Visual detection device and method for paper diaper production

Abstract

The present application relates to paper diaper production detection technical field, disclose a kind of paper diaper production visual detection device and method, including detection rack and the glass protection door being arranged in the detection rack one side, the detection rack inside is equipped with paper diaper forming mechanism, the detection inlet mechanism is equipped in the right side of the paper diaper forming mechanism, the adaptive arc light source mechanism, floating positioning assembly and visual detection component are equipped above the detection inlet mechanism, the floating positioning assembly is arranged in adaptive arc light source mechanism left side, the adaptive arc light source mechanism right side is equipped with air blowing and is rejected component and discharge component;The device passes through adaptive arc light source mechanism, uses the multiple light source module of arc arrangement from different angles Product is irradiated simultaneously, can simultaneously take into account the imaging needs of different parts of paper diaper, so that the area of non-woven fabric surface layer, PE film bottom layer, elastic waist Different material characteristics of area can obtain best imaging contrast, effectively reduce the rate of missed detection, improve detection precision.

Description

Technical Field

[0001] This invention belongs to the field of diaper production and testing technology, specifically relating to a visual inspection device and method for diaper production. Background Technology

[0002] Disposable diapers are disposable absorbent products, mainly composed of multiple layers of materials such as a surface non-woven fabric, an absorbent core, a leak-proof bottom film, an elastic waistband, and Velcro. On high-speed automated production lines, production speeds can typically reach 500 to 1000 diapers per minute. Defects such as material misalignment, tearing, stains, foreign matter, and dimensional deviations may occur, necessitating online quality inspection using visual inspection devices.

[0003] However, most existing visual inspection devices for diapers use light sources with fixed angles and brightness. The material properties of different parts of the diaper vary greatly. The non-woven fabric surface has diffuse reflection characteristics, the PE film bottom layer has specular reflection characteristics, and the elastic waistband has wrinkled and semi-transparent characteristics. Light sources with fixed angles and brightness cannot simultaneously achieve the best imaging effect for different areas, resulting in insufficient contrast for defects in some areas and a high rate of missed detection. At the same time, diaper products have a wide variety of specifications, ranging from newborn size S to adult size XL. Products with different thicknesses and widths require different optimal lighting angles. When changing product specifications, it is necessary to manually adjust the angle and brightness of each light source one by one, which is time-consuming, inefficient, and cannot meet the rapid changeover requirements of flexible production lines.

[0004] To address the aforementioned issues, we propose a visual inspection device and method for diaper production. Summary of the Invention

[0005] This invention provides a visual inspection device and method for diaper production, solving the technical problem in related technologies that light sources with fixed angles and fixed brightness cannot simultaneously achieve the best imaging effect in different areas.

[0006] This invention provides a visual inspection device for diaper production, including an inspection frame and a glass protective door on one side of the inspection frame. The inspection frame is equipped with a diaper forming mechanism inside, and an inspection feeding mechanism is located on the right side of the diaper forming mechanism. An adaptive arc light source mechanism, a floating positioning component, and a visual inspection component are located above the inspection feeding mechanism. The floating positioning component is located on the left side of the adaptive arc light source mechanism, and an air-blowing rejection component and a discharge component are located on the right side of the adaptive arc light source mechanism. The testing frame is provided with a mounting bracket in the middle, and a camera mounting cylinder is provided at the center of the top surface of the mounting bracket. An industrial camera is fixedly installed on the inner wall of the camera mounting cylinder, and a testing lens is provided at the bottom of the industrial camera. The adaptive arc-shaped light source mechanism includes an arc-shaped light source frame, several light source modules, and an angle adjustment mechanism. The arc-shaped light source frame is a semi-circular arc structure. The top of the arc-shaped light source frame is fixedly connected to the bottom of the camera mounting cylinder. The light source modules are arranged at equal intervals along the inner arc surface of the arc-shaped light source frame. Each light source module is hinged to the arc-shaped light source frame through a hinge shaft. The angle adjustment mechanism includes an adjustment motor, a drive screw, a drive ring, and connecting rods. The adjustment motor is fixedly mounted on the top surface of the mounting frame. The upper end of the drive screw is fixedly connected to the output shaft of the adjustment motor. The drive ring is sleeved on the outer circumference of the camera mounting cylinder and is coaxially arranged with the arc-shaped light source frame. A screw nut is fixedly mounted on one side of the drive ring. The screw nut is threadedly engaged with the drive screw. The upper ends of the connecting rods are all hinged to the bottom surface of the drive ring, and the lower ends are respectively hinged to the tail of the corresponding light source module.

[0007] In a preferred embodiment, the light source module includes a module housing, an LED lamp array, and a focusing lens. The module housing is a long strip-shaped housing, the length of which is consistent with the width direction of the feed conveyor belt. The LED lamp array is fixedly installed on the inner end face of the module housing, and the focusing lens is fixedly installed on the light-emitting end of the module housing. The outer end face of the module housing is provided with a plurality of heat dissipation fins, which are equidistantly arranged along the length direction of the module housing.

[0008] In a preferred embodiment, the LED light bar array consists of several independently controllable LED light bars arranged along the length of the module housing, and each LED light bar integrates a visible light chip and a near-infrared light chip.

[0009] In a preferred embodiment, the diaper forming mechanism includes a forming drum, with adsorption stations arranged in a circumferential array around the forming drum. Adsorption holes are provided on the outer side of each adsorption station. The adsorption stations are connected to the inner cavity of the forming drum through a conduit. A negative pressure conduit is rotatably connected to the back side of the inner cavity of the forming drum. A shaft is installed on the back side of the forming drum. A driven gear is fixed on the outer side of the shaft. The driven gear meshes with a driving gear. The driving gear is installed at the output end of a driving motor.

