Integrated online visual inspection station

Abstract

The utility model discloses an integrated online visual inspection station which comprises an equipment rack, a belt conveyor, a manual operation and display interface, a rotating module, a horizontal movement module and a line laser contour sensor, and the equipment rack is used for supporting the whole inspection station. According to the utility model, through the modular design, the flexible configuration of the detection platform is realized, and compared with the traditional detection equipment, the conveyor, the sensor, the code scanner, the horizontal module and the rotating module can be flexibly configured according to the detection requirements of different products, so as to quickly adapt to various detection scenes; multiple groups of cameras can be configured to improve the detection efficiency, manual errors are avoided through an automatic detection program, and the detection precision and efficiency are improved; proper configuration can be selected according to actual requirements, unnecessary equipment investment is avoided, and the cost is reduced; the modular design facilitates maintenance and replacement, and the maintenance cost and the downtime are reduced.

Description

Technical Field

[0001] This utility model relates to the field of online inspection equipment technology, and in particular to an integrated online visual inspection station. Background Technology

[0002] In existing technologies, traditional parts inspection methods mainly include manual measurement and inspection, manual or automatic fixtures, and coordinate measuring machines (CMMs). Manual measurement and inspection involves operators using measuring tools to measure each part individually, recording the data, and making manual judgments. However, this method is inefficient, susceptible to human error, and involves high error rates and data recording and processing. Manual or automatic fixtures use specially designed fixtures to measure parts, offering a high degree of automation. However, different fixtures need to be designed for different products, and it cannot meet the requirements of full-line inspection. Coordinate measuring machines (CMMs) use high-precision measuring equipment to perform three-dimensional coordinate measurement of parts, obtaining complete contour information of the part surface. However, the inspection efficiency is low, template setting and programming are complex, and it cannot meet the rapid inspection needs of production lines. Utility Model Content

[0003] One objective of this invention is to propose an integrated online visual inspection station, which addresses the problems of low efficiency, susceptibility to human factors, poor compatibility, and low inspection efficiency mentioned in the background.

[0004] An integrated online visual inspection station according to an embodiment of this utility model includes an equipment frame, a belt conveyor, a manual operation and display interface, a rotating module, a horizontal motion module, and a line laser profile sensor. The equipment frame supports the entire inspection station. The belt conveyor transports the workpiece to be inspected to the inspection position. The manual operation and display interface is mounted on an operation box and connected to the equipment frame via a rotating arm. The manual operation and display interface is used by the operator to control and view the inspection process and results. The rotating module carries the line laser profile sensor and performs rotational movement. The horizontal motion module carries the rotating module and performs horizontal movement. The line laser profile sensor is used to collect the workpiece surface profile point cloud. Auxiliary components include an electrical control box, a vision controller, a through-beam photoelectric sensor, and a barcode scanner, used to control the inspection process, read workpiece information, and execute programs.

[0005] Preferably, the lower layer of the equipment rack is the equipment area, where the electrical control box and vision controller are placed, the middle layer is the detection area, where the conveyor line and the motion platform carrying the laser contour sensor are located, and the work space is covered by opaque panels on all sides and the top layer to avoid interference from changes in ambient light when the sensor takes contour point clouds.

[0006] Preferably, the front end of the belt conveyor is equipped with a through-beam photoelectric sensor. When the workpiece enters the trigger range of the sensor, it indicates that the workpiece is in place, the conveyor belt stops, and the program starts automatic detection.

[0007] Preferably, a barcode scanner is installed at one end of the conveyor. After the workpiece QR code is scanned, the coding information is automatically read, the system program automatically queries and retrieves the corresponding detection program, and records the results accordingly.

[0008] Preferably, the line laser profile sensor is mounted on a servo motion platform. When detection is started, the line laser profile sensor is turned on, the servo motion platform moves at a constant speed, and the line laser profile sensor reads the encoder values ​​of the translation servo motor and the rotary servo motor and takes a point cloud map.

