Color-coated sheet detection system

Abstract

The utility model discloses a color-coated sheet detection system, which comprises a first industrial camera group, a second industrial camera group, a server and an industrial personal computer, wherein the first industrial camera group and the second industrial camera group are in communication connection with the server and the industrial personal computer through the switch, and the industrial personal computer is in communication connection with the server through the switch; the first industrial camera group and the second industrial camera group are distributed on two sides of the color-coated sheet and are used for shooting a color-coated sheet surface image of the color-coated sheet; the server is used for receiving the color-coated sheet surface image through the switch and analyzing and processing the color-coated sheet surface image to obtain a color-coated sheet detection result; and the industrial personal computer is used for receiving the detection result of the color-coated sheet through the switch. According to the utility model, the industrial camera is used for acquiring the surface images of the two sides of the color-coated sheet, and the switch is communicated with the server, so that the acquired surface images of the two sides of the color-coated sheet can be automatically sent to the server, and the server can analyze and process the acquired surface images of the color-coated sheet to obtain a detection result.

Description

Technical Field

[0001] The utility model relates to the technical field of color-coated plate production and processing, in particular to a color-coated plate detection system. Background Art

[0002] Currently, 95% of the quality problems of color-coated home appliance panels are surface defects. Due to various reasons such as equipment, personnel, and customer standards, the control of product defects has reached a bottleneck stage, and product quality is difficult to further improve.

[0003] The current line speed of the color coating production line is 40-80 meters per minute. At the reeling station, the defect type, level, and location of the color coated coil are manually identified based on experience and visual inspection. This has poor standardization, high labor intensity, and is prone to misjudgment and omission. The defect records are incomplete, and the positioning is inaccurate, so it is only for reference in subsequent processes. Utility Model Content

[0004] The embodiment of the utility model provides a color-coated plate detection system, which is used to solve at least one of the above-mentioned technical problems.

[0005] The present invention provides a color-coated plate inspection system for a color-coated plate production line, which is characterized by comprising: a first industrial camera group 10, a second industrial camera group 20, a server 30 and an industrial computer 40; wherein,

[0006] The first industrial camera group 10 and the second industrial camera group 20 are connected to the server 30 and the industrial computer 40 through a switch 50, and the industrial computer 40 is connected to the server 30 through a switch 50;

[0007] The first industrial camera group 10 and the second industrial camera group 20 are distributed on both sides of the color-coated plate, and are used to capture the color-coated plate surface image of the color-coated plate;

[0008] The server 30 is used to receive the surface image of the color-coated plate through the switch 50, and perform analysis and processing to obtain the color-coated plate detection result;

[0009] The industrial computer 40 is used to receive the color-coated board detection result through the switch 50.

[0010] In some embodiments, the color-coated plate production line includes a drying device and a winding device, and the first industrial camera group 10 and the second industrial camera group 20 are arranged between the drying device and the winding device.

[0011] In some embodiments, an encoder 70 and a programmable logic controller 60 are also included. The encoder 70 is communicatively connected to the programmable logic controller 60, and the encoder 70 is used to detect the running speed of the color-coated plate.

[0012] In some embodiments, a grating sensor 80 is further included. The grating sensor 80 is communicatively connected to the programmable logic controller 60 and is used to detect the color-coated plate.

[0013] In some embodiments, a coding device 90 is further included. The coding device 90 is communicatively connected to the programmable logic controller 60, and the coding device 90 is used to spray codes on the surface of the color-coated plate.

[0014] In some embodiments, a light source device 100 is also included, which is used to provide shooting light for the first industrial camera group 10 and / or the second industrial camera group 20.

[0015] In some embodiments, a third industrial camera group is also included, the first industrial camera group 10 is arranged on the first side of the color-coated plate, and the second industrial camera group 20 and the third industrial camera group are arranged on the second side of the color-coated plate.

[0016] In some embodiments, the first industrial camera group 10 , the second industrial camera group 20 , and the third industrial camera group each include at least two industrial cameras, and the industrial cameras are CCD cameras.

[0017] In some embodiments, the light source device 100 includes a light source 110 and a light source controller 120 , and the light source controller 120 is communicatively connected to the programmable logic controller 60 .

[0018] In some embodiments, an image processor is further included, and the image processor is disposed between the first industrial camera group 10 and / or the second industrial camera group 20 and / or the third industrial camera group and the switch 50 .

