Sensing system, whole vehicle configuration error-proofing detection system and whole vehicle assembly system

Abstract

The utility model provides a sensing system, a whole vehicle configuration error-proofing detection system and a whole vehicle assembly system.The sensing system comprises a plurality of cameras which are fixed through camera supports, the camera supports are fixedly arranged on a detection platform, and the cameras are arranged on the detection platform; a to-be-detected vehicle can be parked on the detection platform or the to-be-detected vehicle can move to pass through the detection platform. The lighting device is used for providing shooting brightness for the camera; the sensor is arranged at the detection platform so as to collect position information of the to-be-detected vehicle relative to the detection platform; wherein the plurality of cameras comprise a lateral camera arranged along the length direction of the detection platform and a top camera arranged above the detection platform, and the length direction of the detection platform is parallel to the length direction of the to-be-detected vehicle. According to the sensing system, the cost is low, the flexibility is high, and the high safety advantage can be provided for man-machine cooperation of whole vehicle configuration mistake-proofing detection.

Description

Technical Field

[0001] The present application relates to the field of automobile manufacturing technology, and in particular to a perception system for detecting errors in the configuration of a whole vehicle, a whole vehicle configuration error detection system, and a whole vehicle assembly system. Background Art

[0002] Users' demand for personalized customization of cars is increasing day by day, and with it comes a surge in the number of optional configuration combinations for car appearance. Car production lines are usually mixed-line production, covering a variety of models and a variety of optional configuration schemes for appearance. During the car assembly process or after the car rolls off the line, the whole vehicle configuration needs to be tested to prevent missing or wrong installation. In practice, in order to ensure that the product meets the order requirements, manual configuration testing is required, which has high labor costs and high misjudgment and missed detection rates.

[0003] In addition, the applicant is also aware of a vehicle configuration error-proofing detection system based on machine vision, in which a robotic arm or robot carries a camera to move and shoot to obtain image data of the appearance configuration of the entire vehicle body. In this system, a special working safety area for the robotic arm or robot is required. This error-proofing detection system will occupy the production cycle and has a high hardware cost.

[0004] It should be noted that the content introduced here only provides background information related to the present disclosure and does not necessarily belong to the prior art. Utility Model Content

[0005] According to different aspects, the purpose of the present application is to provide a perception system for vehicle configuration error prevention detection, such as vehicle appearance configuration error prevention detection, and a vehicle configuration error prevention detection system and a vehicle assembly production system including such a perception system, which have low cost, high flexibility and good scalability.

[0006] In addition, the present application is also intended to solve or alleviate other technical problems existing in the prior art.

[0007] The present application solves the above-mentioned problem by providing a perception system, specifically, it comprises: a plurality of cameras, which are respectively fixed by means of camera brackets, the camera brackets are fixedly arranged at a detection platform, a vehicle to be inspected can be parked on the detection platform or the vehicle to be inspected can move through the detection platform; an illumination device, which is used to provide shooting brightness for the camera;

[0008] A sensor is arranged at the detection platform to collect position information of the vehicle to be inspected relative to the detection platform; wherein the multiple cameras include side cameras arranged along the length direction of the detection platform and a top camera arranged above the detection platform, wherein the length direction of the detection platform is parallel to the length direction of the vehicle to be inspected.

[0009] In the perception system proposed according to the first aspect of the present application, optionally, the side camera includes an end side camera for the front or rear of the vehicle to be inspected and a middle side camera for the side body of the vehicle to be inspected, wherein the middle side camera has translational freedom, and the end side camera has translational freedom and rotational freedom around the vertical direction.

[0010] In the perception system proposed according to the first aspect of the present application, optionally, the top camera has translational freedom and rotational freedom around a horizontal direction.

[0011] In the perception system proposed according to the first aspect of the present application, optionally, the camera bracket includes a fixed base and an adjustment mechanism, the camera is connected to the adjustment mechanism, the adjustment mechanism includes a rod-shaped member and a slider mounted on the rod-shaped member, wherein the camera moves through the relative movement between the rod-shaped member and the slider.

[0012] In the perception system proposed according to the first aspect of the present application, optionally, the lighting device includes an open-hole surface light source directly arranged at the camera.

