Visual inspection system for water channel sealing ring of motor controller

Abstract

The utility model discloses a motor controller water channel sealing ring visual inspection system, which comprises an upper computer, a code scanning gun, a display, an industrial camera, an image collector, a transmission belt, a motor controller tool, a positioning bolt and an MES system, the MES system is in communication connection with the upper computer, the upper computer is connected with the display through a video line, the upper computer is connected with the image collector through a network cable, and the image collector is connected with the transmission belt. The image collector collects pictures shot by the industrial camera; the code scanning gun is connected with the upper computer through a serial port, the positioning bolt is arranged on the conveying belt, a shell of the motor controller provided with the water channel sealing ring is fixed to the motor controller tool, the motor controller tool moves along with the conveying belt and stops on one side of the positioning bolt, and the code scanning gun triggers visual detection by scanning a two-dimensional code of the shell. And the industrial camera shoots an image of the installation state of the sealing ring of the internal water channel of the shell of the motor controller. According to the utility model, the waterproof failure caused by abnormal installation of the water channel sealing ring is effectively avoided.

Description

Technical Field

[0001] This utility model relates to the technical field of visual inspection, specifically to a visual inspection system for the installation status of waterway sealing rings during the assembly process of a motor controller. Background Technology

[0002] The installation and inspection of the internal water channel seals of common new energy vehicle motor controllers mainly rely on visual inspection. During the installation process, workers visually inspect themselves or with each other to check whether there are any missing or improperly installed seals. After the water channel seals are installed on the power module, airtightness is tested by connecting an airtight device through the inlet and outlet water nozzles to determine the sealing effect.

[0003] The main drawbacks are: (1) Manual inspection is wasteful of manpower and lacks error prevention, especially since workers are prone to errors when fatigued, resulting in missing or improperly installed sealing rings, which affects the yield of subsequent airtightness testing. (2) Inspection with airtightness equipment can identify defective parts, but the reduced yield will increase rework costs and may even pose a risk of defective parts being leaked. (3) Neither of the above methods can provide process traceability for sealing ring installation. Utility Model Content

[0004] To overcome the aforementioned problems, the purpose of this utility model is to provide a visual inspection system for water channel sealing rings in motor controllers, which effectively avoids waterproofing failure caused by abnormal installation of water channel sealing rings, thereby ensuring the sealing effect of water channel sealing rings, greatly improving product safety and stability, and also improving the controllability of the production process.

[0005] To achieve the above objectives, the technical solution adopted by this utility model is: a visual inspection system for a water channel seal ring of a motor controller, comprising a host computer, a barcode scanner, a monitor, an industrial camera, an image acquisition device, a conveyor belt, a motor controller fixture, a positioning pin, and a MES system; wherein, the MES system is communicatively connected to the host computer, the host computer is connected to the monitor via a video cable, the host computer is connected to the image acquisition device via a network cable, and the image acquisition device acquires images captured by the industrial camera; the barcode scanner is connected to the host computer via a serial port, the positioning pin is mounted on the conveyor belt, and the housing of the motor controller with the water channel seal ring installed is fixed to the motor... On the controller fixture, the motor controller fixture moves with the conveyor belt and stops on one side of the positioning bolt. The barcode scanner triggers visual inspection by scanning the QR code on the housing. The industrial camera captures an image of the installation status of the internal water channel sealing ring of the motor controller housing and transmits the captured image to the host computer through the image acquisition device. The application software in the host computer compares the current installation status of the internal water channel sealing ring with the installation status of the normally learned water channel sealing ring to identify whether the water channel sealing ring is installed and whether it is installed in place, and displays the judgment result on the display, thus completing the detection of the water channel sealing ring.

[0006] Preferably, the industrial camera is positioned to match the positioning bolt, such that when the motor controller fixture stops on one side of the positioning bolt, the industrial camera is directly above the motor controller fixture, which facilitates image capture.

[0007] Preferably, LED lights are provided around the lower end of the industrial camera.

[0008] Preferably, the LED lights surround the industrial camera in a rectangular arrangement.

[0009] Preferably, the industrial camera is provided with a light shield for an LED light at its lower end.

[0010] Preferably, the host computer uploads the detection results to the MES system to achieve cloud backup and provide online traceability.

[0011] Preferably, the industrial camera is fixed to the frame end of the conveyor belt via a vertical bracket.

