Paint surface defect detection device

Abstract

The embodiment of the utility model belongs to the technical field of automatic detection, and particularly relates to a paint surface defect detection device. The paint surface defect detection device comprises a shell, a light source, a detection camera and a controller. The shell comprises a connecting part and a mounting part which are connected; the connecting part is used for connecting the tail end of the manipulator; the light source is arranged on one side of the mounting part, is flat-plate-shaped and is used for emitting stripe light to the to-be-detected paint surface along the contour of the to-be-detected surface; the detection camera and the light source are arranged on the same side of the mounting part; the detection camera is used for shooting a paint surface picture of the to-be-detected paint surface; and the controller is in communication connection with the detection camera and controls the operation of the light source according to the paint surface picture shot by the detection camera. According to the paint surface defect detection device provided by the embodiment of the invention, the automation of the detection process is realized, and the problems caused by manual operation are avoided.

Description

Technical Field

[0001] The embodiments of the present application relate to the field of automated detection and repair technology, and in particular to a paint defect detection device. Background Art

[0002] Tens of millions of cars are put into production every year around the world. As the world's leading country in automobile production, China's quality control of the painting process in the automobile manufacturing process is crucial. Especially after the topcoat has been dried, any tiny paint defect will not only directly affect the overall visual effect and appearance quality of the vehicle, but also be closely related to consumers' purchasing decisions and trust in the car brand. Therefore, ensuring the accuracy and flawlessness of each painting process is of strategic significance for maintaining brand image, improving market competitiveness and meeting consumers' growing high-quality requirements.

[0003] In the prior art, the traditional methods of paint defect detection and repair technology mainly rely on manual visual inspection and manual grinding and polishing. Operators need to rely on their experience and skills to conduct a comprehensive and detailed inspection of the vehicle surface to find possible paint defects, and use handheld tools to perform physical repairs after the problem is found. However, this manual visual inspection and manual repair method has significant technical problems and limitations. Due to human factors, such as lack of experience or lack of concentration, some defects may be missed or misjudged during the inspection process, thus affecting the quality of the final product.

[0004] Therefore, how to design a paint defect detection device that can automate the detection process and avoid the problems caused by manual operation is a technical problem that urgently needs to be solved. Utility Model Content

[0005] The purpose of the embodiments of the present application is to provide a paint surface defect detection device to solve the problem of low work quality of manual visual inspection.

[0006] To achieve the above-mentioned purpose, the embodiment of the present application provides a paint surface defect detection device. The paint surface defect detection device includes a housing, a light source, a detection camera, and a controller. The housing includes a connecting portion and a mounting portion connected to each other, and the connecting portion is used to connect the end of the manipulator; the light source is arranged on one side of the mounting portion, and the light source is in a flat-plate configuration and is used to emit striped light to the paint surface to be tested along the contour of the surface to be tested; the detection camera and the light source are arranged on the same side of the mounting portion, and the detection camera is used to take a paint surface image of the paint surface to be tested; the controller is connected to the detection camera in communication, and controls the operation of the light source according to the paint surface image taken by the detection camera.

[0007] The paint defect detection device provided in the embodiment of the present application realizes an automated closed-loop of the paint surface detection process through intelligent management and control of the controller, that is, there is no human intervention in the entire process from image acquisition, defect identification to light source adjustment, thereby ensuring high precision and consistency of paint surface detection, realizing automated detection of paint surface defects, and avoiding problems caused by manual operation.

[0008] In some embodiments, the light source is a 24-inch light source.

[0009] In some embodiments, the detection camera includes a 3D camera component and a 2D camera component.

[0010] In some embodiments, the angle between the 3D camera assembly, the 2D camera assembly and the light source is 60°, and the adjustable range is ±5°.

[0011] In some embodiments, a color sensor is disposed in the 2D camera assembly, and the color sensor is disposed at an angle parallel to the light source.

[0012] In some embodiments, the 2D camera assembly is rotatably connected to a polishing spray assembly, which is disposed on a side away from the light source and is communicatively connected to a controller.