[0013] In the perception system proposed according to the first aspect of the present application, optionally, the lighting device includes an ambient light source, and the ambient light source externally surrounds the detection platform and the vehicle to be inspected on the detection platform.

[0014] In the perception system proposed according to the first aspect of the present application, optionally, the perception system further includes a wireless radio frequency identification device for acquiring a vehicle identification code of the vehicle to be inspected.

[0015] In the perception system proposed according to the first aspect of the present application, optionally, the multiple cameras are used to acquire images of key components of the vehicle to be inspected, wherein the key components are selected from the following group, the group including a car body, a car bumper, a car radar, a door handle, a car rim, a car rear wing and a brake caliper.

[0016] In the perception system proposed according to the first aspect of the present application, optionally, each camera is correspondingly assigned to a key component of the key components of the vehicle to be inspected.

[0017] According to the second aspect of the present application, a whole vehicle configuration error prevention detection system is also proposed, which includes a perception unit, a control unit and a warning unit, the perception unit includes the perception system described above, wherein the sensor and camera of the perception system are connected to the control unit to transmit the collected image data and sensor data to the control unit, and the control unit is configured to perform whole vehicle configuration error prevention detection on the vehicle to be inspected and optionally send a warning signal to the warning unit based on the detection result.

[0018] In the vehicle configuration error prevention detection system proposed according to the second aspect of the present application, optionally, it also includes a quality management module, which is connected to the control unit and configured to store image data and corresponding detection results.

[0019] According to a third aspect of the present application, a whole vehicle assembly system is also proposed, which includes the perception system or the whole vehicle configuration error prevention detection system described above.

[0020] The perception system according to the present application is low-cost and highly flexible, and can also provide a high safety advantage for human-machine collaboration in error-proofing detection for the entire vehicle configuration. BRIEF DESCRIPTION OF THE DRAWINGS

[0021] The above and other features of the present application will become apparent with reference to the accompanying drawings, in which:

[0022] Figure 1 A stereoscopic view of a sensing system according to an embodiment is shown, wherein an open-hole surface light source is schematically shown in an enlarged view;

[0023] Figure 2 Shown according to Figure 1 Illustration of the perception system observing along the length direction of the detection platform;

[0024] Figure 3 The arrangement of multiple cameras of the perception system is schematically shown;

[0025] Figure 4 A perspective view of a top camera and a camera bracket attached thereto is shown;

[0026] Figure 5 A perspective view of a central side-facing camera and a camera support associated therewith is shown;

[0027] Figure 6 A perspective view of a terminal side-facing camera and a camera support associated therewith is shown;

[0028] Figure 7 A first embodiment of an adjustment mechanism for a camera support of a perception system is shown;

[0029] Figure 8 A second embodiment of the adjustment mechanism of the camera support of the perception system is shown;

[0030] Fig. 9 From another perspective, it shows Figure 8 The adjustment mechanism of the camera bracket;

[0031] Fig.10 A modular diagram of a vehicle configuration error prevention detection system according to one embodiment is shown. DETAILED DESCRIPTION

[0032] It is easy to understand that according to the technical solution of the present application, without changing the essential spirit of the present application, a person skilled in the art can propose a variety of interchangeable structural modes and implementation modes. Therefore, the following specific implementation modes and drawings are only exemplary descriptions of the technical solution of the present application, and should not be regarded as the entirety of the present application or as a limitation or restriction on the technical solution of the present application.

[0033] The directional terms such as up, down, left, right, front, back, front, back, top, bottom, etc. mentioned or may be mentioned in this specification are defined relative to the structures shown in the drawings. They are relative concepts and may change accordingly according to their different positions and different usage states. Therefore, these or other directional terms should not be interpreted as restrictive terms. In addition, the terms "first", "second", "third", etc. or similar expressions are only used for description and distinction purposes, and cannot be understood as indicating or implying the relative importance of the corresponding components.