[0012] The beneficial effects of this invention are as follows: This system can replace manual inspection of the installation status of the water channel sealing ring of the motor controller, effectively avoiding waterproofing failure caused by abnormal installation of the water channel sealing ring, thereby ensuring the sealing effect of the water channel sealing ring, greatly improving product safety and stability, and also improving the controllability of the production process. This system is simple to operate, highly automated, and has low environmental requirements; moreover, compared with a closed high-precision vision inspection system, it has lower development costs and better stability, significantly improving the reliability of the motor controller product manufacturing process at a relatively low cost. Attached Figure Description

[0013] Figure 1 This is a schematic diagram of the structure of this embodiment;

[0014] Figure 2 This is a flowchart of the detection process in this embodiment;

[0015] Figure 3 This is a schematic diagram illustrating the installation state characteristics of the sealing ring in this embodiment.

[0016] In the diagram: 1. Host computer; 2. Barcode scanner; 3. Monitor; 4. Industrial camera; 5. Image acquisition device; 6. Conveyor belt; 7. Motor controller fixture; 8. Positioning bolt; 9. MES system; 10. Motor controller; 11. LED lighting; 12. Light shield. Detailed Implementation

[0017] The preferred embodiments of the present invention will now be described in detail with reference to the accompanying drawings, so that the advantages and features of the present invention can be more easily understood by those skilled in the art, thereby making a clearer and more definite definition of the scope of protection of the present invention.

[0018] See Figure 1-Figure 3This embodiment discloses a visual inspection system for a water channel seal ring of a motor controller, including a host computer 1, a barcode scanner 2, a display 3, an industrial camera 4, an image acquisition device 5, a conveyor belt 6, a motor controller fixture 7, a positioning pin 8, and a MES system 9. The MES system 9 is communicatively connected to the host computer 1. The host computer 1 is connected to the display 3 via a video cable and to the image acquisition device 5 via a network cable. The image acquisition device 5 acquires images captured by the industrial camera 4. The barcode scanner 2 is connected to the host computer 1 via a serial port. The positioning pin 8 is mounted on the conveyor belt 6. The housing of the motor controller 10 with the water channel seal ring installed is fixed to the motor controller fixture 7. The motor controller fixture 7 follows... The conveyor belt 6 moves and stops on one side of the positioning bolt 8. The barcode scanner 2 triggers visual detection by scanning the QR code on the housing. The industrial camera 4 captures an image of the installation status of the internal water channel sealing ring of the motor controller 10 housing and transmits the captured image to the host computer 1 via the image acquisition device 5. The application software in the host computer 1 compares the current installation status of the internal water channel sealing ring with the installation status of the normal water channel sealing ring that it has learned, that is, whether it is installed and whether it is installed in place, and displays the judgment result on the display 3 to complete the detection of the water channel sealing ring. The host computer 1 uploads the detection result to the MES system 9 to realize cloud backup and provide online traceability.

[0019] The industrial camera 4 is fixed to the frame end of the conveyor belt 6 via a vertical bracket. The position of the industrial camera 4 is matched with the positioning bolt 8, so that when the motor controller fixture 7 stops on one side of the positioning bolt 8, the industrial camera 4 is directly above the motor controller fixture 7, which facilitates its image capture. LED lights 11 are arranged around the lower end of the industrial camera 4 in a rectangular pattern. A light shield 12 for the LED lights 11 is provided at the lower end of the industrial camera 4.

[0020] The entire inspection process begins with the completion of the previous assembly step, namely, the installation of the water channel sealing ring on the motor controller fixture. The motor controller fixture is 500mm x 400mm in length and width, and can fix the housing of one motor controller to be inspected. The water channel sealing ring inside the housing is a black rectangle, and there can be one or more, but they must be within the visual inspection range. First, the conveyor belt stops the motor controller fixture at the visual inspection station via positioning bolts. Directly above this position is the camera sensor of an industrial camera that shoots vertically downwards. The industrial camera is model IV2-G500 series, and there is an LED light surrounding the lower part of the industrial camera. The light source is a 10mm wide and 550mm long white strip LED, arranged in a 200mm x 150mm rectangle around the industrial camera. The industrial camera is surrounded by a 120mm x 100mm yellow light shield. After scanning the housing to be inspected with a barcode scanner, the industrial camera is triggered to capture an image of the internal water channel sealing ring installation status of the motor controller housing at the inspection position. The image acquisition card of the image acquisition device is model IV2-G30F, and the host computer is equipped with the IV2-Navigator application software. In addition, the system saves the acquired images locally on the host computer, and also connects to the MES system through the host computer software to link the QR code on the motor controller housing with the corresponding water channel sealing ring detection results and upload them to the cloud for online traceability.

