Visual inspection system for welding seam

Abstract

The utility model provides a visual inspection system for a welding seam, which comprises a workpiece conveying assembly, a frame, a first position sensor for identifying the position of the detected welding seam, a second position sensor, a plurality of cameras for shooting the detected welding seam, and a main controller. In the process that the workpiece conveying assembly conveys the to-be-detected workpiece, the main controller receives a first identification signal of the first position sensor, and when the first identification signal shows that a detected welding seam is identified, each camera is controlled to shoot an image including the detected welding seam; the main controller analyzes the image and determines whether the shape of the detected welding seam is abnormal or not; the main controller is further used for receiving a second recognition signal of the second position sensor, and when the second recognition signal shows that the detected welding seam is recognized, the cameras are controlled to be turned off. According to the scheme, manpower resources are released, the production efficiency is remarkably improved, and errors caused by manual welding seam positioning are effectively avoided.

Description

Technical Field

[0001] The utility model relates to the technical field of mechatronics, and in particular to a welding seam visual detection system. Background Art

[0002] After welding, it is usually necessary to visually inspect the weld surface to eliminate welding anomalies and improve product quality. With the rapid development of automation technology, the efficiency requirements in various fields are getting higher and higher, and the speed and accuracy of rapid weld inspection are becoming more and more important.

[0003] At present, the commonly used method is to inspect the weld with human eyes, classify the objects to be inspected according to the inspection results, and then proceed to the next step. When the operation is discontinuous, the volume and weight of the workpiece are too large, and errors occur in manual processing, the work of the previous and next stations will be affected, thereby reducing efficiency. In addition, the accuracy of the operation mainly depends on the individual working status of the operator. Therefore, it is urgent to provide a weld surface visual recognition system with a higher degree of automation and higher accuracy. Utility Model Content

[0004] The technical problem to be solved by the utility model is that the existing weld detection requires manual identification. Therefore, the utility model proposes a weld visual detection system.

[0005] In view of the above technical problems, the utility model provides the following technical solutions:

[0006] In a first aspect, the technical solution of the present application provides a weld visual inspection system, comprising:

[0007] A workpiece conveying assembly, used for conveying a workpiece to be tested, wherein the workpiece to be tested has a weld to be tested;

[0008] A frame is arranged above the workpiece conveying assembly; a first position sensor and a second position sensor for identifying the position of the weld to be detected and a plurality of cameras for photographing the weld to be detected are arranged on the frame, and the cameras are arranged between the first position sensor and the second position sensor; the first position sensor and the second position sensor are distance sensors, and the distance sensors are arranged on at least one side frame parallel to the workpiece conveying direction, and the detection surface of the distance sensor faces the workpiece to be detected; the distance sensor detects the distance between the surface of the workpiece to be detected and the detection surface, and determines that the weld to be detected is identified when the change value of the distance is greater than a set threshold value;

[0009] A main controller is connected to the first position sensor. After the first position sensor identifies the weld to be detected, the main controller controls each of the cameras to capture an image of the workpiece to be detected in a transmission state, wherein the image includes the weld to be detected, and the main controller identifies the shape of the weld to be detected. The main controller is also connected to the second position sensor. After the second position sensor identifies the weld to be detected, the main controller controls each of the cameras to be turned off.

[0010] In some embodiments of the weld visual inspection system, the camera includes multiple cameras, and the multiple cameras are arranged at different positions of the frame to capture images including the inspected weld from different directions and angles.

[0011] In some embodiments of the weld visual inspection system, the camera includes at least a camera arranged at the top of the frame and cameras arranged at the four top corners of the frame.

[0012] In some schemes, the weld visual inspection system described in the invention has cameras disposed at the four top corners of the frame mounted on the frame via camera adjustment brackets, and the camera adjustment brackets adjust the shooting direction of the cameras under the control of the main controller.

[0013] The weld visual inspection system described in some embodiments further includes:

[0014] A light source is arranged on the frame and located above the workpiece conveying assembly; the light source is turned on or off under the control of the main controller.