[0010] In a preferred embodiment, the detection feeding mechanism includes an abutting wheel, the left side of which abuts against a friction transmission belt. The friction transmission belt is nested outside the rolling wheel of a support roller. One end of the support roller is fixed to the inner wall of the detection frame. The output end of a power motor is fixedly connected to the center of the back side of the abutting wheel. A feeding transmission belt with clearance fit is provided below the friction transmission belt. A transmission roller is nested inside the feeding transmission belt. The transmission rollers are arranged in a triangular structure. One end of the transmission roller is fixed to the inner wall of the detection frame. One of the transmission rollers is connected to an output motor. The detection lens is perpendicular to the feeding transmission belt.

[0011] In a preferred embodiment, the floating positioning assembly includes a positioning frame fixedly installed on the top surface of the testing frame. Several floating guide rods are slidably installed on the bottom surface of the positioning frame. A floating spring is sleeved on the outer periphery of each floating guide rod. A positioning roller is rotatably installed on the bottom of each floating guide rod. Side guide plates are fixedly installed on both the front and rear sides of the positioning frame. Several guide rollers are rotatably installed on the inner side of each side guide plate.

[0012] In a preferred embodiment, the air-blowing rejection assembly includes a rejection bracket fixedly installed on the top surface of the inspection frame. A plurality of air-blowing nozzles are fixedly installed on the bottom surface of the rejection bracket. The plurality of air-blowing nozzles are arranged at equal intervals along the width direction of the feed conveyor belt. Each air-blowing nozzle is connected to a solenoid valve at its top. A defective product collection hopper is fixedly installed on the right side of the rejection bracket.

[0013] In a preferred embodiment, a human-machine interactive touch screen and a tension controller are installed on the inner wall of the detection frame. A photoelectric trigger sensor is fixedly installed on the bottom surface of the mounting frame on the left side of the vision detection component. The emitting end of the photoelectric trigger sensor is set downwards, and the photoelectric trigger sensor is electrically connected to the PLC controller.

[0014] In a preferred embodiment, the discharge assembly includes a limiting mechanism and a tensioning mechanism. The limiting mechanism includes a limiting conveyor belt, with a rotating roller and a driving roller nested inside the limiting conveyor belt. One end of the driving roller is fixedly connected to a discharge motor. One side of the limiting conveyor belt is located at the tail end of the infeed conveyor belt and is clearance-fitted. The tensioning mechanism includes a tensioning roller, the outer side of which abuts against the outer side of the limiting conveyor belt. One end of the tensioning roller is fixedly equipped with a tension sensor, which is mounted on a sliding block. The sliding block is fitted into a mounting box and is slidably fitted. The upper end of the sliding block is connected to a tension motor via a screw. The tension controller is electrically connected to the tension motor and the tension sensor. A feeding wheel is provided below the infeed conveyor belt, and a discharge conveyor belt is provided on one side of the feeding wheel.

[0015] A method of using a visual inspection device for diaper production, the method comprising the following steps: Step 1: Light source parameter calibration. The light source parameter calibration includes the angle calibration and brightness calibration of the adaptive arc light source mechanism. The angle calibration is achieved by adjusting the motor to drive the lead screw to rotate, which drives the drive ring to move up and down along the camera mounting cylinder axis. The drive ring drives all light source modules to swing synchronously around the hinge axis through the connecting rod, so that the illumination angle of each light source module is synchronously adjusted to the preset angle. The brightness calibration is achieved by independently adjusting the brightness of the visible light chip and near-infrared light chip of each LED light bar according to the product specifications of the diaper to be tested, so that the imaging contrast of different areas reaches the optimal level. Step 2, Product Feeding and Positioning: The product feeding and positioning process involves the diaper products produced by the diaper forming mechanism being transported to the inspection station through the inspection feeding mechanism. When the product passes through the floating positioning component, the positioning rollers press the product downward under the elastic force of the floating spring, and the side guide plates guide and limit the product from both sides, so that the product enters the inspection area in a flat and centered position. Step 3: Image Acquisition. The image acquisition process involves the photoelectric trigger sensor detecting that the product has reached the detection position, triggering the industrial camera to take a picture. The adaptive arc light source mechanism provides multi-angle composite illumination, and the industrial camera acquires a clear image of the product through the detection lens. Step 4, Defect Identification and Classification: The defect identification and classification involves transmitting the acquired images to the PLC controller, using image recognition algorithms to measure the product's dimensions and detect defects, identifying dimensional parameters such as the product's length, width, and positional deviation, as well as surface defects such as stains, damage, creases, and missing materials, and classifying them according to the type and severity of the defects. Step 5, Graded rejection and discharge: When a defective product is detected, the corresponding solenoid valve of the air-blowing rejection component opens, and the air-blowing nozzle sprays compressed air to blow the defective product into the defective product collection hopper. The qualified products continue to be conveyed to the discharge component, and are sent to the discharge conveyor belt for output by the feeding wheel. This completes the visual inspection process of the diapers.

[0016] The beneficial effects of this invention are as follows: 1. This device uses an adaptive arc-shaped light source mechanism and multiple light source modules arranged in an arc shape to simultaneously illuminate the product from different angles. It can simultaneously meet the imaging needs of different parts of the diaper, so that areas with different material properties such as the non-woven fabric surface layer, the PE film bottom layer, and the elastic waistband can obtain the best imaging contrast, effectively reducing the false negative rate and improving the detection accuracy.

[0017] 2. Through the mechanical linkage structure of the angle adjustment mechanism, this device can drive all light source modules to swing synchronously with a single adjustment motor, achieving rapid and precise adjustment of the illumination angle. When changing product specifications, there is no need for manual adjustment one by one, which greatly shortens the changeover time and meets the rapid changeover requirements of flexible production lines.