[0034] First, refer to Figures 1 to 3, the perception system according to the present application is explained from the overall level, which can be used as a part of the automobile production line, and with the help of it, the error-proofing detection of the whole vehicle configuration can be performed during the whole vehicle assembly or after the whole vehicle is off the line, especially the error-proofing detection of the whole vehicle appearance configuration. The perception system 100 includes a plurality of cameras 110, an illumination device 120 and a sensor (which is not shown), wherein the illumination device is used to provide the camera with the required shooting brightness, and the sensor (such as a laser sensor) is used to collect the position information of the vehicle to be inspected. Each camera 110 is arranged at a detection platform (which is not shown) or can be said to be arranged around the detection platform with the help of a camera bracket 130. Here, the camera bracket 130 is fixedly arranged relative to the detection platform. In other words, during the whole vehicle configuration error-proofing detection process, the relative position of the camera bracket 130 with respect to the detection platform is fixed, and the position of the camera bracket 130 can be determined and adjusted in advance when the model of the vehicle to be inspected changes. In this case, the above-mentioned multiple cameras 110 can also be referred to as fixed cameras, wherein "fixed cameras" should be understood relative to cameras that are moved with the aid of a robotic arm or robot during the detection process. Fixed cameras are used to capture images of fixed parts of the car during the whole vehicle configuration error-proofing detection process rather than scanning and capturing images of the entire body or part of the body.

[0035] Instead of robotic arms, robots or gantry cameras, the perception system consisting of multiple fixed cameras has lower cost, higher flexibility and can provide high safety advantages for human-machine collaboration in error-proof detection of the entire vehicle configuration, which is obviously more in line with the cost reduction and efficiency improvement needs of vehicle manufacturing.

[0036] The inspection platform is used to park the vehicle to be inspected, or the vehicle to be inspected can move across the inspection platform during vehicle assembly. Figure 1 In the embodiment shown in , the detection platform is located in an arched space surrounded by ambient light sources. Exemplarily, the vehicle to be inspected reaches the detection platform via a track or a conveyor plate chain, wherein the detection platform is a dedicated platform located above the track or conveyor plate chain, or the detection platform is the part of the track or conveyor plate chain in the arched space.

[0037] According to the present application, the plurality of fixed cameras 110 include a side camera 111 arranged along the length direction of the inspection platform and a top camera 112 arranged above the inspection platform. The length direction of the inspection platform is parallel to the length direction or longitudinal direction of the vehicle to be inspected, or it can be said that the length direction of the inspection platform is parallel to the moving direction of the vehicle to be inspected caused by the track or conveyor chain. Figure 1 In the embodiment, the vehicle to be inspected enters from one side of the arched space and exits from the other side relative thereto, so the side cameras 111 are arranged on both sides of the arched space. By this arrangement, the field of view of the camera can cover the key components of the vehicle to be inspected.

[0038] In some embodiments of the present application, the perception system also includes a wireless radio frequency identification device for obtaining the vehicle identification code (i.e., VIN code, Vehicle Identification Number) of the vehicle to be inspected. When performing error-proofing detection of the whole vehicle configuration, if it is determined that the vehicle to be inspected has arrived on the detection platform based on the position information obtained by the sensor, multiple cameras are activated at the same time to collect image data of key components and activate the wireless radio frequency identification device to obtain the VIN code. These image data and VIN codes serve as the basis for judgment of error-proofing detection, wherein the VIN code corresponds to the theoretical image data of the key components customized by the customer. Here, error-proofing detection is performed with the help of a combination of sensors and fixed cameras, which can replace manual visual inspection and complete the imaging of the required detection points with one trigger, which can meet the needs of mixed-line detection of various models. In addition, there is no need to set up an isolated safety area and no need to carry out complex line body modification, which reduces the cost of modifying the production line.

[0039] In some embodiments of the present application, the key component may involve one or more of the following components: car body, car bumper, car radar, door handle, car rim, car tail, brake caliper, window trim, rearview mirror trim, roof rack, car logo, lower guard plate trim, headlights (including front and rear lights), car tail logo, charging port, car license plate frame, top window or other appearance parts. It should be noted here that the key component refers to a component that can be customized by the user and has a variety of configuration schemes. It is not limited to the components listed here and can be modified according to actual needs.

[0040] Instead of collecting scanning image data, according to the present application, multiple cameras are used to collect images at multiple points for key components of the whole vehicle. In some embodiments of the present application, each camera is correspondingly assigned to a key component of the key components of the vehicle to be inspected. In other words, the arrangement position of the fixed camera depends on the specified key component to be inspected. Exemplarily, it is feasible that if the key component is large in size (such as the lower guard plate trim) and exceeds the field of view of the camera, an image of the characteristic area of ​​the key component can be collected. It is also feasible that if the key component is small in size and the field of view of the same camera covers multiple key components at the same time, a comprehensive error-proofing detection can be performed.