[0015] In some embodiments of the weld visual inspection system, the light source is disposed on the frame via a light source bracket; the light source is disposed perpendicular to the workpiece conveying direction.

[0016] In some embodiments of the weld visual inspection system, the workpiece transfer assembly, the camera, and the light source are all connected to the main controller.

[0017] The technical solution of the utility model has the following technical effects compared with the prior art:

[0018] The weld visual inspection system provided by the utility model includes a workpiece conveying component, a frame, a first position sensor for identifying the position of the weld to be inspected, a second position sensor, and a plurality of cameras for photographing the weld to be inspected, and also includes a main controller. In the process of the workpiece conveying component conveying the workpiece to be inspected, the main controller receives the first recognition signal of the first position sensor, and after the first recognition signal indicates that the weld to be inspected is identified, controls each camera to photograph the image of the workpiece to be inspected in the conveying state, and the image includes the weld to be inspected; the main controller analyzes the image, and can use the existing analysis method to determine whether the shape of the weld to be inspected is abnormal; the main controller is also used to receive the second recognition signal of the second position sensor, and when the second recognition signal indicates that the weld to be inspected is identified, controls each camera to be turned off. Through the above scheme of the present application, it is realized that the position of the weld to be inspected on the workpiece to be inspected is automatically located on the continuous production line, so that the workpiece is moved in a moving state, so that the camera can accurately photograph the weld, without setting up a special inspection station, releasing human resources, and significantly improving production efficiency. BRIEF DESCRIPTION OF THE DRAWINGS

[0019] The preferred embodiments of the present invention will be described in detail below with reference to the accompanying drawings, which will help to understand the purpose and advantages of the present invention, wherein:

[0020] Figure 1 This is a schematic diagram of the structure of a weld visual inspection system according to an embodiment of the present application;

[0021] Figure 2 This is a schematic diagram of the state when the first position sensor in the weld visual inspection system according to one embodiment of the present application identifies the weld to be inspected;

[0022] Figure 3 This is a schematic diagram of the state of a camera photographing a weld being inspected in a weld visual inspection system according to an embodiment of the present application;

[0023] Figure 4 This is a schematic diagram of the state when the second position sensor in the weld visual inspection system described in one embodiment of the present application identifies the weld to be inspected. DETAILED DESCRIPTION

[0024] The technical solution of the utility model will be described clearly and completely below in conjunction with the accompanying drawings. Obviously, the described embodiments are part of the embodiments of the utility model, not all of the embodiments. Based on the embodiments of the utility model, all other embodiments obtained by ordinary technicians in this field without creative work are within the scope of protection of the utility model.

[0025] In the description of the present utility model, it should be noted that the terms "center", "upper", "lower", "left", "right", "vertical", "horizontal", "inside", "outside" and the like indicate positions or positional relationships based on the positions or positional relationships shown in the drawings, and are only for the convenience of describing the present utility model and simplifying the description, rather than indicating or implying that the device or element referred to must have a specific orientation, be constructed and operated in a specific orientation, and therefore cannot be understood as limiting the present utility model. In addition, the terms "first", "second", and "third" are only used for descriptive purposes and cannot be understood as indicating or implying relative importance.

[0026] In the description of the present invention, it should be noted that, unless otherwise clearly specified and limited, the terms "installed", "connected", and "connected" 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 direct connection, or an indirect connection through an intermediate medium, or it can be the internal communication of two components. For ordinary technicians in this field, the specific meanings of the above terms in the present invention can be understood according to specific circumstances.

[0027] In addition, the technical features involved in the different embodiments of the present invention described below can be combined with each other as long as they do not conflict with each other.