[0013] In some embodiments, the polishing spray assembly includes a polishing head, which is mounted on a pneumatic polisher, the pneumatic polisher is connected to a constant force controller, the constant force controller is connected to a cylinder, and the cylinder is connected to a spray valve.

[0014] In some embodiments, the 3D camera assembly is rotatably connected to a polishing mark assembly, which is disposed on a side away from the light source and is communicatively connected to a controller.

[0015] In some embodiments, the polishing mark assembly includes a polishing head, which is mounted on a second pneumatic grinder, which is connected to a second constant force controller, which is connected to a second cylinder, which is connected to a second injection valve.

[0016] In some embodiments, a product identification locator is also included. The product identification locator identifies the product model and determines the position through a 3D camera component. After the color sensor determines the color of the product, it automatically calls the scanning and detection program of the corresponding product. BRIEF DESCRIPTION OF THE DRAWINGS

[0017] One or more embodiments are exemplarily described by pictures in the corresponding drawings, and these exemplified descriptions do not constitute limitations on the embodiments. Elements with the same reference numerals in the drawings represent similar elements, and unless otherwise stated, the figures in the drawings do not constitute proportional limitations.

[0018] Figure 1is a front view of a paint surface defect detection device provided in some embodiments of the present application;

[0019] Figure 2 is a rear view of a paint surface defect detection device provided in some embodiments of the present application;

[0020] Figure 3 is a left side view of a paint surface defect detection device provided in some embodiments of the present application;

[0021] Figure 4 is a right side view of a paint surface defect detection device provided in some embodiments of the present application;

[0022] Figure 5 is a top view of a paint surface defect detection device provided in some embodiments of the present application;

[0023] Figure 6 is a bottom view of a paint surface defect detection device provided in some embodiments of the present application;

[0024] Figure 7 is a detailed diagram of a polishing spray assembly provided in some embodiments of the present application;

[0025] Figure 8 Detailed diagram of a polishing mark assembly provided in some embodiments of the present application.

[0026] Description of reference numerals:

[0027] 11-connecting part; 12-installing part; 121-light source; 122-3D camera assembly; 123-2D camera assembly; 1231-color sensor; 124-polishing spray assembly; 1241-polishing head; 1242-pneumatic grinder one; 1243-constant force controller one; 1244-cylinder one; 1245-injection valve; 125-polishing mark assembly; 1251-polishing head; 1252-pneumatic grinder two; 1253-constant force controller two; 1254-cylinder two; 1255-injection valve two. DETAILED DESCRIPTION

[0028] To make the purpose, technical scheme and advantages of the embodiments of the present application clearer, each embodiment of the present application will be described in detail below in conjunction with the accompanying drawings. However, it will be appreciated by those skilled in the art that in each embodiment of the present application, many technical details are proposed in order to enable the reader to better understand the present application. However, even without these technical details and various changes and modifications based on the following embodiments, the technical scheme claimed in the present application can also be implemented. The division of the following embodiments is for the convenience of description, and the specific implementation of the present application should not constitute any limitation, and the various embodiments can be combined with each other and referenced to each other without contradiction.

[0029] Unless otherwise defined, all technical and scientific terms used herein have the same meaning as commonly understood by technicians in the technical field to which this application belongs; the terms used herein are only for the purpose of describing specific embodiments and are not intended to limit this application; the terms "including" and "having" in the specification and claims of this application and the above-mentioned figure descriptions and any variations thereof are intended to cover non-exclusive inclusions.

[0030] In the description of the embodiments of the present application, the technical terms "first", "second", etc. are only used to distinguish different objects, and cannot be understood as indicating or implying relative importance or implicitly indicating the number, specific order or primary and secondary relationship of the indicated technical features. In the description of the embodiments of the present application, the meaning of "multiple" is more than two, unless otherwise clearly and specifically defined.