[0018] 3. The device features an independently controllable LED light bar array design, where the brightness of each LED light bar can be adjusted independently. It also integrates dual chips for visible light and near-infrared light, allowing for flexible switching of light source types according to different detection needs, thereby further improving the detection effect of different defect types. Attached Figure Description

[0019] Figure 1 This is an overall structural diagram of the present invention.

[0020] Figure 2 This is an external structural diagram of the present invention.

[0021] Figure 3 This is a diagram of the internal structure of the present invention.

[0022] Figure 4 This is a structural diagram of the diaper forming mechanism of the present invention.

[0023] Figure 5 This is a structural diagram of the detection and feeding mechanism of the present invention. Figure 6 This is a partial component assembly structure diagram of the present invention.

[0024] Figure 7 This is a structural diagram of the light source module of the present invention.

[0025] Figure 8 This is a structural diagram of the angle adjustment mechanism of the present invention.

[0026] Figure 9 This is a structural diagram of the floating positioning component of the present invention.

[0027] Figure 10 This is a structural diagram of the visual inspection component of the present invention.

[0028] Figure 11 This is a structural diagram of the air-blowing removal component of the present invention.

[0029] Figure 12 This is a structural diagram of the limiting mechanism of the present invention.

[0030] Figure 13 This is a structural diagram of the tensioning mechanism of the present invention.

[0031] In the diagram: 1. Inspection frame; 2. Glass protective door; 3. Diaper forming mechanism; 31. Forming drum; 32. Adsorption station; 321. Adsorption hole; 33. Shaft cylinder; 34. Driven gear; 35. Drive gear; 36. Drive motor; 4. Inspection and feeding mechanism; 41. Abutment wheel; 42. Friction transmission belt; 43. Support roller; 431. Rolling wheel; 44. Power motor; 45. Feeding transmission belt; 451. Transmission roller; 46. Output motor; 47. Photoelectric trigger sensor; 5. Adaptive arc-shaped light source mechanism; 51. Arc-shaped light source frame; 52. Light source module; 521. Module housing; 522. LED lamp array; 523. Condensing lens; 524. Heat dissipation fins; 53. Angle adjustment mechanism; 531. Adjustment motor; 532. Drive screw; 533. Drive ring; 534. Connecting rod; 535. Screw 54. Nut; 6. Hinged pivot; 7. Floating positioning assembly; 8. Positioning frame; 9. Floating guide rod; 10. Floating spring; 11. Positioning roller; 2. Side guide plate; 3. Vision inspection assembly; 4. Camera mounting cylinder; 5. Industrial camera; 6. Inspection lens; 7. Air blowing rejection assembly; 8. Rejection bracket; 9. Air blowing nozzle; 10. Electromagnetic valve; 11. Non-conforming product collection hopper; 8. Discharge assembly; 9. Limiting mechanism; 9. Limiting conveyor belt; 9. Rotating roller; 9. Driving roller; 9. Discharge motor; 9. Tensioning mechanism; 9. Tensioning roller; 9. Tension sensor; 9. Sliding block; 9. Mounting box; 9. Tension motor; 9. Feeding wheel; 9. Discharge conveyor belt; 11. Mounting frame; 12. Human-machine interface touch screen; 13. Tension controller. Detailed Implementation

[0032] The present application will now be described in further detail with reference to the accompanying drawings. It should be noted that the following specific embodiments are only used to further illustrate the present application and should not be construed as limiting the scope of protection of the present application. Those skilled in the art can make some non-essential improvements and adjustments to the present application based on the above application content.

[0033] Example 1 like Figure 1 , Figure 2 As shown, a visual inspection device for diaper production in this embodiment includes an inspection frame 1 and a glass protective door 2 located on one side of the inspection frame 1. The glass protective door 2 is made of transparent tempered glass, which can both observe the operating status of the equipment and prevent operators from accidentally touching moving parts, thus ensuring production safety. The inspection frame 1 is equipped with a diaper forming mechanism 3, which is used to composite and form multiple layers of materials into a single diaper product. The diaper forming mechanism 3 is equipped with an inspection feeding mechanism 4 on the right side, which is used to smoothly transport the formed product to the inspection station. Above the feeding mechanism 4, there is an adaptive arc light source mechanism 5, a floating positioning component 6, and a vision inspection component 7. The adaptive arc light source mechanism 5 is the core innovative component of this invention, used to provide multi-angle and adjustable angle composite lighting. The floating positioning component 6 is located on the left side of the adaptive arc light source mechanism 5, used to position and level the product to ensure that the product enters the inspection area in the correct posture. The vision inspection component 7 is used to collect product images. On the right side of the adaptive arc light source mechanism 5, there is an air blow rejection component 8 and a discharge component 9. The air blow rejection component 8 is used to reject the detected defective products, and the discharge component 9 is used to output the qualified products. like Figure 10 As shown, the inspection frame 1 has a mounting frame 11 in the middle. The mounting frame 11 is a gantry frame structure that spans above the feed conveyor belt 45 and provides mounting support for the vision inspection component 7 and the adaptive arc light source mechanism 5. A camera mounting cylinder 71 is provided at the center of the top surface of the mounting frame 11. The camera mounting cylinder 71 is a cylindrical structure that is set vertically downward. An industrial camera 72 is fixedly installed on the inner wall of the camera mounting cylinder 71. The industrial camera 72 is a high-resolution area array camera that can quickly acquire clear product images. A detection lens 73 is provided at the bottom of the industrial camera 72. The detection lens 73 is a high-resolution industrial lens that ensures the clarity and sharpness of the image.