[0028] The present application embodiment provides a weld visual inspection system, such as Figure 1 As shown. The system includes a workpiece conveying assembly for conveying a workpiece 1 to be tested, and the workpiece 1 to be tested has a weld to be tested. A frame 7 is arranged above the workpiece conveying assembly and can surround the workpiece 1 to be tested; the frame 7 is provided with a first position sensor 61 for identifying the position of the weld to be tested, a second position sensor 62 and a plurality of cameras for photographing the weld to be tested, and the camera 3 is arranged between the first position sensor 61 and the second position sensor 62. The main controller 8 receives a first recognition signal from the first position sensor 61, and after the first recognition signal indicates that the weld to be tested is identified, controls each of the cameras to photograph an image of the workpiece to be tested in a conveying state, and the image includes the weld to be tested; the main controller 8 analyzes the image to determine whether the shape of the weld to be tested is abnormal; in specific implementation, after identifying the weld to be tested, it can be determined whether it is a straight line, whether there are foreign objects, cold welding and other defects, to determine whether the shape of the weld is abnormal. The main controller 8 is further used to receive a second identification signal from the second position sensor 62, and control each of the cameras to be turned off when the second identification signal indicates that the detected weld has been identified.

[0029] Through the above scheme of the present application, the position of the weld to be detected on the workpiece 1 to be detected is automatically located on the continuous production line, so that the workpiece 1 to be detected can be moved in a moving state, and the camera can accurately capture the weld. There is no need to set up a special inspection station, which releases human resources and significantly improves production efficiency. The recognition result in this scheme can ensure the positioning accuracy and consistency of the weld, and effectively avoid the error of manual weld positioning. By automatically analyzing the weld to be detected, it is determined whether the workpiece to be tested is a good product, which has the advantages of high automation and high precision.

[0030] In a specific implementation, the first position sensor 61 and the second position sensor 62 in the weld visual inspection system are distance sensors, and the distance sensor is arranged on at least one side frame parallel to the workpiece conveying direction, and the detection surface of the distance sensor faces the workpiece 1 to be measured; the distance sensor detects the distance between the surface of the workpiece 1 to be measured and the detection surface, and determines that the detected weld is identified when the change value of the distance is greater than a set threshold. Under normal circumstances, the surface of the workpiece is flat and almost flat, so the distance from the detection surface of the first position sensor 61 and the second position sensor 62 to the surface of the workpiece will hardly change. At the weld position, its flatness is destroyed, so the distance from the weld to the detection surface will change. Therefore, the weld position can be determined based on the distance between the surface of the workpiece 1 to be measured and the detection surface of the first position sensor 61 and the second position sensor 62. In a specific implementation, the first position sensor 61 and the second position sensor 62 can be implemented by devices such as laser displacement sensors. Figure 2-Figure 4 As shown, when the weld to be detected is between the first position sensor 61 and the second position sensor 62, the camera starts the shooting function to shoot an image including the weld to be detected. If the second position sensor 62 also detects the weld to be detected, it means that the workpiece to be detected is about to leave the frame area, and the camera is turned off at this time to avoid wasting resources.

[0031] In the specific implementation, the installation position of the camera needs to ensure that the weld to be inspected can be clearly and completely photographed. Preferably, as shown in the figure, the camera includes multiple cameras, and the multiple cameras are arranged at different positions of the frame to capture images including the weld to be inspected from different directions and angles. Further, the camera at least includes a camera arranged at the top of the frame (the first camera 31 in the figure) and cameras arranged at the four top corners of the frame (the second camera 3 in the figure). The shooting results of the five cameras can ensure that the weld to be inspected is fully photographed from 360 degrees. Whether the weld to be inspected photographed by each camera is a straight line, whether there are defects such as foreign matter and cold welding, it can be determined whether the weld to be inspected is qualified. The image captured by the camera is sent to the main controller, which can be analyzed by the main controller using existing image processing methods.

[0032] Preferably, the cameras 3 arranged at the four top corners of the frame in the above scheme are arranged on the frame 7 through the camera adjustment bracket 2, and the camera adjustment bracket 2 adjusts the shooting direction of the camera under the control of the main controller 8. The camera adjustment bracket 2 can control the movement of the camera in the up, down, front, back, left and right directions, and the bracket can be a structure such as a pan / tilt.