[0031] In the description of the embodiments of the present application, unless otherwise clearly specified and limited, technical terms such as "installed", "connected", "connected" and the like should be understood in a broad sense. For example, it can be a fixed connection, a detachable connection, or an integral connection; it can be a mechanical connection or an electrical connection; it can be a direct connection or an indirect connection through an intermediate medium, and it can be the internal connection of two elements or the interaction relationship between two elements. For ordinary technicians in this field, the specific meanings of the above terms in the embodiments of the present application can be understood according to the specific circumstances.

[0032] The technical solutions for paint defect detection and repair in the prior art are mainly completed by manual visual inspection and manual repair. With rich experience and keen observation, the inspectors conduct meticulous inspections on the surface of the car that has completed the painting process. By examining the paint surface from a close distance and in all directions, various defects such as color difference, scratches, unevenness or particles can be identified. The inspector not only needs to judge whether the overall color of the paint surface is uniform, but also needs to accurately find and determine the specific location, size and type of various defects. Once defects are found in the paint surface, professional technicians need to use handheld tools to grind and polish it. This link involves a variety of techniques and technical requirements, such as strength control, time control, material selection, etc., to ensure that the repaired paint surface meets the original quality standards.

[0033] However, this method has significant disadvantages. Manual inspection is easily affected by the staff, and defects may be missed or misjudged due to negligence of the workers, increasing the risk of defective rate and making it difficult to maintain stable and consistent product quality. In addition, the manual inspection process is time-consuming and limited by factors such as the operator's vision, attention and fatigue. It cannot be compared with automated equipment, and is particularly inefficient in mass production environments.

[0034] In order to ensure the quality of work during detection, some embodiments of the present application provide a paint defect detection device, which realizes closed-loop management of the automated detection process through a controller, from acquiring the paint image to be tested, automatically identifying paint defects, to accurately adjusting the working state of the light source according to the detection results, without manual intervention. This automated closed-loop operation not only ensures high accuracy and consistency in paint defect detection, but also effectively avoids errors, omissions and instability that may be caused by manual operation.

[0035] In order to better understand the technical solution and technical effects of the present application, a specific embodiment of the paint defect detection device will be described in detail below with reference to the accompanying drawings.

[0036] like Figure 1 As shown, the paint surface defect detection device provided by some embodiments of the present application includes a housing, a light source 121, a detection camera, and a controller. The housing includes a connecting portion 11 and a mounting portion 12 connected to each other, and the connecting portion 11 is used to connect the end of the manipulator; the light source 121 is arranged on one side of the mounting portion 12, and the light source 121 is in a flat plate and is used to emit striped light to the paint surface to be tested along the contour of the surface to be tested; the detection camera and the light source 121 are arranged on the same side of the mounting portion 12, and the detection camera is used to take a paint surface image of the paint surface to be tested; the controller is connected to the detection camera for communication, and controls the operation of the light source 121 according to the paint surface image taken by the detection camera.

[0037] The paint defect detection device adopts an innovative integrated structural design, and the shell part is composed of a connection part 11 and a mounting part 12. The connection part 11 is specifically used to seamlessly dock with the end of the manipulator, so that the entire detection equipment can flexibly follow the movement of the manipulator and accurately align with the paint surface areas to be tested at different positions and angles. The light source 121 component is cleverly arranged on one side of the mounting part 12, and is arranged in a flat plate shape. Its function is to emit specific stripe light patterns along the surface contour of the product. These stripe lights can produce obvious texture effects on the paint surface, which helps to highlight and distinguish various types of paint defects.

[0038] At the same time, a high-performance detection camera system is also configured on the same side of the mounting portion 12. The system works closely with the light source 121 and is designed to capture the image information presented by the paint surface after being irradiated by the light source 121. The detection camera uses a high-precision optical lens to capture high-definition images of the paint surface to be tested, and transmits the collected paint surface image to the controller in real time for processing and analysis. As a core intelligent component, the controller can respond quickly according to the received paint surface image data, and dynamically adjust the working mode, intensity or angle and other parameters of the light source 121 to meet different detection needs. This series of precision control processes ensures that the device can achieve efficient and accurate paint defect identification and positioning in a complex and changeable production environment, greatly improving the quality control capability and work efficiency of the automated production line.