[0019] The beneficial effect of the embodiment of the utility model is that a system is provided for realizing automatic detection of color-coated plates, wherein surface images of both sides of the color-coated plates are collected by the first industrial camera group 10 and the second industrial camera group 20, and the switch 50 communicates with the server 30, so that the collected surface images of both sides of the color-coated plates can be automatically sent to the server, so that the server can analyze and process the collected surface images of the color-coated plates to obtain detection results, and further the detection results can be sent to the industrial computer 40 for display through the switch 50, so as to facilitate the staff to view. BRIEF DESCRIPTION OF THE DRAWINGS

[0020] In order to more clearly illustrate the technical solutions of the embodiments of the utility model, the drawings required for use in the description of the embodiments will be briefly introduced below. Obviously, the drawings described below are some embodiments of the utility model. For ordinary technicians in this field, other drawings can be obtained based on these drawings without paying creative work.

[0021] Figure 1 It is a structural schematic diagram of an embodiment of a color-coated plate detection system of the utility model;

[0022] Figure 2 It is a structural schematic diagram of another embodiment of the color-coated plate detection system of the utility model;

[0023] Figure 3 It is a structural schematic diagram of another embodiment of the color-coated plate detection system of the utility model. DETAILED DESCRIPTION

[0024] In order to make the purpose, technical scheme and advantages of the embodiment of the utility model clearer, the technical scheme in the embodiment of the utility model will be clearly and completely described below in conjunction with the drawings in the embodiment of the utility model. Obviously, the described embodiment is a part of the embodiment of the utility model, not all of the embodiments. Based on the embodiments in the utility model, all other embodiments obtained by ordinary technicians in this field without making creative work are within the scope of protection of the utility model. It should be noted that the embodiments in this application and the features in the embodiments can be combined with each other without conflict.

[0025] It should also be noted that, in this article, the terms "include" and "comprise" include not only those elements, but also other elements not explicitly listed, or elements inherent to such processes, methods, articles or equipment. In the absence of further restrictions, the elements defined by the sentence "include..." do not exclude the existence of other identical elements in the process, method, article or equipment that includes the elements.

[0026] The present invention provides a color-coated plate inspection system for a color-coated plate production line, comprising: a first industrial camera group 10, a second industrial camera group 20, a server 30 and an industrial computer 40; wherein:

[0027] The first industrial camera group 10 and the second industrial camera group 20 are connected to the server 30 and the industrial computer 40 through the switch 50, and the industrial computer 40 is connected to the server 30 through the switch 50. Exemplarily, the first industrial camera group 10 communicates with the server 30 through the switch 50, so that the surface image of the color-coated plate taken can be sent to the server for analysis and processing by the server; the first industrial camera 10 communicates with the industrial computer 40 through the switch 50, so that the surface image of the color-coated plate taken can be directly sent to the industrial computer 40 for viewing by the staff.

[0028] The first industrial camera group 10 and the second industrial camera group 20 are distributed on both sides of the color-coated plate to capture the color-coated plate surface image of the color-coated plate. For example, the color-coated plate in the present application can be a color-coated steel plate, and the first industrial camera group 10 and the second industrial camera group 20 are arranged on both sides of the color-coated plate, so that the surface quality of both sides of the color-coated plate can be detected.

[0029] The server 30 is used to receive the surface image of the color-coated plate through the switch 50, and analyze and process it to obtain the color-coated plate detection result. Exemplarily, the server 30 is configured to have an image analysis and processing function, for example, the received surface image of the color-coated plate is analyzed by a neural network model to determine whether there are defects in the surface image of the color-coated plate, or other image analysis and processing technologies in the relevant technical field are used, and this application does not limit this. It should be noted that the invention point of this application is only to provide a system that can be used to realize automatic detection of color-coated plates. Those skilled in the art can realize automatic detection of color-coated plates based on the system of this application combined with the existing technology and instructions in this field.

[0030] The industrial computer 40 is used to receive the color-coated plate detection result through the switch 50. For example, the industrial computer 40 can be a desktop computer, a laptop computer, a tablet computer or other dedicated control computer, which is not limited in this application.