[0034] like Figure 6 , Figure 7 , Figure 8 As shown, the adaptive arc-shaped light source mechanism 5 includes an arc-shaped light source frame 51, several light source modules 52, and an angle adjustment mechanism 53. The arc-shaped light source frame 51 is a semi-circular arc structure made of aluminum alloy, which is lightweight and has good heat dissipation performance. The arc center of the arc-shaped light source frame 51 coincides with the optical axis of the detection lens 73, ensuring that the light from each light source module 52 can be focused on the product detection area. The top of the arc-shaped light source frame 51 is fixedly connected to the bottom of the camera mounting cylinder 71. The light source modules 52 are arranged equidistantly along the inner arc surface of the arc-shaped light source frame 51, with a quantity of 6 to 8. Each light source module 52 is hinged to the arc-shaped light source frame 51 through a hinge shaft 54. The light source module 52 can swing around the hinge shaft 54 ​​to adjust the illumination angle.

[0035] The angle adjustment mechanism 53 includes an adjustment motor 531, a drive screw 532, a drive ring 533, and a connecting rod 534. The adjustment motor 531 is a servo motor, which can precisely control the rotation angle. The adjustment motor 531 is fixedly mounted on the top surface of the mounting bracket 11. The upper end of the drive screw 532 is fixedly connected to the output shaft of the adjustment motor 531. The drive screw 532 is set vertically downward. The drive ring 533 is sleeved on the outer circumference of the camera mounting cylinder 71 and is coaxially arranged with the arc-shaped light source bracket 51. The drive ring 533 can slide up and down along the axial direction of the camera mounting cylinder 71. One side of the drive ring 533 is fixed. A lead screw nut 535 is installed, which is threadedly engaged with the drive lead screw 532. When the drive lead screw 532 rotates, the lead screw nut 535 drives the drive ring 533 to move up and down axially. The upper end of the connecting rod 534 is hinged to the bottom surface of the drive ring 533, and the lower end is hinged to the tail of the corresponding light source module 52. When the drive ring 533 moves up and down, it drives all the light source modules 52 to swing synchronously around the hinge shaft 54 ​​through the connecting rod 534, so as to realize the synchronous adjustment of the illumination angle of all the light source modules 52. This mechanical linkage structure only requires one motor to drive all the light sources to adjust the angle synchronously.

[0036] The light source module 52 includes a module housing 521, an LED lamp array 522, and a focusing lens 523. The module housing 521 is a long strip-shaped housing made of aluminum alloy. Its length direction is consistent with the width direction of the feed conveyor belt 45, which can cover the entire width direction of the product. The LED lamp array 522 is fixedly installed on the inner end face of the module housing 521. The focusing lens 523 is fixedly installed on the light-emitting end of the module housing 521. The focusing lens 523 is a cylindrical lens, which can focus the light emitted by the LED lamp into a uniform strip-shaped light spot, thereby improving the light utilization rate. The outer end face of the module housing 521 is provided with several heat dissipation fins 524. The heat dissipation fins 524 are equidistantly arranged along the length direction of the module housing 521. The heat dissipation fins 524 are used to increase the heat dissipation area, ensure the stable operating temperature of the LED lamp, and extend the service life.

[0037] The LED lamp bar array 522 consists of several independently controllable LED lamp bars arranged along the length of the module housing 521. The brightness of each LED lamp bar can be adjusted independently, and the light intensity distribution can be flexibly adjusted according to the detection needs of different parts of the product. Each LED lamp bar integrates a visible light chip and a near-infrared light chip. The visible light chip is used for conventional surface defect detection, and the near-infrared light chip is used to penetrate the surface to detect internal defects. The two light sources can be switched independently or used in combination to adapt to different detection needs.

[0038] like Figure 4As shown, the diaper forming mechanism 3 includes a forming drum 31, which is a large disc-shaped structure and is the core forming component of the diaper production line. The forming drum 31 has 8 to 12 adsorption stations 32 arranged in a circumferential array around its periphery. Each adsorption station 32 corresponds to the forming position of a product. Adsorption holes 321 are provided on the outer side of the adsorption station 32, and the adsorption holes 321 are densely distributed on the surface of the adsorption station 32. The adsorption station 32 is connected to the inner cavity of the forming drum 31 through a conduit. A negative pressure conduit is rotatably connected to the back side of the inner cavity of the forming drum 31. The negative pressure conduit is connected to an external vacuum system to provide negative pressure adsorption force for the adsorption holes 321. A shaft cylinder 33 is installed on the back side of the forming drum 31. The shaft cylinder 33 is used to support the rotation of the forming drum 31. A driven gear 34 is fixed on the outer side of the shaft cylinder 33. The driven gear 34 meshes with the drive gear 35. The drive gear 35 is installed at the output end of the drive motor 36. The drive motor 36 drives the forming drum 31 to rotate through gear transmission.

[0039] like Figure 5 As shown, the detection and feeding mechanism 4 includes an abutment wheel 41, which is a rubber-coated roller with a certain frictional force on its surface. The left side of the abutment wheel 41 abuts against a friction transmission belt 42, which is made of a high-friction coefficient material and can stably transport products. The friction transmission belt 42 is nested outside the rolling wheel 431 of the support roller 43. One end of the support roller 43 is fixed to the inner wall of the detection frame 1 to support the friction transmission belt 42. The output end of the power motor 44 is fixedly connected to the center of the back side of the abutment wheel 41. The power motor 44 drives the abutment wheel 41 to rotate, which drives the friction transmission belt 42 to move through friction. A feeding transmission belt 45 is provided below the friction transmission belt 42. Furthermore, with a gap fit, the product passes through the gap between the friction conveyor belt 42 and the feed conveyor belt 45, and is held and transported smoothly. The inner side of the feed conveyor belt 45 is nested with drive rollers 451, which are arranged in a triangular structure. The three drive rollers 451 form a triangular support structure to ensure the tension and running stability of the feed conveyor belt 45. One end of the drive roller 451 is fixed to the inner wall of the inspection frame 1. One of the drive rollers 451 is connected to the output motor 46, which drives the feed conveyor belt 45 to rotate. The inspection lens 73 is set perpendicular to the feed conveyor belt 45 to ensure that the camera takes pictures of the product vertically from directly above, and the image has no perspective distortion.

