequentially along the conveying direction, are used to acquire images of the fracture surface of the left seam, the main body area, and the fracture surface of the right seam of the workpiece sheet, respectively. At the same time, vision sensor 6 212 in the folding mechanism 2 performs pre-inspection on the workpiece strips on the conveyor belt 1 22 to identify strips with unbroken seams or that are completely broken. Such strips are directly recycled by the waste tray 1 211 and do not enter the subsequent inspection process.

[0029] Step S2: Defect Feature Extraction and Judgment Defect features were extracted and judged for the three levels of images to obtain the state of the left fracture surface, the state of the main area, and the state of the right fracture surface. The fracture surface state judgment included: extracting the fracture surface contour and calculating the straightness deviation, counting the number and size of residual connection points, detecting the height of edge burrs, and judging them as intact, under-folded, over-folded, or burrs exceeding the standard.

[0030] Step S3: Comprehensive Quality Grade Determination Based on the three-level judgment results of step S2, the folding quality level of the single workpiece sheet is comprehensively evaluated. The quality level includes: qualified, under-folded, skewed, over-folded and seriously unqualified. Among them, the material strips identified by vision sensor 6212 as having unbroken seams or being completely broken are directly classified into the seriously unqualified category, recycled by waste tray 211, and are not included in the statistics of the sliding detection queue in step S4.

[0031] Step S4: Sliding detection queue and trend analysis Establish a sliding detection queue to store the quality grade determination results of N consecutive workpiece sheets and perform trend analysis, where N≥5.

[0032] Step S5: Closed-loop adjustment of folding parameters Based on the trend analysis results, closed-loop adjustments are made to the folding parameters, specifically including the following four scenarios: Under-folding trend adjustment: When the proportion of "under-folding" in the sliding detection queue exceeds the first preset threshold T1, the first control signal C1 is sent to the electric push rod 26 of the folding mechanism 2 to drive the adjustment seat 25 to translate in the direction of increasing the misalignment between the folding pressure roller 28 and the shaft 251. The single adjustment step is the preset value δ1. Adjustment of deflection or over-fracture trend: When the proportion of "deflection" or "over-fracture" in the sliding detection queue exceeds the second preset threshold T2, a second control signal C2 is sent to the electric push rod 26 of the folding mechanism 2 to drive the adjustment seat 25 to translate in the direction of reducing the misalignment between the folding pressure roller 28 and the shaft 251. The single adjustment step is the preset value δ2, and δ1 > δ2. Emergency handling for serious non-conformity: When any workpiece sheet is judged to be "seriously non-conformity", an audible and visual alarm is immediately triggered and the feeding action of the sheet suction mechanism 3 is suspended; at the same time, the seriously non-conformity sheet is pushed to the waste tray 710 by the pneumatic telescopic rod 79, and the control system records the event and marks the corresponding adjustment cycle. Hybrid trend coordinated adjustment: When both "under-fracture" and "over-fracture" exist in the sliding detection queue and neither of them exceeds its respective threshold, if the two types of defects appear alternately, the current parameters remain unchanged; if they show a unilateral increasing trend, the corresponding adjustment is performed according to the type with the larger proportion.

[0033] Step S6: Verification and Iterative Optimization of Adjustment Effects After the adjustment action is executed, the inspection results of the subsequent M workpiece sheets are monitored to verify the adjustment effect and iteratively optimize, where M≥3; if the defect ratio drops below the preset qualified threshold T0, the current parameters are locked; if the defect ratio does not improve or continues to deteriorate, the adjustment continues in the same direction until the adjustment stroke limit of the electric actuator 26 is reached, at which point the system alarm is triggered, indicating that the mechanical parameters need to be recalibrated; during the verification of the adjustment effect, the pneumatic telescopic rod 79 continuously pushes the unqualified sheets into the scrap pan 710; the full status of the scrap pan 211 and the scrap pan 710 is monitored by the control system, and the system issues a pan change prompt when either is full.

[0034] Furthermore, in step S2, the image processing algorithm for defect feature extraction and determination is specifically implemented as follows: Fracture surface contour extraction algorithm: The edge contour of the fracture surface region is extracted by the Canny edge detection operator, the fracture edges are connected by morphological closing operation, the contour baseline is fitted by the least squares method, the residual of each point on the contour line to the baseline is calculated, and when the residual exceeds the preset threshold, it is marked as a contour defect point.

[0035] Residual connection point detection algorithm: Adaptive threshold binarization is used to segment high-brightness connected regions within the fracture surface region. The area and aspect ratio of the connected regions are statistically analyzed. When the area of ​​the connected region is greater than the preset minimum connection point area threshold and the aspect ratio is less than the preset threshold, it is determined to be a residual connection point.

