A method and device for automatically sorting taillight covers for injection molding machines

Abstract

The application relates to a tail lamp cover automatic sorting method and device suitable for an injection molding machine, and relates to the field of sorting devices, which comprises the following steps: collecting a product infrared image; analyzing the product average temperature from the product infrared image to obtain a picking position feature and a product picking position; picking the tail lamp cover at the product picking position after the tail lamp cover is cooled to a reference picking temperature to take the tail lamp cover off the injection molding machine and move the tail lamp cover along a material taking path; performing dry ice spraying treatment on the surface of the tail lamp cover at a surface treatment position in the material taking path to expand processing damage; collecting a product surface image, and performing image recognition on the product surface image to determine whether damage features exist; and classifying the tail lamp cover based on whether the damage features exist to determine a sorting material position of an end point of the material taking path and move the tail lamp cover to the corresponding sorting material position. The application has the effect of improving the tail lamp cover sorting material efficiency.

Description

Technical Field

[0001] This invention relates to the field of sorting devices, and more particularly to an automated sorting method and apparatus for taillight covers of injection molding machines. Background Technology

[0002] Taillight covers are mostly made of PC, PMMA or PC / ABS composite materials and are injection molded in one piece. They have extremely high requirements for surface appearance, structural integrity and control of appearance defects.

[0003] In the industry, the material handling and sorting of taillight covers after injection molding generally adopts the traditional operation mode. After the injection molding machine completes production, the robot takes out the molded taillight covers and stacks them in a designated inspection area. Then, the products in the inspection area are sorted one by one by manual labor to sort them into good and bad products.

[0004] However, the existing sorting process relies entirely on manual labor for subsequent centralized inspection and sorting, which requires high skill levels from workers and is prone to missing minor defects such as shallow cracks, minor scratches, and hidden cracks on the product surface, resulting in low overall sorting efficiency. Summary of the Invention

[0005] To improve the sorting efficiency of taillight covers, this invention provides an automated sorting method and apparatus for taillight covers adapted to injection molding machines.

[0006] In a first aspect, the present invention provides an automated sorting method for taillight covers adapted to injection molding machines, employing the following technical solution: An automated sorting method for taillight covers adapted to injection molding machines includes: Infrared images of the taillight cover on the injection molding machine are captured to obtain infrared images of the product. The average temperature of the product is obtained by analyzing the infrared image of the product, and the pickup location features and product pickup location are obtained by feature recognition. After the taillight cover cools down to the preset reference pick-up temperature, the taillight cover is picked up at the product pick-up position to remove it from the injection molding machine and move it along the preset pick-up path. Dry ice is sprayed onto the surface of the taillight cover at a preset surface treatment location in the material handling path to amplify processing damage. Collect images of the product surface and perform image recognition on the product surface images to determine whether there are preset damage features; The taillight covers are classified based on the presence or absence of damage characteristics to determine the sorting location at the end of the material picking path, and the taillight covers are moved to the corresponding sorting location.

[0007] By adopting the above technical solution, during the process of the robotic arm gripping and moving the product, low-temperature dry ice is sprayed onto the product. The dry ice can enter the cracks of the defective product. Through the principle of rapid low-temperature cooling of the product by the dry ice and the sudden expansion of the dry ice itself through sublimation, the cracks of the product are enlarged and made easier to identify. The dry ice also cleans the product surface, removing impurities that may interfere with the image detection results, making it easier to detect defects in the product by subsequent image acquisition, and improving the sorting efficiency of the taillight cover.

[0008] Optionally, dry ice treatment methods include: The dry ice ejection parameters are matched based on the preset product model, and the dry ice ejection parameters are used as fixed parameters in each round of material sorting. When the taillight cover moves to the surface treatment position, in response to the preset first positioning signal, the preset nozzle is controlled to spray dry ice according to the dry ice spraying parameters. The convergence angle of multiple nozzles for concentrated spraying is determined based on the preset product rib parameters. The lifting speed of the nozzle as it circulates and lifts on both sides of the material picking path is determined based on the preset product size parameters, preset moving speed, and preset nozzle spray width. When the taillight cover passes the surface treatment position and is sprayed with dry ice, the multiple nozzles arranged in parallel are converged and controlled at the convergence angle, and the nozzles are controlled to circulate and spray on both sides of the taillight cover by the lifting and lowering speed.

[0009] Optional methods for matching dry ice ejection parameters include: Based on the product model, retrieve the product wall thickness information and product material information, and match the product impact resistance information according to the product wall thickness information, product material information and reference pickup temperature; The impact velocity of dry ice is determined based on the product's impact resistance information and the preset dry ice particle parameters. The dry ice impact velocity is output as a parameter for dry ice ejection.

[0010] Optionally, the process of the nozzle spraying dry ice also includes: The tensile strength of the product is retrieved based on the product model, and the critical pressure for product failure is set based on the tensile strength of the product. The test pressure is calculated based on the product's critical damage pressure and the preset redundant pressure. During the process of spraying dry ice from the nozzle, the preset clamping device is controlled to clamp the two sides of the taillight cover and apply force with test pressure.

[0011] By adopting the above technical solution, during the dry ice spraying process, the clamping component assists in clamping and applying tension to both sides of the product. Under the dual action of dry ice and the clamping component, the defects of products with hidden cracks are further magnified, thereby improving the efficiency of subsequent image acquisition and detection.