[0040] like Figure 9As shown, the floating positioning assembly 6 includes a positioning frame 61 fixedly installed on the top surface of the inspection frame 1. The positioning frame 61 is a portal frame structure, spanning above the feed conveyor belt 45. Several floating guide rods 62 are slidably installed on the bottom surface of the positioning frame 61. The floating guide rods 62 can slide up and down in the vertical direction. Each floating guide rod 62 is fitted with a floating spring 63 on its outer periphery, which provides downward elastic force. Positioning rollers 64 are rotatably installed at the bottom of the floating guide rods 62. The positioning rollers 64 are made of silicone material, with a soft surface that will not scratch the product. Under the elastic force of the floating springs 63, the positioning rollers 64 press the product downward to keep the product flat and prevent product warping from affecting the inspection. Side guide plates 65 are fixedly installed on both the front and rear sides of the positioning frame 61. The side guide plates 65 are set along the conveying direction to limit the product from both sides. Several guide rollers are rotatably installed on the inner side of the side guide plates 65. The guide rollers roll in contact with the side of the product to reduce friction.

[0041] like Figure 11 As shown, the air-blowing rejection assembly 8 includes a rejection bracket 81 fixedly installed on the top surface of the inspection frame 1. The rejection bracket 81 has a gantry structure and spans across the feed conveyor belt 45. Several air-blowing nozzles 82 are fixedly installed on the bottom surface of the rejection bracket 81. The air-blowing nozzles 82 are arranged at equal intervals along the width direction of the feed conveyor belt 45. Each air-blowing nozzle 82 corresponds to a width area of ​​the product. The corresponding nozzle can be activated individually according to the defect location. Each air-blowing nozzle 82 is connected to a solenoid valve 83 at its top. The solenoid valve 83 controls the on / off of compressed air. A defective product collection hopper 84 is fixedly installed on the right side of the rejection bracket 81. The defective product collection hopper 84 is used to collect defective products rejected by air-blowing.

[0042] The inner wall of the inspection frame 1 is equipped with a human-machine interface touch screen 12 and a tension controller 13. The human-machine interface touch screen 12 is used to set inspection parameters, display inspection results, and view production data. It is the main interface for operators to interact with the equipment. The tension controller 13 is used to control the tension of the discharge conveyor belt to ensure stable conveying. The bottom surface of the mounting frame 11 is located on the left side of the vision inspection component 7 and is fixedly installed with a photoelectric trigger sensor 47. The emitter end of the photoelectric trigger sensor 47 is set downward. When a product passes by, the photoelectric trigger sensor 47 detects the product and sends a trigger signal to trigger the industrial camera 72 to take a picture. The photoelectric trigger sensor 47 is electrically connected to the PLC controller. The PLC controller is the control core of the entire equipment and coordinates the actions of various components.

[0043] like Figure 12 , Figure 13As shown, the discharge assembly 9 includes a limiting mechanism 91 and a tensioning mechanism 92. The limiting mechanism 91 is used to limit the product at the discharge end to prevent the product from deviating. The limiting mechanism 91 includes a limiting conveyor belt 911, which presses the product from above to ensure stable product conveying. The limiting conveyor belt 911 has a rotating roller 912 and a driving roller 913 nested inside it. The driving roller 913 is the driving roller, and the rotating roller 912 is the driven roller. One end of the driving roller 913 is fixedly connected to the discharge motor 914. The discharge motor 914 drives the limiting conveyor belt 911 to run. One side of the limiting conveyor belt 911 is located on one side of the tail of the feed conveyor belt 45 and is fitted with a gap. The product enters the gap between the limiting conveyor belt 911 and the feed conveyor belt 45 from the tail of the feed conveyor belt 45 and is clamped and continued to be conveyed. The tensioning mechanism 92 includes a tensioning roller 921, the outer side of which abuts against the outer side of the limiting conveyor belt 911. The tensioning roller 921 is used to adjust the tension of the limiting conveyor belt 911. A tension sensor 922 is fixed to one end of the tensioning roller 921. The tension sensor 922 is used to detect the tension of the conveyor belt in real time. The tension sensor 922 is mounted on a sliding block 923, which is fitted into and slidably engaged in the mounting box 924. The sliding block 923 can slide up and down along the mounting box 924, thereby driving the tensioning roller 921 up and down. The tension of the conveyor belt is adjusted by moving and adjusting the tension. The upper end of the sliding block 923 is connected to the tension motor 925 through a screw. When the tension motor 925 rotates, it drives the sliding block 923 to move up and down through the screw. The tension controller 13 is electrically connected to the tension motor 925 and the tension sensor 922 to form a closed-loop tension control system. The tension sensor 922 detects the tension value in real time and feeds it back to the tension controller 13. The tension controller 13 controls the tension motor 925 to act according to the set value and automatically adjusts the position of the tension roller 921 to keep the tension of the conveyor belt constant. Below the feed conveyor belt 45 is a feeding wheel 93. The feeding wheel 93 has a star-shaped structure and multiple arc-shaped claws on its outer periphery, which are used to push the product off the feed conveyor belt 45. A discharge conveyor belt 94 is provided on one side of the feeding wheel 93. The pushed-off product falls onto the discharge conveyor belt 94 and is transported to the next section.