[0021] The complete visual inspection process for waterway seals in motor controllers includes the following key points:

[0022] 1. Waterway sealing ring installation status feature learning: The feature learning is performed on the shell with the waterway sealing ring correctly installed. Under a stable LED lighting environment, the appropriate waterway sealing ring status features, such as edge, shape, brightness, etc., are located and selected.

[0023] 2. Set detection thresholds and compare the feature values ​​of correct and problematic parts, such as the difference in features corresponding to the presence or absence of a water channel seal ring or whether the water channel seal ring is installed properly, and select an appropriate judgment threshold.

[0024] 3. Waterway sealing ring installation: After the waterway sealing ring of the motor controller is installed at the previous station, the motor controller fixture is transferred to the positioning bolt for visual inspection via conveyor belt.

[0025] 4. Waterway sealing ring barcode scanning and recording: Use a barcode scanner to scan the housing of the motor controller with the waterway sealing ring assembled on the motor controller fixture to record the barcode, in order to meet the MES system's station passing requirements and trigger the visual inspection of the waterway sealing ring.

[0026] 5. Visual inspection of waterway sealing ring: The host computer receives the scanning signal from the barcode scanner and automatically triggers the host computer software to capture the image of the motor controller that has reached the detection position. After image preprocessing, the identification feature area of ​​the waterway sealing ring is located, relevant feature values ​​are calculated, and the detection result is judged by comparing them with the detection threshold.

[0027] 6. The test results are displayed on the monitor by the host computer, which provides on-site operation instructions.

[0028] 7. Upload test results: The host computer records the barcode of the currently inspected shell and the corresponding water channel sealing ring test results, and uploads them to the MES system.

[0029] 8. Power module installation: After visual inspection of the water channel seal ring inside the current motor controller, the motor controller tooling is transported to the next workstation via conveyor belt for power module installation.

[0030] In some embodiments, the industrial camera can also be adjusted in front-back, left-right, or up-down position by a movable end cap provided on a vertical bracket. The end cap is provided with a handle for easy positioning and fixing of the industrial camera.

[0031] The above embodiments are only for illustrating the technical concept and features of this utility model. Their purpose is to enable those skilled in the art to understand the content of this utility model and implement it. They cannot be used to limit the protection scope of this utility model. All equivalent changes or modifications made in accordance with the spirit and essence of this utility model should be covered within the protection scope of this utility model.

Claims

1. A visual inspection system for waterway sealing rings in a motor controller, characterized in that, The system includes a host computer, a barcode scanner, a monitor, an industrial camera, an image acquisition unit, a conveyor belt, a motor controller fixture, a positioning pin, and a MES system. The MES system is communicatively connected to the host computer, which is connected to the monitor via a video cable and to the image acquisition unit via a network cable. The image acquisition unit captures images from the industrial camera. The barcode scanner is connected to the host computer via a serial port. The positioning pin is mounted on the conveyor belt. The housing of the motor controller, with its water channel sealing ring installed, is fixed to the motor controller fixture. The motor controller fixture moves with the conveyor belt and stops at one side of the positioning pin. The barcode scanner triggers visual inspection by scanning the QR code on the housing. The industrial camera captures images of the internal water channel sealing ring installation status of the motor controller housing and transmits these images to the host computer via the image acquisition unit. The application software on the host computer compares the image with the installation status of previously learned normal water channel sealing rings to identify the current installation status of the internal water channel sealing ring—whether it is installed and whether it is properly installed—and displays the result on the monitor, thus completing the water channel sealing ring detection.

2. The visual inspection system for waterway sealing rings of a motor controller according to claim 1, characterized in that, The industrial camera is positioned to match the positioning bolt, so that when the motor controller fixture stops on one side of the positioning bolt, the industrial camera is directly above the motor controller fixture, which facilitates image capture.

3. The visual inspection system for waterway sealing rings of a motor controller according to claim 1, characterized in that, LED lights are installed around the lower part of the industrial camera.

4. The visual inspection system for waterway sealing rings of a motor controller according to claim 3, characterized in that, The LED lights surround the industrial camera in a rectangular arrangement.

5. The visual inspection system for waterway sealing rings of a motor controller according to claim 4, characterized in that, The industrial camera is equipped with a light shield for LED lighting at its lower end.

6. The visual inspection system for waterway sealing rings of a motor controller according to claim 1, characterized in that, The host computer uploads the detection results to the MES system to achieve cloud backup and provide online traceability.

7. The visual inspection system for waterway sealing rings of a motor controller according to claim 1, characterized in that, The industrial camera is fixed to the frame end of the conveyor belt via a vertical bracket.

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