[0012] Optionally, the steps prior to acquiring images of the product surface may include: In response to a preset second positioning signal, the jet handling procedure is initiated; The sublimation propulsion time of dry ice when blowing air onto the taillight cover is accelerated based on the preset matching of blowing air force and blowing temperature. The sublimation time of dry ice within the crack was determined. The difference between the sublimation time and the sublimation propulsion time of the microcracked dry ice is calculated and defined as the blowing reserve time; The passing speed of the taillight cover through the preset air blowing position is determined based on the air blowing time and the preset distance to the air blowing position. Based on the jet processing program, the air blower head preset at the air blowing processing position is controlled to blow air with air force and air temperature, and the taillight cover is controlled to pass through the air blowing processing position at a passing speed.

[0013] By adopting the above technical solution, after completing the dry ice spraying step, the product is then treated with hot air so that all the dry ice on the product surface is removed, leaving only dry ice in the cracks of defective products. The remaining dry ice cracks will appear white, which will facilitate subsequent image recognition of the cracks.

[0014] Optionally, methods for acquiring product surface images and performing image recognition include: The taillight cover is rotated 360° at a preset rotation shooting speed, and fragment images of the taillight cover are captured at preset acquisition intervals during the rotation. All image fragments are compared for features, common image features are removed, and they are merged to form a product surface image; Identify the presence of pre-defined white dry ice features from product surface images; The presence of white dry ice characteristics is defined as the presence of damage characteristics.

[0015] Optional, also includes: During the rotation of the taillight cover, the taillight cover is illuminated with a preset illumination intensity and angle, and the illumination angle is at an angle to the direction of image acquisition. When there is no white dry ice feature, the image pickup position in the product surface image is obtained based on the product pickup position; The image pickup location in the product surface image is shaded using a preset shading method; Image recognition is performed on the image pickup location from the product surface image to determine whether there is a crack; When a crack is present, it is defined as the presence of a damage characteristic.

[0016] Secondly, this application provides an automated sorting device for taillight covers adapted to injection molding machines, employing the following technical solution: An automated sorting device for taillight covers adapted to an injection molding machine is controlled by an automated sorting method for taillight covers adapted to an injection molding machine. The device includes a robotic arm for picking up taillight covers from the injection molding machine, a dry ice treatment device for dry ice treatment of the taillight covers, a blower mechanism for blowing air onto the taillight covers, and a discharging mechanism for sorting and discharging the taillight covers. The robotic arm has a material picking path between the injection molding machine and the discharging mechanism, and the dry ice treatment device and the blower mechanism are sequentially arranged on the material picking path.

[0017] Optionally, the end of the robotic arm is provided with a mounting plate and a pickup component, a collection component, and a lighting component mounted on the mounting plate; the pickup component includes a suction cup for adsorbing the taillight cover and clamping members located on both sides of the suction cup for assisting in clamping from both sides of the taillight cover.

[0018] Optionally, the dry ice processing device includes a dry ice control box located on both sides of the material feeding path, a path adjustment mechanism installed on the dry ice control box, and a plurality of nozzles installed on the path adjustment mechanism for spraying dry ice.

[0019] In summary, this application includes at least one of the following beneficial technical effects: During the process of the robotic arm gripping and moving the product, low-temperature dry ice is sprayed onto the product. The dry ice can enter the cracks of the defective product. Through the principle of rapid low-temperature cooling of the product by the dry ice and the sudden expansion of the dry ice itself by sublimation, the cracks of the product are enlarged and made easier to identify. The dry ice also cleans the product surface and removes impurities that may interfere with the image detection results, making it easier to detect defects in the product by subsequent image acquisition and improving the sorting efficiency of taillight covers. During the dry ice spraying process, the clamping device helps to clamp and apply tension to both sides of the product. Under the dual action of dry ice and clamping device, the defects of products with hidden cracks are further magnified, improving the efficiency of subsequent image acquisition and detection. After the dry ice spraying step is completed, the product is then treated with hot air to remove all the dry ice from the product surface. Only the cracks in defective products have dry ice left in them. The remaining cracks with dry ice will appear white, which will facilitate subsequent image recognition of the cracks. Attached Figure Description

[0020] Figure 1 This is a schematic diagram of the overall structure of an automated sorting device for taillight covers adapted to an injection molding machine according to an embodiment of the present invention. Figure 2 This is a schematic diagram of the dry ice processing device according to an embodiment of the present invention; Figure 3 This is a schematic diagram of the structure of the robotic arm according to an embodiment of the present invention; Figure 4 This is a flowchart of an automated sorting method for taillight covers adapted to injection molding machines, according to an embodiment of the present invention.

[0021] The parts referred to by the numbers in the above attached figures are as follows: 1. Robotic arm; 11. Pick-up component; 111. Suction cup; 112. Clamping component; 12. Collection component; 13. Lighting component; 14. Mounting plate; 2. Dry ice processing device; 21. Dry ice control box; 22. Path adjustment mechanism; 221. Vertical track component; 222. Horizontal arc track component; 23. Nozzle; 3. Blowing mechanism; 4. Discharge mechanism. Detailed Implementation

[0022] To make the objectives, technical solutions, and advantages of this invention clearer, the invention will be further described in detail below with reference to the accompanying drawings and embodiments. It should be understood that the specific embodiments described herein are merely illustrative and not intended to limit the invention.

[0023] This application discloses an automated sorting device for taillight covers adapted to injection molding machines.