[0041] exist Figures 1 to 3In the illustrated embodiment, the perception system 100 has 12 fixed cameras, including two top cameras 112 located above the detection platform and 10 side cameras 111 arranged along the length direction of the detection platform. Here, the side cameras are arranged symmetrically about the detection platform (that is, symmetrically about the longitudinal direction of the vehicle to be inspected thereon), and are further divided into a middle side camera 1111 for acquiring an image of the side body of the vehicle to be inspected and a terminal side camera 1112 for acquiring the front or rear of the vehicle to be inspected. Specifically, in the illustrated embodiment, three middle side cameras 1111 and two terminal side cameras 1112 are respectively provided on the left and right sides of the detection platform.

[0042] In some embodiments of the present application, the middle lateral camera 1111 and the terminal lateral camera 1112 have different adjustability, which is for the camera relative to the corresponding camera bracket. Here, the middle lateral camera 1111 has at least translational freedom. The translational freedom refers to the mobility of the camera as a whole along a straight line, which involves translational movement in a horizontal plane, or in a vertical plane, or in a horizontal plane and a vertical plane. In contrast, the terminal lateral camera 1112 has a rotational freedom around the vertical direction in addition to the above-mentioned translational freedom, so that it can be aligned with key components at the front or rear of the vehicle through a rotational movement or, in other words, a flipping movement. Here, the arrangement position of the terminal lateral camera is more flexible and the spatial arrangement is thus optimized.

[0043] In some embodiments of the present application, the top camera 112 also has a rotational freedom around the horizontal direction in addition to the above-mentioned translational freedom, so as to be able to aim at key components on the upper surface of the car, such as the top window.

[0044] exist Figure 4 The top camera 112 is shown in FIG. Figure 5 The middle side camera 1111 is shown in FIG. Figure 6 The end side camera 1112 is shown in FIG. 1 , and the three differ in the camera brackets they are equipped with. Figures 7 to 9The camera support 130 includes a fixed base 131 and an adjustment mechanism 132, and a camera 110 is connected to the adjustment mechanism. The adjustment mechanism includes a rod-shaped member and a slider mounted on the rod-shaped member, wherein the camera moves by the relative movement between the rod-shaped member and the slider. The adjustability of the camera is achieved by a multi-degree-of-freedom camera support assigned to it, and the degrees of freedom of the multi-degree-of-freedom camera support are adjusted by the number of rod-shaped members and sliders of the adjustment mechanism. Here, each additional slider and rod-shaped member can increase the rotational freedom around the length direction of the rod-shaped member and the translational freedom along the length direction of the rod-shaped member accordingly. In addition, each camera and the camera support assigned to it can be independently adjustable, thereby balancing the flexibility and complexity of the system.

[0045] Specifically, the fixing base 131 of the camera bracket 130 can be fixed on the ground, and the slider is an annular slider and is fixed to the rod-shaped member by means of a threaded fastener. The camera 110 is fixed to the rod-shaped member by means of a camera base 140. After the threaded fastener is loosened, on the one hand, the camera can be driven to rotate by rotating the rod-shaped member (which is Figures 7 to 9 On the other hand, the camera can be caused to perform translational movement by pulling the rod-shaped member (indicated by an arc with double arrows in FIG. Figures 7 to 9 In the Figure 7 The adjustment mechanism 132 of the camera support 130 shown in FIG. 1 has three rods and three sliders, one of which is connected to the fixed base 131. Figure 8 and Fig. 9 The adjustment mechanism 132 of the camera bracket 130 shown in the figure has five rod-shaped members and five sliders, one of which is connected to the fixed base 131. Here, the spatial motion range of the camera bracket is associated with the length of the rod-shaped member. By making the length of the rod-shaped member adaptable to multiple vehicle models, unnecessary waste of resources and motion interference can be avoided while improving vehicle compatibility.

[0046] Of course, the freedom of movement of the camera holder and the freedom of movement of the camera relative to it can also be achieved in that a plurality of rod-shaped members are movable relative to each other, for example, they can be rotated or moved around a vertical direction or a horizontal direction.