[0039] The paint defect detection device provided in some embodiments of the present application, through its precise layout and intelligent linkage characteristics, can effectively solve the problems of low efficiency, missed detection and false detection existing in traditional manual inspection and repair, and ensure comprehensive, rapid and high-quality detection of paint defects on the surface of automobiles and other objects to be tested.

[0040] In some embodiments of the present application, the light source 121 is a 24-inch light source.

[0041] like Figure 1 As shown, due to the large size of 24 inches, it can better cover and adapt to the different surfaces and shapes of various models of cars, and can evenly and effectively illuminate the entire area to be tested even with complex product contours. The light source 121 can emit stripe light along the contour surface of the product. This special light source 121 mode helps to enhance the visual characteristics of surface defects and improve the accuracy of the 2D camera component 123 in judging the type and location of paint defects. And when working in conjunction with the 3D camera component 122, the light source 121 can help build a more accurate three-dimensional model. Through different illumination angles and intensity changes of the light source 121, more depth information can be collected, which is conducive to accurate spatial positioning and defect analysis.

[0042] In some embodiments of the present application, the detection camera includes a 3D camera component 122 and a 2D camera component 123 .

[0043] like Figure 1 As shown, the 3D camera component 122 and the 2D camera component 123 are used in combination. This design aims to make full use of the different advantages of the two cameras to achieve more comprehensive and accurate paint defect detection. Among them, the 3D camera component 122 can use structured light technology to obtain a three-dimensional image of the paint surface, capturing depth information and the concave and convex changes on the surface of the object; while the 2D camera component 123 focuses on capturing high-definition images of the paint surface, including surface defects and color information. The combination of the two can not only complement each other's deficiencies and improve the accuracy and completeness of defect identification, but also can flexibly switch or integrate applications according to actual conditions, ensuring that the entire inspection process can identify both tiny planar defects and complex three-dimensional defects, thereby achieving efficient and automated detection and repair of automotive paint defects.

[0044] In some embodiments of the present application, the angle between the 3D camera assembly 122, the 2D camera assembly 123 and the light source 121 is 60°, and the adjustable range is ±5°.

[0045] like Figure 5 , 6As shown, the design of the inspection camera includes a 3D camera assembly 122 and a 2D camera assembly 123, and the installation angle of the two camera assemblies and the light source 121 is 60°, and this angle can be adjusted within a range of ±5°. The characteristics of this angle setting and adjustability allow the camera to capture detailed information of the paint surface to be inspected at the most suitable viewing angle, whether it is a three-dimensional shape or a two-dimensional surface feature.

[0046] In some embodiments of the present application, a color sensor 1231 is disposed in the 2D camera assembly 123 , and the color sensor 1231 is disposed at an angle parallel to the light source 121 .

[0047] like Figure 1 As shown, the 2D camera assembly 123 is not only used to capture a two-dimensional image of the paint surface to be inspected, but the color sensor 1231 integrated therein is designed to be parallel to the light source 121. This design enables the color sensor 1231 to work under optimal lighting conditions, because the parallel arrangement of the light source 121 can ensure that the paint surface is evenly illuminated, avoiding color reading errors caused by uneven lighting. Uniform lighting is critical for accurately identifying the color of the paint surface, especially in applications where color differences are particularly important for defect detection. This setting improves the ability to detect the consistency of paint color and makes color analysis more accurate, thereby ensuring the accuracy of color matching during the paint repair process and ensuring the visual quality of the final product. This innovation provides significant technical advantages in automated inspection and quality control.

[0048] In some embodiments of the present application, the 2D camera assembly 123 is rotatably connected to a polishing spray assembly 124 . The polishing spray assembly 124 is disposed on a side away from the light source and is communicatively connected to a controller.