[0031] An embodiment of the utility model provides a system that can be used to realize automatic detection of color-coated plates, wherein surface images of both sides of the color-coated plates are collected by a first industrial camera group 10 and a second industrial camera group 20, and the switch 50 communicates with the server 30, so that the collected surface images of both sides of the color-coated plates can be automatically sent to the server, so that the server can analyze and process the collected surface images of the color-coated plates to obtain detection results, and further the detection results can be sent to the industrial computer 40 for display through the switch 50, so as to facilitate the staff to view.

[0032] Exemplarily, the first industrial camera group 10 in the present application may include multiple CCD cameras, and the second industrial camera group 20 may include multiple CCD cameras. The CCD cameras in each industrial camera group are configured to shoot the color-coated plate from different angles so as to obtain surface images of the color-coated plate at different angles.

[0033] like Figure 1As shown, in some embodiments of the color-coated plate detection system of the present application, an image processor 11 (or 21) corresponding to the first industrial camera group 10 and the second industrial camera group 20 is also included. The image processor 11 (or 21) is communicatively connected with the corresponding industrial camera group, and the image processor 11 (or 21) is also communicatively connected with the server 30 through the switch 50. Exemplarily, the image processor 11 (or 21) can adopt an edge-end embedded vision processor, model Gbox-4CL-MN-00, for processing and sending the collected data of the linear array camera.

[0034] Based on the image processor 11 (or 21) in the embodiment of the present application, the control of the first industrial camera group 10 and the second industrial camera group 20 can be realized. In addition, the captured surface image of the color-coated plate can also be processed, for example, the surface image of the color-coated plate can be encoded.

[0035] In some embodiments, the color coating task of the color coated plate is completed on the color coated plate production line, and the color coated plate needs to be dried and rolled after the color coating is completed. The color coated plate production line includes a drying device and a rolling device, and the first industrial camera group 10 and the second industrial camera group 20 are arranged between the drying device and the rolling device. In this embodiment, the first industrial camera group 10 and the second industrial camera group 20 are arranged between the drying device and the rolling device to dry the color coated plate after the production line completes the color coating of the color coated plate, and the color coated plate is inspected after drying and before rolling, so as to avoid the false detection of color coated plate defects due to the unformed color coated plate before drying.

[0036] In some embodiments of the color-coated plate inspection system of the present application, a light source device 100 is also included, which is used to provide a shooting light source for the first industrial camera group 10 and / or the second industrial camera group 20.

[0037] In some embodiments of the color-coated plate inspection system of the present application, the light source device 100 includes a light source 110 and a light source controller 120, and the light source controller 120 is in communication connection with the programmable logic controller 60. In this embodiment, by setting the light source controller 120, the light source 110 can be controlled, and the light source 110 can be adjusted to a state suitable for the first industrial camera group 10 and the second industrial camera group 20 as needed.

[0038] like Figure 2 As shown, in some embodiments of the color-coated plate detection system of the present application, an encoder 70 and a programmable logic controller 60 are further included. The encoder 70 is connected to the programmable logic controller 60 for communication. The encoder 70 is used to detect the running speed of the color-coated plate. For example,

[0039] Exemplarily, the encoder 70 uses a contact encoder, for example, a pulse encoder, which obtains the running speed pulse of the color-coated plate through the contact encoder and then synchronously controls the first industrial camera group 10, the second industrial camera group 20 and the inkjet device 90.

[0040] In some embodiments of the color-coated plate detection system of the present application, a grating sensor 80 is further included, and the grating sensor 80 is connected to the programmable logic controller 60 for communication, and the grating sensor 80 is used to detect the color-coated plate. For example, the grating sensor 80 in the color-coated plate detection system adopts the N3210L1NC-1Z model grating sensor, and the ESN series safety grating adopts an independent dual-circuit output design, with output circuit self-test function and output overcurrent protection function; adopts a unique optical lens design scheme, and the grating shooting distance can reach more than 30 meters; the grating working voltage is industrial voltage DC10V~30V wide voltage power supply, and the output is a transistor output mode, which can be directly connected to the PLC contact for use; the housing adopts a double-sided slide installation design, which is convenient for the grating to be installed in a variety of ways.

[0041] like Figure 2 As shown, in some embodiments of the color-coated board detection system of the present application, a coding device 90 is also included, and the coding device 90 is connected to the programmable logic controller 60 (PLC), and the coding device 90 is used to spray codes on the surface of the color-coated board. For example, the PLC model is Delta AS228T, which can meet basic control performance and has a high cost performance.