[0024] Reference Figure 1 An automated sorting device for taillight covers adapted to injection molding machines includes a robotic arm 1, a dry ice treatment device 2, a blower mechanism 3, and a discharge mechanism 4. The robotic arm 1 picks up the finished injection-molded taillight covers from the injection molding machine and places them on the discharge mechanism 4, which sorts and discharges the taillight covers. During the movement of the taillight covers from the injection molding machine to the discharge mechanism 4, the robotic arm 1 moves along a pre-defined picking path. The dry ice treatment device 2 and the blower mechanism 3 are located along the picking path. The dry ice treatment device 2 and the blower mechanism 3 process the taillight covers sequentially; the dry ice treatment device 2 sprays dry ice onto the surface of the taillight cover, and the blower mechanism 3 blows air onto the surface of the taillight cover.

[0025] Reference Figure 1 and Figure 2The dry ice processing device 2 includes a dry ice control box 21, a path adjustment mechanism 22, and a nozzle 23. The dry ice control box 21 supplies dry ice, the nozzle 23 sprays the dry ice from the control box 21 onto the taillight cover, and the path adjustment mechanism 22 adjusts the position and orientation of the nozzle 23. The path adjustment mechanism 22 is mounted on the dry ice control box 21, and the nozzle 23 is mounted on the path adjustment mechanism 22 and connected to the control box 21 via a pipe.

[0026] The path adjustment mechanism 22 includes a vertical track assembly 221 and a horizontal arc-shaped track assembly 222 mounted on the vertical track assembly 221. The nozzle 23 is mounted on the horizontal arc-shaped track assembly 222. The vertical track assembly 221 generates vertical displacement, and the horizontal arc-shaped track assembly 222 generates horizontal arc-shaped path displacement. Both the vertical track assembly 221 and the horizontal arc-shaped track assembly 222 are driven by miniature motors.

[0027] In this embodiment, the horizontal arc-shaped track assembly 222 has multiple nozzles 23. The position of each nozzle 23 on the horizontal arc-shaped track assembly 222 is first adjusted and fixed. Then, as the taillight cover product passes by, the vertical track assembly 221 drives all nozzles 23 to synchronously circulate vertically upwards and downwards, thereby spraying dry ice onto the product surface. The nozzles 23 have different orientation angles depending on their position on the horizontal arc-shaped track assembly 222.

[0028] In this embodiment, there are two dry ice treatment devices 2 located on both sides of the material handling path. The nozzles 23 in the two dry ice treatment devices 2 spray dry ice onto the product from both sides, so that all parts of the product surface can be sprayed with dry ice.

[0029] There are two blower mechanisms 3, which are installed on both sides of the material handling path.

[0030] The unloading mechanism 4 is located at the end of the material handling path and includes a qualified product conveyor belt and a defective product conveyor belt. The qualified product conveyor belt is used to unload taillight covers that have passed inspection. The defective product conveyor belt is used to unload taillight covers that have failed inspection. After the robot arm 1 removes the taillight cover from the injection molding machine and inspects it, it automatically places the taillight cover on the corresponding qualified product conveyor belt or defective product conveyor belt according to the inspection result.

[0031] Reference Figure 1 and Figure 3In this embodiment, the robotic arm 1 is equipped with a picking component 11, a collection component 12, and a lighting component 13 to facilitate product gripping and inspection throughout the entire process. The picking component 11, the collection component 12, and the lighting component 13 are mounted on a mounting plate 14 of the robotic arm 1. The robotic arm 1 is a conventional multi-degree-of-freedom robotic arm structure found in the prior art, and will not be described in detail here. The mounting plate 14 is fixedly mounted on the output end of the robotic arm 1.

[0032] The pickup assembly 11 includes a suction cup 111 and a clamping member 112. The suction cup 111 is connected to an external vacuum pump via a pipe. The clamping member 112 is rotatably mounted on both sides of the mounting plate 14 and is driven by a motor. When the suction cup 111 picks up the taillight cover, the clamping member 112 rotates and clamps onto both sides of the taillight cover, thereby providing auxiliary clamping.

[0033] The acquisition component 12 includes an industrial camera that is always positioned directly facing the product to capture images. The illumination component 13 includes a light source that illuminates the product while the industrial camera is acquiring images. An angle exists between the shooting direction of the industrial camera and the illumination direction of the light source, causing the light source to illuminate the product at an angle.

[0034] Based on the same inventive concept, this invention provides an automated sorting method for taillight covers adapted to injection molding machines.

[0035] Reference Figure 4 An automated sorting method for taillight covers adapted to injection molding machines includes the following steps: Step S1: Acquire an infrared image of the taillight cover on the injection molding machine to obtain an infrared image of the product.

[0036] The product infrared image refers to the image captured by an infrared camera of a taillight cover that is still on the injection molding machine and has not yet been removed. The infrared camera is mounted on robotic arm 1, and it captures an image of the taillight cover before robotic arm 1 picks it up.

[0037] Step S2: Analyze the product's infrared image to obtain the product's average temperature and obtain the pickup location features and product pickup location through feature recognition.

[0038] The product's average temperature refers to the average surface temperature of the taillight cover. This is achieved by identifying the color of various points on the taillight cover surface from infrared images of the product, collecting temperature values ​​from multiple locations, and averaging them to obtain the product's average temperature. In infrared images, different colors represent different temperature ranges, and the intensity of the color represents the temperature level. Therefore, analyzing the color and intensity of a specific location allows us to obtain the temperature value at that location.