[0047] In some embodiments of the present application, the lighting device 120 for providing the camera with shooting brightness includes an open-hole surface light source 121, which is also fixed to the adjustment mechanism 132 of the camera bracket 130 through the camera base 140. Specifically, the camera 110 or its camera head passes through the central opening of the open-hole surface light source 121, and the light-emitting points are arranged around the camera. Figure 1 as well as Figures 7 to 9In particular, each camera can be equipped with its own open-aperture surface light source and its light intensity can also be independently adjusted, so as to accurately control the shooting conditions and image quality.

[0048] In some embodiments of the present application, the lighting device 120 further includes a plurality of ambient light sources 122, for example in the form of a light box, which are assembled and fixed by a light source bracket 123. Specifically, Figure 1 As shown in , a plurality of ambient light sources 122 constitute a light gallery, which covers the inspection platform, the vehicle to be inspected, and the camera arranged at the inspection platform. The ambient light source 122 can be composed of a combination of strip light bands of warm tones (such as yellow) and cold tones (such as blue light) to better cope with the complex lighting conditions in the vehicle assembly workshop. It should be noted here that the ambient light source is not mandatory. If the ambient light in the vehicle assembly workshop can meet the brightness required for shooting, only an open-hole surface light source can be provided at the camera.

[0049] Reference again Figures 4 to 6 , the camera support in the embodiment of the light gallery composed of the above-mentioned ambient light sources is described. Figure 4 In the embodiment, the fixing base 131 of the camera support 130 assigned to the top camera 112 can be fixed to the light source support above. It is also possible that the fixing base 131 for the top camera 112 can be replaced by the light source support above, or it can be said that the light source support above is used as the fixing base 131. Figure 5 For the middle side camera 1111, the fixing base 131 of the camera support 130 can be directly formed by the side light source support. Of course, it is also feasible that the fixing base 131 of the camera support 130 for the middle side camera 1111 is fixed to the side light source support. Figure 6 For the terminal lateral camera 1112, the fixed base 131 of the camera bracket can be fixed on the ground between the detection platform and the light corridor.

[0050] With the help of the perception system according to the present application, the whole vehicle configuration error prevention detection can be performed as follows: first, adjust each camera bracket to determine the camera position; then adjust the camera parameters, including exposure parameters, gain parameters, white balance parameters, focal length, etc.; adjust and determine the position of the sensor, the position of the wireless radio frequency identification device, and the lighting parameters of the lighting device; when the sensor data is used to identify that the vehicle to be inspected has moved to the specified position, trigger the recognition process of the wireless radio frequency identification device and the image acquisition process of the camera; finally, input these data into the controller for error prevention detection.

[0051] In summary, the perception system according to the present application is low-cost and highly flexible, and can provide a high safety advantage for human-machine collaboration in error-proofing detection of the entire vehicle configuration. In some embodiments according to the present application, by reasonably configuring the adjustability of cameras at different positions, it is possible to take into account both the camera field of view and cost consumption. In some embodiments according to the present application, by combining an open-hole surface light source directly adjacent to the camera and an ambient light source, the camera shooting environment and image quality can be reliably controlled. In some embodiments of the present application, instead of collecting full-body images of the vehicle, the camera is associated with key components of the vehicle, which can reduce the computing power requirements for subsequent error-proofing detection.

[0052] In addition, the present application also relates to a vehicle configuration error prevention detection system 200, which is modularized in a Fig.10 . The whole vehicle configuration error prevention detection system 200 includes a perception unit 210, a control unit 220 and a warning unit 230, and the perception unit includes a perception system according to any one or more embodiments described above. The sensor and camera of the perception system are connected to the control unit 220 to transmit the collected image data and sensor data to the control unit. The control unit 220 is configured to perform whole vehicle configuration error prevention detection on the vehicle to be inspected and optionally send a warning signal to the warning unit 230 according to the detection result. Specifically, the control unit 220 is configured to compare the image data of key components collected by each camera with the image data of key components that meet the customer's customization requirements, and determine whether there is missing or wrong installation based on the comparison result, wherein the image data of key components that meet the customer's customization requirements can be called from the whole vehicle production system according to the VIN code identified by the wireless radio frequency identification device.

[0053] Exemplarily, the warning unit 230 may include an acoustic and optical alarm device for sending an acoustic signal or an optical signal to the workshop staff according to the signal of the control unit, so as to timely review the detection results and correct the vehicle assembly errors in time.