[0049] like Figure 2 , 3 As shown, the polishing spray assembly 124 is arranged on the side away from the light source 121 to prevent the liquid sprayed during the polishing process from splashing onto the light source 121 or the camera lens, affecting the detection effect. The polishing spray assembly 124 is connected to the controller for communication and can be rotatably connected to the 2D camera assembly 123. This design enables the polishing spray assembly 124 to accurately align the defect position for polishing or spraying after the 2D camera detects the paint defect. The configuration of the rotating connection allows the polishing spray assembly 124 to dynamically adjust the viewing angle of the 2D camera 123, thereby maintaining the optimal focus and operating position on the defect at all times, ensuring the accuracy and efficiency of the repair operation. This arrangement significantly improves the efficiency of the automated repair process, reduces the need for manual intervention, and enhances the consistency of the repair quality.

[0050] In some embodiments of the present application, the polishing spray assembly 124 includes a polishing head 1241, which is installed on a pneumatic polisher 1242, which is connected to a constant force controller 1243, which is connected to a cylinder 1244, and which is connected to a spray valve 1245.

[0051] like Figure 7 As shown, the grinding head 1241 is installed on a pneumatic grinder 1242, and the grinding head can perform the grinding action with the help of the power output of the pneumatic grinder 1242. The pneumatic grinder 1242 is closely connected to the constant force controller 1243, and the power output of the pneumatic grinder 1242 is precisely controlled by the constant force controller 1243 to ensure constant pressure during the grinding process. Furthermore, the constant force controller 1243 forms a communication relationship with the cylinder 1244, and indirectly controls the movement state of the grinding head 1241 by adjusting the air pressure state inside the cylinder 1244. At the same time, the cylinder 1244 is also physically connected to the injection valve 1245, and the injection valve 1245 can adjust the injection rate and time of the liquid or gas according to the control instruction, and cooperate with the grinding process synchronously to ensure the coordinated operation of grinding and liquid spraying.

[0052] In some embodiments of the present application, the 3D camera assembly 122 is rotatably connected to a polishing mark assembly 125 , and the polishing mark assembly 125 is disposed on a side away from the light source 121 and is communicatively connected to the controller.

[0053] like Figure 2 , 4 As shown, the polishing mark assembly 125 is arranged on the side away from the light source 121 to prevent the liquid sprayed during the polishing process from splashing onto the light source 121 or the camera lens, thereby affecting the detection effect. The design of the polishing mark assembly 125 is not only connected to the controller in communication to ensure that it can receive instructions from the control system, but also connected to the 3D camera assembly 122 by rotation. The advantage of this structural layout is that the stereoscopic image provided by the 3D camera assembly 122 can accurately determine the position and shape of the paint surface defects, and the polishing mark assembly 125 can then accurately locate these defects based on this information for polishing and marking. The rotational connection allows the polishing mark assembly 125 to follow the adjustment of the viewing angle of the 3D camera assembly 122, further enhancing the ability to finely polish irregular paint surfaces, ensuring the accuracy and efficiency of the defect repair process, and greatly improving the surface quality of the final product.

[0054] In some embodiments of the present application, the polishing marking assembly 125 includes a polishing head 1251, which is installed on a pneumatic grinder 1252, and the pneumatic grinder 1252 is connected to a constant force controller 1253, and the constant force controller 1253 is connected to a cylinder 1254, and the cylinder 1254 is connected to an injection valve 1255.

[0055] like Figure 8 As shown, the polishing head 1251 is mounted and fixed on the pneumatic grinder 1252, and the power generated by the pneumatic grinder 1252 drives the polishing head 1251 to perform the polishing operation. The pneumatic grinder 1252 is electrically or pneumatically connected to the constant force controller 1253, and the constant force controller 1253 can accurately adjust and control the force output by the pneumatic grinder 1252 to ensure that the force is constant and stable during the polishing process. On this basis, the constant force controller 1253 and the cylinder 1254 establish a communication mechanism to indirectly adjust the working state of the polishing head 1251 by controlling the change of the internal air pressure of the cylinder 1254. In addition, the cylinder 1254 is also physically connected to the injection valve 1255, and the injection valve 1255 controls the injection timing and amount of the liquid or marking material according to the preset program or real-time control instructions to ensure that the polishing and marking operations are carried out synchronously and accurately.