[0039] The pickup position feature refers to the position point on the taillight cover where the suction cup 111 on the robotic arm 1 picks it up. The product pickup position refers to the specific position of the pickup position feature on the taillight cover relative to the injection molding machine. The position point on the taillight cover where the suction cup 111 picks it up is a fixed position point. The image features of this position point are pre-collected and stored in a database. By inputting the product infrared image into the database and comparing it with the pre-stored image features, the pickup position feature in the product infrared image and its position in the image can be obtained, and finally, the actual product pickup position of the taillight cover can be obtained.

[0040] Step S3: After the taillight cover cools down to the preset reference pick-up temperature, pick up the taillight cover at the product pick-up position to remove the taillight cover from the injection molding machine and move it along the preset material pick-up path.

[0041] The reference pickup temperature is the maximum temperature threshold at which the suction cup 111 can pick up the taillight cover. It is a parameter set by technicians based on the actual production conditions of the taillight cover. When the temperature of the taillight cover is higher than the reference pickup temperature, its material may not be fully cured. Forcibly picking it up may cause product damage. Only when the temperature of the product is reduced to the reference pickup temperature can the product be protected from damage during pickup.

[0042] The material handling path is the route taken by the robot arm 1 to move the finished injection-molded and cooled product from the injection molding machine to the conveyor table of the discharge mechanism 4. This path is set by technicians based on the actual structural conditions of the equipment on site.

[0043] Step S4: Apply dry ice to the surface of the taillight cover at a preset surface treatment location in the material handling path to increase processing damage.

[0044] The surface treatment location is where the dry ice treatment device 2 is located. When the robotic arm 1 moves the taillight cover to the surface treatment location, the system controls the nozzle 23 of the dry ice treatment device 2 to spray dry ice onto the surface of the taillight cover. The purpose of spraying dry ice is twofold: firstly, dry ice can clean the product surface, preventing impurities from interfering with subsequent image defect detection; secondly, after contact with the product, the dry ice rapidly heats up and sublimates, causing a sudden expansion that enlarges any hidden cracks on the taillight cover, making them more visible. Furthermore, the low temperature of the dry ice causes stress concentration at the cracks, resulting in inconsistent thermal contraction and further tearing and expansion of the cracks, making them more apparent and improving the efficiency of subsequent image detection and recognition. Simultaneously, some dry ice remains in the cracks after they expand; since dry ice is white, the cracks also appear white. The specific dry ice spraying method will not be detailed here but will be described in detail in subsequent embodiments.

[0045] Step S5: Acquire images of the product surface and perform image recognition on the product surface images to determine whether there are preset damage features.

[0046] Product surface image refers to an image obtained by taking a picture of the surface of the taillight cover using an industrial camera mounted on robot arm 1.

[0047] Damage characteristics include defects such as scratches and cracks.

[0048] After the taillight cover is dry-ice sprayed, the system controls an industrial camera to acquire images of the product surface. By analyzing these images, the system determines if any damage exists. The specific methods for acquiring and recognizing these product surface images are not detailed here but will be described in detail in subsequent embodiments.

[0049] Step S6: Classify the taillight covers based on the presence or absence of damage characteristics to determine the sorting location at the end of the material picking path and move the taillight covers to the corresponding sorting location.

[0050] The sorting location is where the discharge mechanism 4 is located. There are two sorting locations, corresponding to the qualified product conveyor belt and the defective product conveyor belt, respectively. By judging whether there are any damage characteristics, the picked-up taillight covers can be classified to determine whether they are qualified or unqualified products. For different types, the system will control the robot arm 1 to place the product into the corresponding sorting location according to the type, that is, qualified products are placed on the qualified product conveyor belt, and unqualified products are placed on the defective product conveyor belt.

[0051] The dry ice treatment method includes the following steps: Step S400: Match the dry ice spraying parameters based on the preset product model, and use the dry ice spraying parameters as fixed parameters in each round of material sorting.

[0052] The product model refers to the model of the injection-molded taillight cover.

[0053] The dry ice ejection parameters refer to the parameters of dry ice ejected by nozzle 23, specifically the speed at which nozzle 23 ejects the dry ice. In this embodiment, since the dry ice is solid, in order to ensure that the dry ice ejected by nozzle 23 does not easily cause direct damage to the surface of the taillight cover, that is, to prevent the dry ice from causing damage to the product surface due to impact and friction, and to ensure that the dry ice only acts on the hidden cracks and fissures of the defective product, it is necessary to control the speed of dry ice ejection.

[0054] The dry ice emission parameters are related to the product model. The specific method for determining the matching of dry ice emission parameters will not be elaborated here, but will be described in detail in subsequent embodiments.

[0055] For taillight covers of the same product model, the system controls the dry ice processing device 2 with the same dry ice emission parameters, that is, the dry ice emission parameters are fixed parameters.

[0056] Step S401: When the taillight cover moves to the surface treatment position, in response to the preset first positioning signal, the preset nozzle 23 is controlled to spray dry ice according to the dry ice spraying parameters.

[0057] The first positioning signal refers to the signal triggered when the robot arm 1 moves to the surface treatment position. A photoelectric sensor is set at the surface treatment position. When the robot arm 1 passes by, the photoelectric sensor detects and sends out the first positioning signal.

[0058] When the first positioning signal is detected, the system controls the first positioning signal to spray dry ice in response to the signal.

[0059] Step S402: Determine the convergence angle of multiple nozzles 23 for convergent spraying based on the preset product rib parameters.