[0009] Preferably, the motion platform consists of a horizontal module and a rotating module, the line laser profile sensor is mounted on the rotating module, and the rotating module is further mounted on the horizontal module.

[0010] Preferably, the horizontal module is driven by a servo motor, the horizontal module has a ball screw transmission structure inside, the horizontal module is guided by a linear guide rail inside, the bracket mounted on the horizontal module is connected to the linear guide rail on the other side of the frame, and the control cable and sensor communication cable are connected to the moving end of the horizontal module through a drag chain.

[0011] Preferably, the rotating module consists of a frame, guide wheel set, arc guide rail, transmission plate, drive gear and rotary servo motor. The line laser contour sensor is mounted on the transmission plate via a bracket. The arc guide rail is mounted on the transmission plate and is inserted into multiple sets of guide wheel sets mounted on the frame. The transmission plate rotates according to the arc radius and center set by the guide wheel set.

[0012] The beneficial effects of this utility model are:

[0013] This invention features a modular design, enabling flexible configuration of the testing station. Compared to traditional testing equipment, it allows for flexible configuration of conveyors, sensors, barcode scanners, horizontal modules, and rotating modules to meet the testing needs of different products, quickly adapting to various testing scenarios. Multiple cameras can be configured to improve testing efficiency, and automated testing procedures avoid human error, enhancing both accuracy and efficiency. Appropriate configurations can be selected based on actual needs, avoiding unnecessary equipment investment and reducing costs. The modular design facilitates maintenance and replacement, reducing maintenance costs and downtime. Attached Figure Description

[0014] The accompanying drawings are provided to further illustrate the present invention and form part of the specification. They are used together with the embodiments of the present invention to explain the present invention, but do not constitute a limitation thereof. In the drawings:

[0015] Figure 1 This is a structural diagram of the integrated online visual inspection station proposed in this utility model;

[0016] Figure 2 This is a front view of the integrated online visual inspection station proposed in this utility model;

[0017] Figure 3 This is a side view of the integrated online visual inspection station proposed in this utility model;

[0018] Figure 4 This is a structural diagram of the rotating module of the integrated online visual inspection station proposed in this utility model;

[0019] In the diagram: 1. Equipment frame; 2. Belt conveyor; 3. Manual operation and display interface; 4. Rotating arm; 5. Linear guide rail; 6. Rotating module; 7. Support; 8. Horizontal module; 9. Translation servo motor; 10. Linear laser profile sensor; 11. Cable chain; 12. Barcode scanner; 13. Through-beam photoelectric sensor; 14. Vision controller; 15. Drive gear; 16. Rotary servo motor; 17. Frame; 18. Guide wheel assembly; 19. Arc guide rail; 20. Transmission plate; 21. Electrical control box. Detailed Implementation

[0020] The present invention will now be described in further detail with reference to the accompanying drawings. These drawings are simplified schematic diagrams, illustrating only the basic structure of the present invention, and therefore only show the components relevant to the present invention.

[0021] refer to Figure 1-4 An integrated online vision inspection station includes a frame 1, a belt conveyor 2, a manual operation and display interface 3, a rotating module 6, a horizontal motion module, and a line laser profile sensor 10. The frame 1 supports the entire inspection station. The belt conveyor 2 transports the workpiece to the inspection position. The manual operation and display interface 3 is mounted on an operation box and connected to the frame 1 via a rotating arm 4. The manual operation and display interface 3 allows operators to control and view the inspection process and results. The rotating module 6 carries the line laser profile sensor 10 and rotates it. The horizontal motion module carries the rotating module 6 and moves it horizontally. The line laser profile sensor 10 collects the workpiece surface profile point cloud. Auxiliary components include an electrical control box 21, a vision controller 14, a through-beam photoelectric sensor 13, and a barcode scanner 12, used to control the inspection process, read workpiece information, and execute programs. The integrated online vision inspection station, through its modular design, allows for flexible configuration of the inspection platform, improving inspection efficiency, accuracy, and adaptability, reducing labor and maintenance costs, and facilitating data management and traceability.