[0056] In some embodiments of the present application, a product identification locator is also included. The product identification locator identifies the product model and determines the position through the 3D camera component 122. After the color sensor 1231 determines the product color, it automatically calls the scanning detection program of the corresponding product.

[0057] The 3D camera assembly 122 combined with the color sensor 1231 can accurately determine the position and color of the product, reducing the risk of invalid detection or missed detection due to recognition errors, thereby improving the overall detection quality. Automatically calling the scanning and detection program of the corresponding product means that the device can formulate personalized detection standards and strategies according to different models and colors of products, ensuring targeted and accurate detection of various types of automotive paint defects.

[0058] The above is only a preferred embodiment of the present application and does not constitute any formal limitation to the present application. Although the present application has been disclosed as above with a preferred embodiment, it is not intended to limit the present application. Any technician familiar with the art can make many possible changes and modifications to the technical solution of the present application using the methods and technical contents disclosed above without departing from the scope of the technical solution of the present application, or modify it into an equivalent embodiment of equivalent changes. Therefore, any simple modification, equivalent change and modification made to the above embodiments based on the technical essence of the present application without departing from the content of the technical solution of the present application still fall within the scope of protection of the technical solution of the present application.

Claims

1. A paint surface defect detection device, characterized in that: include: The housing comprises a connecting portion and a mounting portion connected to each other, wherein the connecting portion is used to connect the end of the manipulator; Light source: arranged at one side of the mounting portion, the light source is in a flat plate configuration and is used to emit stripe light along the contour of the surface to be tested toward the paint surface to be tested; Detection camera: arranged on the same side of the mounting portion as the light source, the detection camera is used to photograph the paint surface image of the paint surface to be tested; Controller: connected to the detection camera for controlling the operation of the light source according to the paint surface image captured by the detection camera.

2. The paint surface defect detection device according to claim 1, characterized in that: The light source is a 24-inch light source.

3. The paint surface defect detection device according to claim 1, characterized in that: The detection camera includes a 3D camera component and a 2D camera component.

4. The paint surface defect detection device according to claim 3, characterized in that: The included angle between the 3D camera assembly, the 2D camera assembly and the light source is 60°, and the adjustable range is ±5°.

5. The paint surface defect detection device according to claim 3, characterized in that: The 2D camera assembly is provided with a color sensor, and the color sensor is arranged at an angle parallel to the light source.

6. The paint surface defect detection device according to claim 3, characterized in that: The 2D camera component is rotatably connected to a polishing spray component, and the polishing spray component is arranged on a side away from the light source and is communicatively connected to the controller.

7. The paint surface defect detection device according to claim 6, characterized in that: The polishing spray assembly includes a polishing head, which is installed on a pneumatic polisher. The pneumatic polisher is connected to a constant force controller, which is connected to a cylinder, and the cylinder is connected to an injection valve.

8. The paint surface defect detection device according to claim 3, characterized in that: The 3D camera component is rotatably connected to a polishing mark component, and the polishing mark component is arranged on a side away from the light source and is communicatively connected to the controller.

9. The paint surface defect detection device according to claim 8, characterized in that: The polishing marking assembly includes a polishing head, which is installed on a second pneumatic grinder. The second pneumatic grinder is connected to a second constant force controller. The second constant force controller is connected to a second cylinder, and the second cylinder is connected to a second injection valve.

10. The paint surface defect detection device according to claim 5, characterized in that: It also includes a product identification locator, which identifies the product model and determines the position through the 3D camera component. After the color sensor determines the product color, it automatically calls the scanning and detection program of the corresponding product.

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