[0060] Product rib parameters refer to the size and position parameters of the ribs on the back of the taillight cover. These are fixed parameters of the product and can be directly retrieved from the system database.

[0061] In this embodiment, direct spraying cannot fully cover the surface of all the ribs on the back of the taillight cover. It is necessary to spray dry ice at a certain angle to the ribs. Therefore, the spray angle of the nozzle 23 needs to be set. This spray angle is the convergence angle, which is related to and determined by the product rib parameters.

[0062] In this embodiment, multiple nozzles 23 are mounted on an arc-shaped track. By moving the nozzles 23 on the arc-shaped track and adjusting the adjacent spacing, the convergence angle of the nozzles 23 is changed.

[0063] Step S403: Determine the lifting speed of the nozzle 23 as it circulates and lifts on both sides of the material picking path based on the preset product size parameters, preset moving speed, and preset nozzle spray width.

[0064] Product size parameters refer to the length, width, and height of the taillight cover, which are fixed design parameters for the product. Moving speed is the speed at which the robotic arm 1 moves along the material handling path, as set by the technicians. Nozzle spray width refers to the width of the dry ice sprayed from nozzle 23 covering the product surface as the taillight cover passes the surface treatment position; this is a parameter preset by the technicians.

[0065] Since the dry ice sprayed from nozzle 23 cannot directly cover the entire product surface in the height direction, in order to ensure that the dry ice sprayed by the equipment can cover the entire surface of the taillight cover when it passes through the surface treatment position, it is necessary to control nozzle 23 to lift and spray when the robot arm 1 moves, and control the lifting and lowering speed of nozzle 23, which is the minimum speed.

[0066] When the nozzle 23 rises and falls, the spray paths on the product surface must overlap. Therefore, the total time it takes for the product to pass through the surface treatment position can be obtained by using the length of the taillight cover and the moving speed of the robotic arm 1. The total lifting distance of the nozzle 23 relative to the product surface is calculated based on the height and length of the taillight cover and the nozzle spray width. Finally, the lifting speed is calculated by combining the total lifting distance and time. When calculating the total lifting distance, adjacent spray paths of the nozzle 23 on the product surface overlap with the minimum overlap area.

[0067] Step S404: When the taillight cover passes the surface treatment position and the dry ice spraying operation is performed, the multiple nozzles 23 arranged in parallel are controlled to converge at the convergence angle and the nozzles 23 are controlled to circulate and spray on both sides of the taillight cover by the lifting and lowering speed.

[0068] In this embodiment, when the equipment is started, the angles of multiple nozzles 23 in the dry ice processing device 2 are adjusted in advance according to the product. By adjusting the distribution position of the nozzles 23 on the arc track, the spray angle is different depending on the distribution position.

[0069] In actual production, when the taillight cover passes the surface treatment position, the system controls the nozzle 23 to circulate and lift on both sides of the product and spray dry ice on both sides of the product during the lifting process. Since the nozzle 23 does not spray directly, the entire surface of the product can be sprayed with dry ice.

[0070] The method for matching dry ice ejection parameters includes the following steps: Step S410: Retrieve product wall thickness information and product material information based on product model, and match product impact resistance information according to product wall thickness information, product material information and reference pickup temperature.

[0071] Product wall thickness information refers to the wall thickness of the taillight cover, and product material information refers to the material of the taillight cover. Both of these parameters are fixed parameters designed by engineers for the taillight cover. These two parameters can be retrieved by inputting the product model into the system's database.

[0072] Product impact resistance information refers to the maximum impact force that the surface of the taillight cover can withstand without easily deforming it. This information is related to the current parameters of the taillight cover and its fixed parameters. The current parameters include the reference pickup temperature, while the fixed parameters include the product wall thickness and material information. The product impact resistance information is obtained by inputting the product wall thickness, material information, and reference pickup temperature into a preset impact data table. This impact data table is compiled through manual testing of the taillight cover under different temperature conditions.

[0073] Step S411: Determine the dry ice impact velocity based on the product's impact resistance information and the preset dry ice particle parameter information.

[0074] Dry ice particle parameter information refers to the weight characteristics of each dry ice particle.

[0075] Dry ice impact velocity refers to the speed at which dry ice impacts the surface of the taillight cover when it is ejected from nozzle 23. Dry ice impact velocity is the quotient of the product's impact resistance information and the dry ice particle parameter information.

[0076] Step S412: Output the dry ice impact velocity as a dry ice ejection parameter.

[0077] The nozzle 23 of the dry ice treatment device 2 sprays out dry ice at the dry ice impact speed.

[0078] The process of spraying dry ice by nozzle 23 also includes the following steps: Step S420: Retrieve the tensile strength of the product based on the product model, and set the critical pressure for product failure based on the tensile strength of the product.

[0079] The tensile strength of a product refers to the maximum tensile force that a taillight cover can withstand at a reference pick-up temperature without deforming. The tensile strength of a product can be retrieved directly from the system based on the product model.

[0080] The critical pressure at which a product will break down refers to the maximum pressure applied to a taillight cover without damaging the product. This pressure, however, will further exacerbate damage to a product with inherent defects. The critical pressure at which a product will break down is directly proportional to its tensile strength; the greater the tensile strength, the greater the critical pressure at which a product will break down.

[0081] Step S421: Calculate the test pressure based on the product damage critical pressure and the preset redundant pressure.