[0042] In the embodiment of the present application, the programmable logic controller 60 (PLC) obtains the real-time production speed of the color-coated production line by receiving the pulse of the encoder 70, and simultaneously sends the pulse of the encoder 70 to the image processor 11 (21) and the inkjet printer 90 through the IO, so as to complete the mapping of the color-coated plate image and the inkjet printer identification coordinates on the back of the color-coated plate. For example, the encoder 70 model is E38S6-800-3-T-24. The system previously used the encoder model E6B2-CWZ6C. During the implementation process, there were problems such as poor anti-interference ability and pulse loss during operation. Therefore, E38S6-800-3-T-24 was adopted; the inkjet printer used the Linx8800 series inkjet printer. Other series of inkjet printers were used before, but in the actual application process, a series of problems such as inkjet transfer occurred, causing secondary damage to the surface of the steel plate. Finally, the Linx8800 series inkjet printer was adopted.

[0043] like Figure 3 As shown, in some embodiments of the color-coated plate inspection system of the present application, a third industrial camera group is also included, the first industrial camera group 10 is arranged on the first side of the color-coated plate (for example, the back of the color-coated plate), and the second industrial camera group 20 and the third industrial camera group are arranged on the second side of the color-coated plate (for example, the front of the color-coated plate).

[0044] In some embodiments of the color-coated plate inspection system of the present application, the first industrial camera group 10, the second industrial camera group 20 and the third industrial camera group each include at least two industrial cameras, and the industrial cameras are CCD cameras.

[0045] like Figure 2 As shown, in some embodiments of the color-coated plate detection system of the present application, three groups of cameras are used to obtain multi-angle, multi-directional, and multi-region surface images of the color-coated plate by setting different physical positions, wherein two groups of cameras are deployed on the front of the steel plate (i.e., the color-coated plate) to obtain the front image of the color-coated plate from different angles, and one group of cameras is deployed on the back of the camera to obtain the back image of the color-coated plate; the present application adopts a high-speed inkjet printer to complete the inkjet printer positioning function on the back of the color-coated plate; a contact encoder is used to obtain the running speed pulse of the color-coated plate and then synchronize the industrial camera and the inkjet printer; a grating sensor 80 is used to detect the roll signal of the color-coated plate.

[0046] In addition, based on the above system of the present application, a complete production line detection system including the upper computer software system part and the lower computer electrical control part can also be realized. Based on the above system of the present application, the upper and lower computers of the system can also work together to complete the real-time generation task of the quality map. The main content of the lower computer electrical control part is to control the encoder to send synchronization pulses to the industrial camera and inkjet equipment. At the same time, the PLC also controls the actions of actuators such as grating sensors and light sources, thereby completing a complete set of defect collection actions suitable for color coating production lines; the upper computer software system is mainly responsible for real-time processing of steel plate image data collected by the production line, detecting defects, calculating the physical coordinates of defects and storing related data. The upper computer software system also has the functions of querying and analyzing the historical steel coil quality map and the subsequent physical object association. At the same time, the upper computer can also remotely control the actions of the lower computer.

[0047] It should be noted that the software or algorithm design part of the above system is not the content required to be protected by this application. Those skilled in the art can implement it in combination with relevant technologies in the field, and this application does not limit this.

[0048] Based on the above system of the present application, the following method steps can be implemented:

[0049] Step 1: The grating sensor detects the punching on the color-coated plate, obtains the punching signal, and sends the punching signal to the PLC;

[0050] Step 2: After the PLC receives the punching signal of the color-coated plate, it starts to record the number of encoder pulses and divides the obtained encoder high-speed pulse signal into 3 channels, which are sent to the industrial camera image processor, inkjet printer and host computer respectively. The PLC sends the origin pulse count, new roll signal and new roll count information to the host computer software system;

[0051] Exemplarily, after the PLC detects the punching signal, it sends a control signal to the encoder, and the encoder starts to accumulate the encoder's pulse count (the value is placed in the PLC's origin pulse count register). When the origin pulse count reaches 8000 (1m of steel plate), the PLC resets the origin pulse count register and re-accumulates it. At the same time, the PLC sends the encoder's pulse to the industrial camera image processor and the inkjet printer at the same time. At this time, the image processor receives the pulse signal to control the industrial camera to start acquiring images (the current image frame number is 1), and the inkjet printer receives the pulse signal to start inkjet printing (the current inkjet printer coordinate is 0). The PLC sends the pulse origin count (0 at this time), the new roll signal (punching signal flag = 1), and the new roll count (1 at this time) to the host computer. After receiving the corresponding information, the host computer starts to parse it, where the new roll signal is a flag for starting the detection algorithm, the origin pulse count is used to separate the defects of different steel coils, and the new roll count is used to record which roll the current steel coil is in the production process.