[0033] Preferably, the weld visual inspection system in the above scheme also includes a light source 5, which is arranged on the frame 7 and located above the workpiece conveying assembly; the light source 5 is turned on or off under the control of the main controller 8. Through the auxiliary role of the light source 5, sufficient brightness can be provided for the camera shooting environment to ensure the clarity of the image. Further preferably, the light source 5 is arranged on the frame 7 through a light source bracket; the light source 5 is arranged perpendicular to the workpiece conveying direction. The light source 5 can be a surface light source. When the light source 5 is turned on, it can illuminate the area where the weld to be inspected is located, and at the same time, it can also increase the brightness of the light in a certain spatial range around it to a level that meets the camera shooting requirements.

[0034] In some solutions of the present application, the workpiece conveying assembly, the camera and the light source are all connected to the main controller 8. In the above solutions of the present application, the main controller 8 can automatically control the camera shutter time and the luminous intensity of the light source according to the conveying speed of the workpiece to be tested, the camera resolution, the field of view of the camera and other related information to ensure that the captured image has sufficient clarity and accuracy, and provide an accurate image for accurately identifying the information of the weld to be tested.

[0035] The above solution of the present application realizes automatic positioning of the weld of the workpiece to be tested on a continuous production line, so that the camera can accurately capture the weld when the workpiece is moving, without setting up a special inspection station, thereby significantly improving production efficiency. This solution can ensure the positioning accuracy and consistency of the weld and effectively avoid the error of manual weld positioning. In addition, this solution can automatically analyze the image to identify the surface characteristics of the weld and automatically screen out abnormal welds. The inspection accuracy and repeatability are significantly better than visual inspection.

[0036] Obviously, the above embodiments are merely examples for the purpose of clear explanation, and are not intended to limit the implementation methods. For those skilled in the art, other different forms of changes or modifications can be made based on the above description. It is not necessary and impossible to list all the implementation methods here. The obvious changes or modifications derived therefrom are still within the scope of protection of the present utility model.

Claims

1. A weld visual inspection system, characterized in that: include: A workpiece conveying assembly, used for conveying a workpiece to be tested, wherein the workpiece to be tested has a weld to be tested; A frame is arranged above the workpiece conveying assembly; a first position sensor and a second position sensor for identifying the position of the weld to be detected and a plurality of cameras for photographing the weld to be detected are arranged on the frame, and the cameras are arranged between the first position sensor and the second position sensor; the first position sensor and the second position sensor are distance sensors, and the distance sensors are arranged on at least one side frame parallel to the workpiece conveying direction, and the detection surface of the distance sensor faces the workpiece to be detected; the distance sensor detects the distance between the surface of the workpiece to be detected and the detection surface, and determines that the weld to be detected is identified when the change value of the distance is greater than a set threshold value; A main controller is connected to the first position sensor. After the first position sensor identifies the weld to be detected, the main controller controls each of the cameras to capture an image of the workpiece to be detected in a transmission state, wherein the image includes the weld to be detected, and the main controller identifies the shape of the weld to be detected. The main controller is also connected to the second position sensor. After the second position sensor identifies the weld to be detected, the main controller controls each of the cameras to be turned off.

2. The weld visual inspection system according to claim 1, characterized in that: The cameras include a plurality of cameras, which are arranged at different positions of the frame to capture images including the inspected weld from different directions and angles.

3. The weld visual inspection system according to claim 2, characterized in that: The cameras at least include a camera arranged at the top of the frame and cameras arranged at the four top corners of the frame.

4. The weld visual inspection system according to claim 1, characterized in that: The cameras arranged at the four top corners of the frame are arranged on the frame through a camera adjustment bracket, and the camera adjustment bracket adjusts the shooting direction of the camera under the control of the main controller.

5. The weld visual inspection system according to any one of claims 1 to 4, characterized in that: Also includes: A light source is arranged on the frame and located above the workpiece conveying assembly; the light source is turned on or off under the control of the main controller.

6. The weld visual inspection system according to claim 5, characterized in that: Also includes: The light source is arranged on the frame through a light source bracket; the light source is arranged perpendicular to the workpiece conveying direction.

7. The weld visual inspection system according to claim 6, characterized in that: The workpiece transfer assembly, the camera and the light source are all connected to the main controller.

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