[0082] Redundant pressure refers to the difference between the pressure actually applied to avoid damaging the product and the critical pressure at which the product will fail. Test pressure is the actual pressure applied. Test pressure is the difference between the critical pressure at which the product will fail and the redundant pressure.

[0083] Step S422: During the process of spraying dry ice at the nozzle 23, the preset clamping member 112 is controlled to clamp the two sides of the taillight cover and apply force with test pressure.

[0084] When the taillight cover is attracted by the suction cup 111, clamping members 112 will rotate out from both sides of the robotic arm 1 to assist in clamping the taillight cover. The clamping members 112 apply force to the taillight cover with test pressure during clamping.

[0085] In this embodiment, when dry ice causes the product to expand its microcracks, the clamping member 112 provides auxiliary clamping, and the clamping force further promotes the expansion of the microcracks.

[0086] The steps prior to acquiring images of the product surface also include the following: In this embodiment, a blower treatment position is set after the surface treatment position. When the robot arm 1 holds the taillight cover and passes through the blower treatment position, the blower head at the blower treatment position will blow the taillight cover.

[0087] Step S430: In response to a preset second position signal, initiate the jet processing procedure.

[0088] Similar to the first positioning signal in step S401, the second positioning signal refers to the signal triggered when the robot arm 1 moves to the air blowing position. A photoelectric sensor is set at the air blowing position. When the robot arm 1 passes by, the photoelectric sensor detects and sends out the second positioning signal.

[0089] The jet treatment program is the degree of control stored in the system for the blower mechanism 3. After the jet treatment program is activated, the blower mechanism 3 begins to work, blowing air onto the taillight cover.

[0090] Step S431: Based on the preset matching of blowing force and blowing temperature, the sublimation propulsion time of dry ice on the taillight cover is accelerated.

[0091] The airflow force refers to the size of the air blown out by the blower head of the blower mechanism 3, and the airflow temperature refers to the temperature of the air blown out by the blower head of the blower mechanism 3. Both the airflow force and the airflow temperature are fixed parameters that are set in advance by technicians for the blower mechanism 3 according to the product specifications.

[0092] After dry ice is ejected, it needs a certain amount of time to sublimate into a gaseous state. Sublimation propulsion time refers to the time saved during the accelerated sublimation process. Sublimation propulsion time is related to the blowing force and temperature; the stronger the blowing force and the higher the temperature, the longer the sublimation propulsion time and the shorter the sublimation time of the dry ice. The sublimation propulsion time can be matched by inputting the blowing force and temperature into a preset dry ice sublimation database. This database is obtained by technicians through pre-simulated test environments. By simulating different blowing forces and temperatures and detecting the corresponding sublimation propulsion times, the database is created.

[0093] Step S432: Obtain the sublimation time of the dry ice within the crack.

[0094] The sublimation time of cracked dry ice refers to the sublimation time of dry ice when it is located in the gaps of a product and is not accelerated by air blowing. The sublimation time of cracked dry ice is obtained by technicians through pre-simulated test environments and stored in the system database, so the sublimation time of cracked dry ice can be directly retrieved from the system.

[0095] Step S433: Calculate the difference between the sublimation time and the sublimation propulsion time of the cracked dry ice and define it as the blowing reserve time.

[0096] The blowing time refers to the time required for the blower mechanism 3 to blow air onto the taillight covers so that the dry ice in the microcracks is at the critical point of sublimation. The blowing time is the difference between the sublimation time and the sublimation propagation time of the dry ice in the microcracks.

[0097] Step S434: Determine the passing speed of the taillight cover as it passes through the preset air blowing position based on the air blowing time and the preset distance to the air blowing position.

[0098] The distance to the air blowing treatment location refers to the length of the air blowing treatment location in the material handling path. This parameter is a fixed parameter of the equipment.

[0099] Through speed refers to the speed at which the robotic arm 1 moves from the air-blowing processing position while gripping the taillight cover. Through speed is the quotient of the distance to the air-blowing processing position and the air-blowing time allowance.

[0100] Step S435: Based on the jet processing procedure, control the air blower head preset at the air blowing position to blow air with air force and air temperature, and control the taillight cover to pass through the air blowing position at a passing speed.

[0101] When the robotic arm 1 moves the taillight cover to the air blowing position, the system adjusts the moving speed of the robotic arm 1 so that it moves at a passing speed. Under this parameter, when the taillight cover passes the air blowing position, the air blown by the blower can blow away the dry ice on the surface of the taillight cover, so that the dry ice only exists in the hidden cracks of the taillight cover. The dry ice in the hidden cracks will not sublimate immediately, and the hidden cracks can be displayed as white during image detection.

[0102] Simultaneously, air is blown onto the taillight cover, causing its temperature to rise again from the state of being cooled by dry ice. This temperature change further promotes the expansion of hidden cracks in the defective product. In this embodiment, the dry ice temperature is -78.5°C. When the taillight cover is sprayed with dry ice, its temperature gradually approaches this temperature. The blowing temperature of the blower mechanism 3 is set to 50°C to 60°C, allowing the cooled taillight cover to heat up to near the blowing temperature.

[0103] The method for acquiring product surface images and performing image recognition includes the following steps: Step S500: Control the taillight cover to rotate 360° at a preset rotation shooting speed, and capture segment images of the taillight cover at preset acquisition intervals during the rotation.