[0022] Example 1: The lower layer of the equipment frame 1 is the equipment area, housing the electrical control box 21 and the vision controller 14. The middle layer is the detection area, where the conveyor line and the motion platform carrying the laser contour sensor 10 are located. The workspace is shielded by opaque panels on all sides and the top layer to prevent ambient light changes from interfering with the sensor's contour point cloud acquisition. A through-beam photoelectric sensor 13 is installed at the front end of the belt conveyor 2. When the workpiece enters the sensor's trigger range, it indicates that the workpiece is in position, the conveyor belt stops, and the program starts automatic detection. A barcode scanner 12 is installed at one end of the conveyor. After scanning the workpiece's QR code label, the system automatically reads the encoded information. The system program automatically queries and retrieves the corresponding detection program and records the results. Through modular design and automated processes, the detection efficiency, accuracy, and reliability are effectively improved, while reducing labor and maintenance costs and facilitating data management and traceability. Simultaneously, the opaque panel design avoids ambient light interference with detection, ensuring the accuracy of the detection results.

[0023] Example 2: The line laser profile sensor 10 is mounted on a servo motion platform. Upon startup, after the line laser profile sensor 10 is activated, the servo motion platform moves at a constant speed. The line laser profile sensor 10 reads the encoder values ​​of the translation servo motor 9 and the rotary servo motor 16 and captures a point cloud image. The motion platform consists of a horizontal module 8 and a rotary module 6. The line laser profile sensor 10 is mounted on the rotary module 6, which is further mounted on the horizontal module 8. The horizontal module 8 is driven by a servo motor and has an internal ball screw drive structure. The horizontal module 8 is guided by a linear guide rail 5, and a bracket 7 mounted on the horizontal module 8 bridging... On the other side of the frame, on the linear guide rail 5, the control cable and sensor communication cable are connected to the moving end of the horizontal module 8 via a drag chain 11. The rotating module 6 consists of a frame 17, guide wheel sets 18, arc guide rails 19, a transmission plate 20, a drive gear 15, and a rotary servo motor 16. The line laser contour sensor 10 is mounted on the transmission plate 20 via a bracket 7. The arc guide rails 19 are mounted on the transmission plate 20 and are engaged with multiple sets of guide wheel sets 18 mounted on the frame 17. The transmission plate 20 rotates according to the arc radius and center set by the guide wheel sets 18. By using a servo motion platform to carry the line laser contour sensor 10, high-precision and high-efficiency workpiece surface contour point cloud acquisition is achieved. The coordinated movement of the horizontal module 8 and the rotating module 6 ensures the comprehensiveness and accuracy of the point cloud acquisition. At the same time, the design of the drag chain 11 facilitates the connection and movement of the cables, improving the reliability and stability of the equipment.

[0024] In use, the workpiece to be inspected enters the working area via a conveyor; after the photoelectric sensor 13 senses its position, the conveyor stops moving, and the workpiece enters the inspection position; the barcode scanner 12 reads the QR code on the workpiece to identify the workpiece model; the system automatically retrieves the corresponding model's inspection program and prepares for inspection; the system controls the horizontal module 8 and the rotary module 6 in the motion platform to perform scanning trajectory movement; simultaneously, the trigger line laser contour sensor 10 performs image acquisition work in the corresponding position area; according to the inspection requirements of different workpieces, the scanning area and position can be set intermittently to reduce the amount of computation, or repeated scanning can be used to eliminate noise, movement, and other unexpected interference, thereby increasing the quality of the image acquisition. Overall stability: The system stitches together all point cloud images to form a complete outline of the workpiece being inspected; based on this, the inspection program locates the areas to be inspected and compared according to pre-programmed requirements, extracts features, calculates and records the relevant dimensions; after comparing with the set acceptable size range, it generates an inspection report indicating whether the workpiece is acceptable or unacceptable, and displays, uploads, or stores it; the inspection results are displayed on the human-machine interface touchscreen; the peripheral lights of the equipment change color to indicate the inspection results, green for acceptable and red for unacceptable; after automatic inspection is completed, the conveyor continues to move, sending the workpiece out; simultaneously, the next workpiece to be inspected is sent in, entering the next round of inspection process.