[0044] A visual inspection method for diaper production, comprising the following steps: Step 1: Light source parameter calibration. Light source parameter calibration includes angle calibration and brightness calibration of the adaptive arc light source mechanism 5. Angle calibration is achieved by adjusting the motor 531 to drive the drive screw 532 to rotate, which in turn drives the drive ring 533 to move up and down along the axis of the camera mounting cylinder 71. The drive ring 533 drives all light source modules 52 to swing synchronously around the hinge shaft 54 ​​through the connecting rod 534, so that the illumination angle of each light source module 52 is synchronously adjusted to the preset angle. This can be flexibly adjusted according to the product thickness and material characteristics. Brightness calibration is achieved by independently adjusting the brightness of the visible light chip and near-infrared light chip of each LED light bar according to the product specifications of the diaper to be tested, so that the imaging contrast of different areas reaches the best. For non-woven fabric areas with diffuse reflection characteristics, the brightness is appropriately reduced to avoid overexposure. For PE film areas with specular reflection characteristics, the brightness is appropriately increased to ensure sufficient signal strength. Step 2, Product Feeding and Positioning: The diaper products produced by the diaper forming mechanism 3 are conveyed to the detection station by the detection feeding mechanism 4. When the adsorption station 32 on the forming drum 31 carries the formed product to the discharge position, the negative pressure is closed, the product is separated from the forming drum 31, and is smoothly conveyed to the feeding conveyor belt 45 under the clamping of the abutment wheel 41 and the friction transmission belt 42. When the product passes through the floating positioning component 6, the positioning roller 64 presses the product down under the elastic force of the floating spring 63 to flatten the product and prevent warping. The side guide plate 65 guides and limits the product from both sides to keep the product centered. Step 3: Image acquisition. When the photoelectric trigger sensor 47 detects that the product has arrived at the detection position, it triggers the industrial camera 72 to take pictures. The adaptive arc light source mechanism 5 provides multi-angle composite lighting. Multiple light source modules 52 illuminate the product surface from different angles at the same time, so that different parts of the product and areas with different material properties can obtain uniform and high-contrast lighting. The industrial camera 72 acquires clear images of the product through the detection lens 73, providing image data for subsequent defect identification. Step 4: Defect Identification and Classification. Defect identification and classification involves transmitting the acquired images to the PLC controller. Image recognition algorithms are used to measure the product's dimensions and detect defects. First, edge detection algorithms are used to identify the product's outline and measure dimensional parameters such as the product's length, width, waist patch position, and core position to determine if there are any dimensional deviations. Then, texture analysis and feature extraction algorithms are used to detect whether there are surface defects such as stains, damage, creases, missing materials, and glue leakage on the product's surface. Step 5: When a defective product is detected, the corresponding solenoid valve 83 of the air-blowing rejection component 8 opens according to the defect location information, and the corresponding air-blowing nozzle 82 sprays compressed air to blow the defective product into the defective product collection hopper 84. Defects at different locations are rejected by different air-blowing nozzles 82, resulting in high rejection accuracy. Qualified products continue to be conveyed to the discharge component 9, where the limiting conveyor belt 911 presses the product from above to ensure smooth product conveying. The tensioning mechanism 92 adjusts the conveyor belt tension in real time to ensure stable conveying speed. Finally, the product is pushed to the discharge conveyor belt 94 by the feeding wheel 93 for output, thus completing the visual inspection process of the diapers.

[0045] The working principle of the above embodiments is as follows: Before use, the device requires calibration of the light source parameters. Based on the specifications of the currently produced diaper products, the optimal light source angle and brightness parameters are set. During angle adjustment, the adjusting motor 531 drives the drive screw 532 to rotate. The screw nut 535 drives the drive ring 533 to move up and down along the camera mounting cylinder 71 axially. The drive ring 533, through the connecting rod 534, drives all light source modules 52 to swing synchronously around the hinged shaft 54. Due to the mechanical linkage structure, the swing angles of all light source modules 52 are completely consistent, resulting in high adjustment precision and good synchronization. Only one adjustment is needed to complete the angle setting of all light sources, eliminating the need for manual adjustment and significantly shortening changeover time. During brightness adjustment, the brightness of each LED can be independently controlled. Different brightness settings can be used for areas with different material properties, improving the imaging contrast of each area.

[0046] During production, the active motor 36 of the diaper forming mechanism 3 drives the forming drum 31 to rotate via the active gear 35 and the driven gear 34. The adsorption station 32 on the forming drum 31 adsorbs the materials of each layer under negative pressure, and the layers are compounded one by one as the drum rotates, finally forming a complete diaper product. When the product rotates to the discharge position, the negative pressure is turned off, the product is removed from the forming drum 31, and enters the detection and feeding mechanism 4.

[0047] In the inspection and feeding mechanism 4, the power motor 44 drives the abutment wheel 41 to rotate. The abutment wheel 41 drives the friction transmission belt 42 to move through friction. The product is smoothly conveyed forward under the clamping of the friction transmission belt 42 and the feeding transmission belt 45. The output motor 46 drives the feeding transmission belt 45 to rotate, conveying the product to the inspection station.

[0048] When the product passes the floating positioning component 6, the positioning roller 64 presses the product down under the elastic force of the floating spring 63, flattening the product and preventing it from warping and affecting the detection effect. The side guide plate 65 guides the product from both sides, keeping the product in the center position and ensuring that the product is in the same position and posture during each detection, thereby improving the consistency and accuracy of the detection.

[0049] When the product reaches below the vision inspection component 7, the photoelectric trigger sensor 47 detects the product and sends a trigger signal, and the industrial camera 72 immediately takes a picture. Multiple light source modules 52 of the adaptive curved light source mechanism 5 simultaneously illuminate the product from different angles. The curved arrangement of the light sources provides multi-angle composite illumination, enabling areas with different material properties, such as the non-woven fabric surface, the PE film bottom layer, and the elastic waistband, to obtain good imaging results, effectively avoiding the problem of missed detection of certain angle defects caused by a single-direction light source.