[0054] In some embodiments of the present application, the vehicle configuration error-proofing detection system 200 further includes a quality management module 240, which is connected to the control unit 220 and configured to store image data and corresponding detection results. The quality management module 240 can be deployed in the cloud so that error-proofing detection traceability can be performed later based on the stored data.

[0055] As for the vehicle configuration error prevention detection system according to the present application, the advantages and characteristics that have been explained about the perception system according to the present application can be particularly derived. Therefore, the vehicle configuration error prevention detection system can refer to the explanation made about the perception system according to the present application accordingly.

[0056] Finally, the present application also relates to a whole vehicle assembly system (i.e., a whole vehicle assembly line), which includes a perception system or a whole vehicle configuration error prevention detection system according to any one or more of the above embodiments. With respect to the whole vehicle assembly system according to the present application, the advantages and features described in relation to the perception system according to the present application can be particularly derived, and therefore, with respect to the whole vehicle assembly system, reference can be made to the description of the perception system according to the present application.

[0057] It should be understood that all the above preferred embodiments are illustrative rather than restrictive, and various modifications or variations made by those skilled in the art to the specific embodiments described above under the concept of the present application should be within the legal protection scope of the present application.

Claims

1. A perception system for vehicle configuration error prevention detection, characterized in that: It includes: A plurality of cameras, each of which is fixed by means of a camera bracket, wherein the camera bracket is fixedly arranged at a detection platform, on which a vehicle to be inspected can be parked or can move through the detection platform; a lighting device, which is used to provide shooting brightness for the camera; A sensor is arranged at the detection platform to collect position information of the vehicle to be inspected relative to the detection platform; wherein the multiple cameras include side cameras arranged along the length direction of the detection platform and a top camera arranged above the detection platform, wherein the length direction of the detection platform is parallel to the length direction of the vehicle to be inspected.

2. The sensing system according to claim 1, characterized in that: The side cameras include an end side camera for the front or rear of the vehicle to be inspected and a middle side camera for the side body of the vehicle to be inspected, wherein the middle side camera has translational freedom, and the end side camera has translational freedom and rotational freedom around the vertical direction.

3. The sensing system according to claim 1, characterized in that: The top camera has translational freedom and rotational freedom about the horizontal direction.

4. The sensing system according to claim 2 or 3, characterized in that: The camera bracket includes a fixed base and an adjustment mechanism, the camera is connected to the adjustment mechanism, and the adjustment mechanism includes a rod-shaped member and a slider sleeved on the rod-shaped member, wherein the camera moves through the relative movement between the rod-shaped member and the slider.

5. The sensing system according to claim 1, characterized in that: The lighting device comprises an open-aperture surface light source arranged directly at the camera.

6. The sensing system according to claim 1, characterized in that: The lighting device comprises an ambient light source, and the ambient light source externally surrounds the detection platform and the vehicle to be detected on the detection platform.

7. The sensing system according to claim 1, characterized in that: The sensing system also includes a wireless radio frequency identification device for obtaining a vehicle identification code of the vehicle to be inspected.

8. The sensing system according to claim 1, characterized in that: The multiple cameras are used to obtain images of key components of the vehicle to be inspected, wherein the key components are selected from the following group, and the group includes a car body, a car bumper, a car radar, a door handle, a car rim, a car rear wing and a brake caliper.

9. The sensing system according to claim 8, characterized in that: Each camera is correspondingly assigned to a key component of the key components of the vehicle to be inspected.

10. A vehicle configuration error prevention detection system, characterized in that: It includes a perception unit, a control unit and a warning unit, wherein the perception unit includes a perception system according to any one of claims 1 to 9, wherein the sensor and camera of the perception system are connected to the control unit to transmit the collected image data and sensor data to the control unit, and the control unit is configured to perform vehicle configuration error prevention detection on the vehicle to be inspected and optionally send a warning signal to the warning unit based on the detection result.

11. The vehicle configuration error prevention detection system according to claim 10, characterized in that: A quality management module is also included, which is connected to the control unit and is configured to store image data and corresponding detection results.

12. A vehicle assembly system, characterized in that: It comprises a sensing system according to any one of claims 1 to 9.

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