[0025] The equipment has a clear and simple operating procedure, is easy to operate, and can effectively improve testing efficiency and accuracy while reducing labor costs, making it an ideal choice for end-of-line testing.

[0026] The above description is only a preferred embodiment of the present utility model, but the protection scope of the present utility model is not limited thereto. Any equivalent substitutions or changes made by those skilled in the art within the technical scope disclosed in the present utility model, based on the technical solution and the inventive concept of the present utility model, should be included within the protection scope of the present utility model.

Claims

1. An integrated online visual inspection station, characterized in that, The equipment includes a frame (1), a belt conveyor (2), a manual operation and display interface (3), a rotating module (6), a horizontal motion module, and a line laser profile sensor (10). The frame (1) supports the entire inspection station. The belt conveyor (2) delivers the workpiece to be inspected to the inspection position. The manual operation and display interface (3) is mounted on the operation box and connected to the frame (1) via a rotating arm (4). The manual operation and display interface (3) is used by the operator to control and view the inspection process and results. The rotating module (6) carries the line laser profile sensor (10) and performs rotational movement. The horizontal motion module carries the rotating module (6) and performs horizontal movement. The line laser profile sensor (10) is used to collect the surface profile point cloud of the workpiece. The auxiliary components include an electrical control box (21), a vision controller (14), a photoelectric sensor (13), and a barcode scanner (12), which are used to control the inspection process, read workpiece information, and execute programs.

2. The integrated online visual inspection station according to claim 1, characterized in that, The lower layer of the equipment rack (1) is the equipment area, where the electrical control box (21) and vision controller (14) are placed. The middle layer is the detection area, where the conveyor line and the motion platform carrying the line laser contour sensor (10) are located. The work space is covered by opaque panels on all sides and the top layer.

3. The integrated online visual inspection station according to claim 1, characterized in that, The belt conveyor (2) is equipped with a photoelectric sensor (13) at its front end.

4. The integrated online visual inspection station according to claim 1, characterized in that, A barcode scanner (12) is installed at one end of the conveyor.

5. The integrated online visual inspection station according to claim 1, characterized in that, The line laser profile sensor (10) is mounted on a servo motion platform.

6. The integrated online visual inspection station according to claim 2, characterized in that, The motion platform consists of a horizontal module (8) and a rotating module (6). The line laser profile sensor (10) is mounted on the rotating module (6), and the rotating module (6) is further mounted on the horizontal module (8).

7. The integrated online visual inspection station according to claim 6, characterized in that, The horizontal module (8) is driven by a servo motor. The horizontal module (8) has a ball screw transmission structure inside. The horizontal module (8) is guided by a linear guide rail (5). The bracket (7) mounted on the horizontal module (8) is connected to the linear guide rail (5) on the other side of the frame. The control cable and sensor communication cable are connected to the moving end of the horizontal module (8) through a drag chain (11).

8. The integrated online visual inspection station according to claim 6, characterized in that, The rotating module (6) consists of a frame (17), a guide wheel set (18), an arc guide rail (19), a transmission plate (20), a drive gear (15), and a rotary servo motor (16). The line laser contour sensor (10) is mounted on the transmission plate (20) via a bracket (7). The arc guide rail (19) is mounted on the transmission plate (20) and is inserted into multiple sets of guide wheel sets (18) mounted on the frame (17). The transmission plate (20) rotates according to the arc radius and center set by the guide wheel set (18).

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