[0050] The acquired images are transmitted to the PLC controller and processed by an image recognition algorithm. The algorithm first performs dimensional measurement, identifying the product's outline and measuring dimensional parameters such as length, width, and positional deviation; then it performs defect detection, identifying surface defects such as stains, damage, creases, and missing materials.

[0051] If a defective product is detected, when the product is conveyed to the air-blowing rejection assembly 8, the corresponding solenoid valve 83 opens, and the air-blowing nozzle 82 sprays compressed air to blow the defective product into the defective product collection hopper 84. Multiple air-blowing nozzles 82 are arranged along the width direction, and the corresponding nozzle can be activated according to the width and position of the defect.

[0052] Qualified products continue to be conveyed to the discharge assembly 9, where the limiting conveyor belt 911 presses the products from above to ensure smooth conveying. The tension sensor 922 of the tensioning mechanism 92 monitors the conveyor belt tension in real time, and the tension controller 13 controls the tension motor 925 based on the tension feedback, automatically adjusting the position of the tension roller 921 to maintain constant conveyor belt tension and avoid changes in conveying speed and product position deviations caused by tension fluctuations. Finally, the products are fed to the discharge conveyor belt 94 by the feeding roller 93 and conveyed to the next stage.

[0053] The embodiments described above are merely examples of several implementations of the present invention, and while the descriptions are relatively specific and detailed, they should not be construed as limiting the scope of the present invention. It should be noted that those skilled in the art can make various modifications and improvements without departing from the concept of the present invention, and these modifications and improvements all fall within the scope of protection of the present invention.

Claims

1. A visual inspection device for diaper production, comprising an inspection frame (1) and a glass protective door (2) disposed on one side of the inspection frame (1), wherein a diaper forming mechanism (3) is provided inside the inspection frame (1), and an inspection feeding mechanism (4) is provided on the right side of the diaper forming mechanism (3), characterized in that, The detection feeding mechanism (4) is provided with an adaptive arc light source mechanism (5), a floating positioning component (6) and a vision detection component (7) above it. The floating positioning component (6) is located on the left side of the adaptive arc light source mechanism (5), and the adaptive arc light source mechanism (5) is provided with an air blowing rejection component (8) and a discharge component (9) on the right side. The inspection frame (1) is provided with a mounting frame (11) in the middle. A camera mounting cylinder (71) is provided at the center of the top surface of the mounting frame (11). An industrial camera (72) is fixedly installed on the inner wall of the camera mounting cylinder (71). An inspection lens (73) is provided at the bottom of the industrial camera (72). The adaptive arc-shaped light source mechanism (5) includes an arc-shaped light source frame (51), several light source modules (52), and an angle adjustment mechanism (53). The arc-shaped light source frame (51) is a semi-circular arc structure. The top of the arc-shaped light source frame (51) is fixedly connected to the bottom of the camera mounting tube (71). The light source modules (52) are arranged equidistantly along the inner arc surface of the arc-shaped light source frame (51). Each light source module (52) is hinged to the arc-shaped light source frame (51) through a hinge shaft (54). The angle adjustment mechanism (53) includes an adjustment motor (531), a drive screw (532), a drive ring (533), and a connecting rod (534). The adjustment motor (531) is fixedly installed on the top surface of the mounting bracket (11). The upper end of the drive screw (532) is fixedly connected to the output shaft of the adjustment motor (531). The drive ring (533) is sleeved on the outer circumference of the camera mounting cylinder (71) and coaxially arranged with the arc-shaped light source frame (51). A screw nut (535) is fixedly installed on one side of the drive ring (533). The screw nut (535) is threadedly engaged with the drive screw (532). The upper ends of the connecting rods (534) are all hinged to the bottom surface of the drive ring (533), and the lower ends are respectively hinged to the tail of the corresponding light source module (52).

2. The visual inspection device for diaper production according to claim 1, characterized in that, The light source module (52) includes a module housing (521), an LED lamp array (522), and a focusing lens (523). The module housing (521) is a long strip-shaped housing, and its length direction is consistent with the width direction of the feed conveyor belt (45). The LED lamp array (522) is fixedly installed on the inner end face of the module housing (521). The focusing lens (523) is fixedly installed on the light-emitting end of the module housing (521). The outer end face of the module housing (521) is provided with several heat dissipation fins (524), and the several heat dissipation fins (524) are arranged at equal intervals along the length direction of the module housing (521).

3. The visual inspection device for diaper production according to claim 2, characterized in that, The LED lamp array (522) is composed of several independently controllable LED lamps arranged along the length of the module housing (521), and each LED lamp is integrated with a visible light chip and a near-infrared light chip.

4. The visual inspection device for diaper production according to claim 3, characterized in that, The diaper forming mechanism (3) includes a forming drum (31), and the forming drum (31) is provided with adsorption stations (32) arranged in a circumferential array around its periphery. The adsorption stations (32) are provided with adsorption holes (321) on their outer sides. The adsorption stations (32) are connected to the inner cavity of the forming drum (31) through a conduit. A negative pressure conduit is rotatably connected to the back side of the inner cavity of the forming drum (31). A shaft cylinder (33) is installed on the back side of the forming drum (31). A driven gear (34) is fixed on the outer side of the shaft cylinder (33). The driven gear (34) meshes with a drive gear (35). The drive gear (35) is installed at the output end of the drive motor (36).