[0104] Rotational shooting speed refers to the rotational speed of the taillight cover itself when the industrial camera captures images of the taillight cover. In this embodiment, after the clamping member 112 clamps the taillight cover from both sides, the micro motor on the clamping member 112 can drive the taillight cover to rotate circumferentially. During the rotation, the image acquisition direction of the industrial camera is always perpendicular to the rotation axis of the taillight cover in space.

[0105] The acquisition interval refers to the time interval between adjacent single shots when the industrial camera acquires images of the taillight cover. This parameter is preset by technicians for the industrial camera.

[0106] A segment image refers to an image captured by an industrial camera from one angle of a vehicle's taillight cover. By rotating the taillight cover 360° during shooting, the industrial camera can capture multiple segment images around the circumference of the taillight cover, with a certain amount of overlap between adjacent segment images.

[0107] Step S501: Perform feature comparison on all fragment images, remove common image features, and merge them to form a product surface image.

[0108] Shared image features refer to the overlapping portions of adjacent image segments. A product surface image refers to an image that includes all features of the taillight cover surface.

[0109] In this embodiment, it is necessary to obtain a complete surface image of the taillight cover. If all the segment images are directly overlapped, there will be duplicate images at the edges of the segment images. Therefore, before overlapping the segment images, feature comparison is performed on every two adjacent segment images to eliminate the common image features. Finally, none of the segment images contain duplicate image features. At this time, all the segment images are edge-connected and merged to form a product surface image.

[0110] Step S502: Identify whether a preset white dry ice feature exists in the product surface image.

[0111] Since dry ice will sublimate naturally after being sprayed out, and the sublimation speed of dry ice in the gap is slow, and the blowing mechanism 3 is used to further process the dry ice on the surface, so that the dry ice only exists in the cracks, making the cracks appear white. Therefore, the presence of cracks is determined by detecting whether there is a white dry ice feature through image detection.

[0112] Step S503: When the white dry ice feature exists, it is defined that a damage feature exists.

[0113] If the white dry ice feature exists, it indicates that there is a damage feature of cracks, which means that the taillight cover is a defective product. However, if there is no white dry ice feature, it cannot directly indicate that the taillight cover is a qualified product, and further detection and identification are required. The specific detection and identification method will not be described in detail here, and will be introduced in detail in subsequent embodiments.

[0114] The method for acquiring a product surface image and performing image recognition further includes the following steps: Step S510: During the rotation of the taillight cover, the taillight cover is illuminated at a preset illumination intensity and a preset illumination angle, and there is an included angle between the illumination angle and the image acquisition direction.

[0115] The illumination intensity is the intensity of light emitted when the illumination assembly 13 on the manipulator 1 illuminates the taillight cover. The illumination angle is the angle at which the illumination assembly 13 illuminates the taillight cover. This angle is not directly facing the product, and there is an included angle between it and the direction in which the industrial camera performs image acquisition, and the included angle is an acute angle. The above two parameters are both parameters preset by those skilled in the art to optimize the image acquisition quality.

[0116] Step S511: When the white dry ice feature does not exist, obtain the corresponding image pickup position in the product surface image based on the product pickup position.

[0117] The image pickup position refers to the position point in the product surface image of the position on the taillight cover where the suction cup 111 is attached. This position point can be obtained by corresponding the actual position of the product pickup position on the product to the position in the product surface image one by one.

[0118] When the taillight cover rotates to acquire circumferential images, it first contacts the suction cup 111 to expose the position where the suction cup 111 is attached, and then acquires circumferential images.

[0119] Step S512: Add shadows to the image pickup position in the product surface image using a preset shadow enhancement method.

[0120] By tilting the light to illuminate the crack location and capturing images directly at the crack location, and then using a shadow deepening method to deepen the shadow, the color difference of the crack can be highlighted if there is a crack on the product surface.

[0121] The shadow deepening method refers to the method of deepening the color contrast of the shadow at the crack location in an image. The specific method here is as follows: first, increase the image contrast at the image pickup location to separate the shadow at the crack from the surrounding plastic; then, decrease the image height to make the crack texture stand out; next, increase the image clarity and sharpness to enhance the edges of fine lines; finally, increase the shadows in the dark areas to make the lines thicker and darker.

[0122] Step S513: Perform image recognition on the image pickup location from the product surface image to determine whether there is a crack.

[0123] After the above image shadow processing steps, image recognition is performed on the image pickup position in the product surface image to determine whether there are cracks.

[0124] Step S514: When a crack exists, it is defined as the presence of a damage feature.

[0125] If there are cracks, it means that the product is defective.

[0126] The above description is merely a preferred embodiment of the present invention. The scope of protection of the present invention is not limited to the above embodiments. All technical solutions falling within the scope of the present invention's concept are within the scope of protection of the present invention. It should be noted that for those skilled in the art, any improvements and modifications made without departing from the principles of the present invention should also be considered within the scope of protection of the present invention.

Claims

1. An automated sorting method for taillight covers adapted to injection molding machines, characterized in that, include: Infrared images of the taillight cover on the injection molding machine are captured to obtain infrared images of the product. The average temperature of the product is obtained by analyzing the infrared image of the product, and the pickup location features and product pickup location are obtained by feature recognition. After the taillight cover cools down to the preset reference pick-up temperature, the taillight cover is picked up at the product pick-up position to remove it from the injection molding machine and move it along the preset pick-up path. Dry ice is sprayed onto the surface of the taillight cover at a preset surface treatment location in the material handling path to amplify processing damage. Collect images of the product surface and perform image recognition on the product surface images to determine whether there are preset damage features; The taillight covers are classified based on the presence or absence of damage characteristics to determine the sorting location at the end of the material picking path, and the taillight covers are moved to the corresponding sorting location.