[0036] Edge burr height detection algorithm: After extracting the edge contour of the fracture surface, scan the gray-scale gradient change along the contour normal direction to calculate the burr protrusion height. When the burr height exceeds the preset threshold, it is determined that the burr exceeds the standard.

[0037] Crack detection algorithm: Gabor filter bank is used to extract multi-directional texture response in the main area image. When a linear low grayscale area is detected and its length exceeds a preset threshold, it is determined to be a crack defect.

[0038] The above description is only a preferred embodiment of the present invention, but the scope of protection of the present invention is not limited thereto. Any equivalent substitutions or modifications made by those skilled in the art within the scope of the technology disclosed in the present invention, based on the technical solution and inventive concept of the present invention, should be covered within the scope of protection of the present invention.

Claims

1. A folding and stacking integrated device, comprising a frame (1), characterized in that, The top of the frame (1) is equipped with a sequentially arranged sheet suction mechanism (3), a strip folding mechanism (2), a strip suction mechanism (4), a vibratory feeder (5), a linear vibratory feeder (6), a detection mechanism (7), and a stacking mechanism (8), wherein: The suction mechanism (3) is used to pick up workpiece strips one by one and transfer them to the folding station; The folding mechanism (2) is used to apply force to the joint of the workpiece strip and break it; The suction bar mechanism (4) is used to transfer the broken workpiece sheet; The vibratory feeder (5) and the linear vibratory feeder (6) are used for screening, reversing and directional conveying; The inspection mechanism (7) is used to perform multi-level visual inspection on the workpiece sheet and provide feedback to adjust the folding parameters; The stacking mechanism (8) is used for automatically stacking and placing qualified sheets; The control system is electrically connected to each mechanism.

2. The integrated folding and stacking equipment according to claim 1, characterized in that, The suction mechanism (3) includes a feeding trough (31), a carrier (32) slidably installed in the feeding trough (31), an electric push rod two (33) fixed to the bottom of the carrier (32), a vision sensor five (34) and a gas nozzle (35) fixed to the top of the feeding trough (31), an electric linear module one (36) and a dual-axis cylinder one (37) and a vacuum suction cup one (38) mounted on its slider; the folding mechanism (2) includes a mounting frame one (21), a conveyor belt one (22) and a conveyor belt two (23) rotatably installed on the mounting frame one (21), a fixed seat (24) fixed to the mounting frame one (21), and a sliding mounting on the fixed seat. The adjustment seat (25) at the bottom of the seat (24), the electric push rod (26) fixed on the fixed seat (24) and connected to the piston rod end of the adjustment seat (25), the folding pressure roller (28) rotatably installed on the wheel frame (27) and the compression spring (29) on the top of the wheel frame (27), the adjustment seat (25) is provided with a shaft (251), the mounting frame (21) is equipped with a waste tray (211) and a vision sensor (212), the vision sensor (212) is used to identify workpiece strips on the conveyor belt (22) with unbroken or broken seams, the vacuum suction cup (38) does not grab them, and makes them fall into the waste tray (211).

3. The integrated folding and stacking equipment according to claim 2, characterized in that, A vision sensor (210) is fixed on the mounting frame (21), located on the side of the conveyor belt (23) near the suction mechanism (3) and above the horizontal part of the conveyor belt (22), for detecting whether there is a workpiece strip on the conveyor belt (22), and the control system controls the feeding start and stop of the suction mechanism (3) according to the detection result.

4. The integrated folding and stacking equipment according to claim 1, characterized in that, The detection mechanism (7) includes a second mounting frame (71), a third conveyor belt (72) rotatably mounted on the top of the second mounting frame (71), and a second vision sensor (76), a third vision sensor (77), and a fourth vision sensor (78) arranged sequentially along the conveying direction, which respectively collect images of the fracture surface of the left seam, the main body area, and the fracture surface of the right seam of the workpiece sheet; a pneumatic telescopic rod (79) and a waste tray (710) are also fixed on the second mounting frame (71). The pneumatic telescopic rod (79) is used to push the workpiece sheet that is not qualified by the second vision sensor (76), the third vision sensor (77), and the fourth vision sensor (78) to the waste tray (710).

5. The integrated folding and stacking equipment according to claim 1, characterized in that, The stacking mechanism (8) includes a mounting frame three (81), an electric linear module three (82) fixed on the mounting frame three (81), a translation plate (83) fixed on the slider of the electric linear module three (82), a plurality of placement slots (831) opened on the translation plate (83), a material frame (84) movably installed in the placement slot (831) with a top opening, and a pneumatic telescopic gripper (85) adapted to the material frame (84); the detection mechanism (7) also includes a holding rack (74) fixed on the top of the frame (1) and a dual-axis cylinder three (75) fixed on the mounting frame two (71). The two piston rod ends of the dual-axis cylinder three (75) are fixed with pressure blocks (73) adapted to the top opening of the material frame (84), which are used to periodically press and level the top layer of sheet material during the stacking process of workpiece sheet material.