5. The visual inspection device for diaper production according to claim 4, characterized in that, The detection feeding mechanism (4) includes an abutting wheel (41), the abutting wheel (41) abuts against the friction transmission belt (42) on the left side, the friction transmission belt (42) is nested on the outside of the rolling wheel (431) of the support roller (43), one end of the support roller (43) is fixed to the inner wall of the detection frame (1), the output end of the power motor (44) is fixedly connected to the center of the back side of the abutting wheel (41), a feeding transmission belt (45) is provided below the friction transmission belt (42) with clearance fit, a transmission roller (451) is nested inside the feeding transmission belt (45), the transmission roller (451) is arranged in a triangular structure, one end of the transmission roller (451) is fixed to the inner wall of the detection frame (1), one of the transmission rollers (451) is connected to the output motor (46), and the detection lens (73) is set perpendicular to the feeding transmission belt (45).

6. The visual inspection device for diaper production according to claim 5, characterized in that, The floating positioning assembly (6) includes a positioning frame (61) fixedly installed on the top surface of the testing frame (1). Several floating guide rods (62) are slidably installed on the bottom surface of the positioning frame (61). A floating spring (63) is sleeved on the outer periphery of each floating guide rod (62). A positioning roller (64) is rotatably installed on the bottom of the floating guide rod (62). Side guide plates (65) are fixedly installed on the front and rear sides of the positioning frame (61). Several guide rollers are rotatably installed on the inner side of the side guide plate (65).

7. The visual inspection device for diaper production according to claim 6, characterized in that, The air-blowing rejection assembly (8) includes a rejection bracket (81) fixedly installed on the top surface of the inspection frame (1). Several air-blowing nozzles (82) are fixedly installed on the bottom surface of the rejection bracket (81). The several air-blowing nozzles (82) are arranged at equal intervals along the width direction of the feed conveyor belt (45). Each air-blowing nozzle (82) is connected to a solenoid valve (83) at its top. A defective product collection hopper (84) is fixedly installed on the right side of the rejection bracket (81).

8. The visual inspection device for diaper production according to claim 7, characterized in that, The inner wall of the inspection frame (1) is equipped with a human-machine interactive touch screen (12) and a tension controller (13). The bottom surface of the mounting frame (11) is located on the left side of the visual inspection component (7) and a photoelectric trigger sensor (47) is fixedly installed. The transmitting end of the photoelectric trigger sensor (47) is set downwards, and the photoelectric trigger sensor (47) is electrically connected to the PLC controller.

9. A visual inspection device for diaper production according to claim 8, characterized in that, The discharge assembly (9) includes a limiting mechanism (91) and a tensioning mechanism (92). The limiting mechanism (91) includes a limiting conveyor belt (911), with a rotating roller (912) and a driving roller (913) nested inside the limiting conveyor belt (911). One end of the driving roller (913) is fixedly connected to the discharge motor (914). One side of the limiting conveyor belt (911) is located on one side of the tail of the infeed conveyor belt (45) and is clearance-fitted. The tensioning mechanism (92) includes a tensioning roller (921), the outer side of which abuts against the limiting conveyor belt (911). On the outside, a tension sensor (922) is fixed at one end of the tension roller (921). The tension sensor (922) is mounted on the sliding block (923). The sliding block (923) is fitted into the mounting box (924) and slides. The upper end of the sliding block (923) is connected to the tension motor (925) through a screw. The tension controller (13) is electrically connected to the tension motor (925) and the tension sensor (922). A feeding wheel (93) is provided below the feeding conveyor belt (45). A discharging conveyor belt (94) is provided on one side of the feeding wheel (93).

10. A method of using a visual inspection device for diaper production, characterized in that, A visual inspection device for diaper production according to any one of claims 1-9, wherein the visual inspection method for diaper production includes the following steps: Step 1: Light source parameter calibration. The light source parameter calibration includes the angle calibration and brightness calibration of the adaptive arc light source mechanism (5). The angle calibration is achieved by adjusting the motor (531) to drive the drive screw (532) to rotate, which drives the drive ring (533) to move up and down along the axis of the camera mounting cylinder (71). The drive ring (533) drives all light source modules (52) to swing synchronously around the hinge shaft (54) through the connecting rod (534), so that the illumination angle of each light source module (52) is synchronously adjusted to the preset angle. The brightness calibration is achieved by independently adjusting the brightness of the visible light chip and near-infrared light chip of each LED light bar according to the product specifications of the diaper to be tested, so that the imaging contrast of different areas reaches the best. Step 2, Product feeding and positioning: The product feeding and positioning is that the diaper products produced by the diaper forming mechanism (3) are transported to the detection station through the detection feeding mechanism (4). When the product passes through the floating positioning component (6), the positioning roller (64) presses the product down under the elastic force of the floating spring (63), and the side guide plate (65) guides and limits the product from both sides, so that the product enters the detection area in a flat and centered position. Step 3, image acquisition. The image acquisition is triggered when the photoelectric trigger sensor (47) detects that the product has arrived at the detection position, triggering the industrial camera (72) to take pictures. The adaptive arc light source mechanism (5) provides multi-angle composite lighting, and the industrial camera (72) acquires a clear image of the product through the detection lens (73). Step 4, Defect Identification and Classification: The defect identification and classification involves transmitting the acquired images to the PLC controller, using image recognition algorithms to measure the product's dimensions and detect defects, identifying dimensional parameters such as the product's length, width, and positional deviation, as well as surface defects such as stains, damage, creases, and missing materials, and classifying them according to the type and severity of the defects. Step 5, graded rejection and discharge: When a defective product is detected, the corresponding solenoid valve (83) of the air-blowing rejection component (8) is opened, and the air-blowing nozzle (82) sprays compressed air to blow the defective product into the defective product collection hopper (84). The qualified products continue to be transported to the discharge component (9) and are pushed to the discharge conveyor belt (94) by the feeding wheel (93) for output. This completes the visual inspection process of the diapers.

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