2. The automated sorting method for taillight covers adapted to injection molding machines according to claim 1, characterized in that, Dry ice treatment methods include: The dry ice ejection parameters are matched based on the preset product model, and the dry ice ejection parameters are used as fixed parameters in each round of material sorting. When the taillight cover moves to the surface treatment position, in response to the preset first position signal, the preset nozzle (23) is controlled to spray dry ice according to the dry ice spray parameters; The convergence angle of multiple nozzles (23) for convergent spraying is determined according to the preset product rib parameters; The lifting speed of the nozzle (23) is determined based on the preset product size parameters, preset moving speed and preset nozzle spray width, so as to make the nozzle (23) circulate and lift on both sides of the material picking path. When the taillight cover passes the surface treatment position and is sprayed with dry ice, the multiple nozzles (23) arranged in parallel are converged and controlled at the convergence angle, and the nozzles (23) are controlled to circulate and spray on both sides of the taillight cover by the lifting and lowering speed.

3. The automated sorting method for taillight covers adapted to injection molding machines according to claim 2, characterized in that, Methods for matching dry ice ejection parameters include: Based on the product model, retrieve the product wall thickness information and product material information, and match the product impact resistance information according to the product wall thickness information, product material information and reference pickup temperature; The impact velocity of dry ice is determined based on the product's impact resistance information and the preset dry ice particle parameters. The dry ice impact velocity is output as a parameter for dry ice ejection.

4. The automated sorting method for taillight covers adapted to injection molding machines according to claim 2, characterized in that, The process of spraying dry ice by the nozzle (23) also includes: The tensile strength of the product is retrieved based on the product model, and the critical pressure for product failure is set based on the tensile strength of the product. The test pressure is calculated based on the product's critical damage pressure and the preset redundant pressure. During the process of spraying dry ice at the nozzle (23), the preset clamping device (112) is controlled to clamp the two sides of the taillight cover and apply force with test pressure.

5. The automated sorting method for taillight covers adapted to injection molding machines according to claim 2, characterized in that, The steps before acquiring product surface images also include: In response to a preset second positioning signal, the jet handling procedure is initiated; The sublimation propulsion time of dry ice when blowing air onto the taillight cover is accelerated based on the preset matching of blowing air force and blowing temperature. The sublimation time of dry ice within the crack was determined. The difference between the sublimation time and the sublimation propulsion time of the microcracked dry ice is calculated and defined as the blowing reserve time; The passing speed of the taillight cover through the preset air blowing position is determined based on the air blowing time and the preset distance to the air blowing position. Based on the jet processing program, the air blower head preset at the air blowing processing position is controlled to blow air with air force and air temperature, and the taillight cover is controlled to pass through the air blowing processing position at a passing speed.

6. The automated sorting method for taillight covers adapted to injection molding machines according to claim 1, characterized in that, Methods for acquiring product surface images and performing image recognition include: The taillight cover is rotated 360° at a preset rotation shooting speed, and fragment images of the taillight cover are captured at preset acquisition intervals during the rotation. All image fragments are compared for features, common image features are removed, and they are merged to form a product surface image; Identify the presence of pre-defined white dry ice features from product surface images; The presence of white dry ice characteristics is defined as the presence of damage characteristics.

7. The automated sorting method for taillight covers adapted to injection molding machines according to claim 6, characterized in that, Also includes: During the rotation of the taillight cover, the taillight cover is illuminated with a preset illumination intensity and angle, and the illumination angle is at an angle to the direction of image acquisition. When there is no white dry ice feature, the image pickup position in the product surface image is obtained based on the product pickup position; The image pickup location in the product surface image is shaded using a preset shading method; Image recognition is performed on the image pickup location from the product surface image to determine whether there is a crack; When a crack is present, it is defined as the presence of a damage characteristic.

8. An automated sorting device for taillight covers adapted to an injection molding machine, controlled by an automated sorting method for taillight covers adapted to an injection molding machine as described in any one of claims 1 to 7, characterized in that, The device includes a robotic arm (1) for picking up taillight covers from an injection molding machine, a dry ice treatment device (2) for dry ice treatment of the taillight covers, a blower mechanism (3) for blowing air onto the taillight covers, and a discharge mechanism (4) for sorting and discharging the taillight covers. The robotic arm (1) has a material picking path between the injection molding machine and the discharge mechanism (4), and the dry ice treatment device (2) and the blower mechanism (3) are arranged sequentially on the material picking path.

9. An automated sorting device for taillight covers adapted to an injection molding machine according to claim 8, characterized in that, The end of the robotic arm (1) is provided with a mounting plate (14) and a pickup component (11), a collection component (12) and a lighting component (13) mounted on the mounting plate (14); the pickup component (11) includes a suction cup (111) for adsorbing the taillight cover and a clamping member (112) located on both sides of the suction cup (111) for auxiliary clamping from both sides of the taillight cover.

10. An automated sorting device for taillight covers adapted to an injection molding machine according to claim 8, characterized in that, The dry ice processing device (2) includes a dry ice control box (21) located on both sides of the material feeding path, a path adjustment mechanism (22) installed on the dry ice control box (21), and a number of nozzles (23) installed on the path adjustment mechanism (22) for spraying dry ice.

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