6. A visual inspection closed-loop control method, applied to the integrated folding and stacking device according to any one of claims 1-5, characterized in that, Includes the following steps: S1: Image acquisition and pre-inspection are separated. Vision sensor 2 (76), vision sensor 3 (77) and vision sensor 4 (78) are arranged sequentially along the conveying direction to acquire images of the fracture surface of the left seam of the workpiece sheet, the main area and the fracture surface of the right seam respectively. Vision sensor 6 (212) in the folding mechanism (2) performs pre-inspection on the workpiece strip on conveyor belt 1 (22) to identify strips with unbroken seams or broken as a whole. Such strips are directly recycled by waste tray 1 (211) and do not enter the subsequent inspection process. S2: Defect feature extraction and judgment. Defect features are extracted and judged for the three-level images respectively to obtain the state of the left fracture surface, the state of the main area and the state of the right fracture surface. S3: Comprehensive quality grade determination. Based on the three-level determination results of step S2, the folding quality grade of the single workpiece sheet is comprehensively determined. S4: Establish a sliding detection queue to store the quality grade judgment results of N consecutive workpiece sheets and perform trend analysis, where N≥5; S5: Closed-loop adjustment of folding parameters, which performs closed-loop adjustment of folding parameters based on trend analysis results; S6: Adjustment effect verification and iterative optimization. After the adjustment action is performed, continue to monitor the detection results of the subsequent M workpiece sheets, verify the adjustment effect and iteratively optimize, M≥3; the unqualified sheets judged by the three-level visual inspection are pushed to the waste tray two (710) by the pneumatic telescopic rod (79) for centralized recycling.

7. The visual detection closed-loop control method according to claim 6, characterized in that, The fracture surface condition determination in step S2 includes: extracting the fracture surface contour and calculating the straightness deviation, counting the number and size of residual connection points, and detecting the edge burr height, and determining them as intact, under-folded, over-folded or burr exceeding the standard respectively; the quality level in step S3 includes: qualified, under-folded, skewed, over-folded and seriously unqualified; among them, the joints that are not broken or the whole broken material strips identified by the visual sensor six (212) are directly classified into the seriously unqualified category and recycled by the waste tray one (211), and do not participate in the sliding detection queue statistics in step S4.

8. The visual detection closed-loop control method according to claim 6, characterized in that, The closed-loop adjustment in step S5 includes: Under-folding trend adjustment: When the proportion of "under-folding" in the sliding detection queue exceeds the first preset threshold T1, the first control signal C1 is sent to the electric push rod (26) of the folding mechanism (2) to drive the adjustment seat (25) to translate in the direction of increasing the misalignment between the folding pressure roller (28) and the shaft (251); Deflection or over-fracture trend adjustment: When the proportion of "deflection" or "over-fracture" in the sliding detection queue exceeds the second preset threshold T2, a second control signal C2 is sent to the electric push rod (26) of the folding mechanism (2) to drive the adjustment seat (25) to translate in the direction of reducing the misalignment between the folding pressure roller (28) and the shaft (251); Serious non-conformance emergency handling: When any workpiece sheet is judged to be "serious non-conformance", an audible and visual alarm is immediately triggered and the feeding action of the sheet suction mechanism (3) is suspended; at the same time, the seriously non-conformance sheet is pushed to the waste tray two (710) by the pneumatic telescopic rod (79), and the control system records the event and marks the corresponding adjustment cycle; Hybrid trend coordinated adjustment: When both "under-fracture" and "over-fracture" exist in the sliding detection queue and neither exceeds its respective threshold, if the two types of defects appear alternately, the current parameters are maintained; if they show a unilateral increasing trend, the adjustment is performed according to the type with the larger proportion.

9. The visual detection closed-loop control method according to claim 8, characterized in that, In the under-bending trend adjustment, the single adjustment step size is a preset δ1; in the deflection or over-bending trend adjustment, the single adjustment step size is a preset δ2, and δ1 > δ2.

10. A visual detection closed-loop control method according to claim 6, characterized in that, Step S6 includes verifying the adjustment effect: if the defect rate drops below the preset qualified threshold T0, then the current parameter is locked; If the defect percentage does not improve or continues to worsen, continue to adjust in the same direction until the adjustment stroke limit of electric actuator (26) is reached. At this time, the system alarm is triggered to indicate that the mechanical parameters need to be recalibrated. During the verification of the adjustment effect, the pneumatic telescopic rod (79) continuously pushes the unqualified sheet into the second waste tray (710). The full status of the first waste tray (211) and the second waste tray (710) is monitored by the control system. When either is full, the system issues a tray replacement prompt.

Images