[0052] Step 3: The image processor of the industrial camera receives the external pulse signal and starts to collect the surface image of the steel plate (color-coated plate). At the same time, the inkjet printer also starts the synchronous inkjet printing action after receiving the external pulse signal.

[0053] Step 4: The image captured by the industrial camera is encoded by the image processor and sent to the application server. After receiving the steel plate image, the application server decodes it and performs algorithm processing on the steel plate defects in the image. The defect detection results are sent to the host computer in real time via the HTTP protocol for display, processing and storage.

[0054] Step 5: Complete the association configuration of the color-coated steel plate with the quality map in the database, and finally complete the task of generating the surface quality map of the color-coated plate, so as to achieve the goal of matching the actual color-coated plate with the data one by one.

[0055] Finally, it should be noted that the above embodiments are only used to illustrate the technical solutions of the present application, rather than to limit it. Although the present application has been described in detail with reference to the aforementioned embodiments, those skilled in the art should understand that they can still modify the technical solutions described in the aforementioned embodiments, or make equivalent replacements for some of the technical features therein. However, these modifications or replacements do not deviate the essence of the corresponding technical solutions from the spirit and scope of the technical solutions of the embodiments of the present application.

Claims

1. A color-coated plate detection system, used in a color-coated plate production line, characterized in that: include: A first industrial camera group (10), a second industrial camera group (20), a server (30) and an industrial computer (40); wherein: The first industrial camera group (10) and the second industrial camera group (20) are communicatively connected to the server (30) and the industrial computer (40) via a switch (50), and the industrial computer (40) is communicatively connected to the server (30) via the switch (50); The first industrial camera group (10) and the second industrial camera group (20) are distributed on both sides of the color-coated plate and are used to capture the color-coated plate surface image of the color-coated plate; The server (30) is used to receive the surface image of the color-coated plate through the switch (50), and perform analysis and processing to obtain the color-coated plate detection result; The industrial computer (40) is used to receive the color-coated plate detection result through the switch (50); The color-coated plate production line comprises a drying device and a winding device, and the first industrial camera group (10) and the second industrial camera group (20) are arranged between the drying device and the winding device.

2. The system according to claim 1, characterized in that It also comprises an encoder (70) and a programmable logic controller (60), wherein the encoder (70) is communicatively connected with the programmable logic controller (60), and the encoder (70) is used to detect the running speed of the color-coated plate.

3. The system according to claim 2, characterized in that It also includes a grating sensor (80), which is communicatively connected to the programmable logic controller (60) and is used to detect color-coated plates.

4. The system according to claim 3, characterized in that It also includes a coding device (90), the coding device (90) is communicatively connected to the programmable logic controller (60), and the coding device (90) is used to spray codes on the surface of the color-coated plate.

5. The system according to any one of claims 2 to 4, characterized in that: It also includes a light source device (100) for providing a shooting light source for the first industrial camera group (10) and / or the second industrial camera group (20).

6. The system according to claim 5, characterized in that It also includes a third industrial camera group, wherein the first industrial camera group (10) is arranged on the first side of the color-coated plate, and the second industrial camera group (20) and the third industrial camera group are arranged on the second side of the color-coated plate.

7. The system according to claim 6, characterized in that The first industrial camera group (10), the second industrial camera group (20) and the third industrial camera group each include at least two industrial cameras, and the industrial cameras are CCD cameras.

8. The system according to claim 5, characterized in that The light source device (100) comprises a light source (110) and a light source controller (120), and the light source controller (120) is communicatively connected to the programmable logic controller (60).

9. The system according to claim 1, characterized in that It also includes an image processor, which is arranged between the first industrial camera group (10) and / or the second industrial camera group (20) and / or the third industrial camera group and the switch (50).

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