Wire flaw detection device based on visual camera

Abstract

The utility model relates to the technical field of wire flaw detection devices, and discloses a wire flaw detection device based on a visual camera, which comprises a detection chamber. According to the wire rod flaw detection device based on the visual camera, through the arrangement of the adjusting mechanism, a high-resolution camera on one side shoots the surface of a wire rod body, a driving motor in a motor box at the bottom is started, the driving motor drives a screw rod at the bottom to rotate, and then a vertical frame in threaded connection with the surface of the screw rod moves front and back; the distance between the high-resolution camera on one side of the vertical frame and the wire rod body is adjusted, then a servo motor in a motor box on one side can be started according to the position, needing to be shot, of the surface of the wire rod body, and the servo motor drives a lead screw at the tail end to rotate. And then the high-resolution camera mounted on the surface of the lead screw moves left and right on the lead screw, so that the effects of left-right movement and front-back movement of the high-resolution camera are achieved, and the comprehensiveness, accuracy and adaptability of flaw detection are improved.

Description

A wire flaw detection device based on a vision camera Technical Field

[0001] This utility model relates to the technical field of wire flaw detection devices, and in particular to a wire flaw detection device based on a vision camera. Background Technology

[0002] In the manufacturing process of quenched and tempered steel wire for automotive suspension springs, strict requirements are placed on the surface quality control of the steel wire material. No obvious macroscopic defects visible to the naked eye are allowed on the material surface, as these defects negatively impact the fatigue life of the spring. The existing online inspection method is eddy current testing, which has high sensitivity for identifying surface defects in cold states. However, after induction heating heat treatment, eddy current testing of steel wire suffers from severe false alarms and poor signal-to-noise ratio, significantly reducing its recognition accuracy. This is mainly because the material undergoes martensitic transformation after induction heat treatment, resulting in significant grain distortion and increased internal stress, which severely interferes with the eddy current magnetic induction lines, thus worsening the recognition of surface defects. To address this pain point in surface defect detection for quenched and tempered spring steel wire in the industry, a visual inspection system for the steel wire material surface is proposed. This system enables 100% identification of visible defects on the material surface, significantly improving the surface quality of quenched and tempered spring steel wire.

[0003] However, relying solely on a fixed-position vision camera has certain limitations in practical applications. Due to potential positional shifts and vibrations during the conveying of steel wires on the production line, and the differences in diameter and shape between different specifications of steel wires, a fixed camera cannot guarantee comprehensive and clear capture of all areas of the steel wire surface under various working conditions. To overcome these problems and improve the adaptability and accuracy of the vision inspection system, it is essential to incorporate a structure that allows the camera to move left and right as well as forward and backward. Therefore, a wire flaw detection device based on a vision camera is proposed. Summary of the Invention

[0004] (a) Technical problems to be solved

[0005] The purpose of this invention is to provide a wire flaw detection device based on a vision camera, thereby solving the problem of flexible adjustment of the camera mentioned in the background art.

[0006] (II) Technical Solution

[0007] To achieve the above objectives, this utility model provides the following technical solution: a wire flaw detection device based on a vision camera, comprising a detection chamber with an internal cavity, an adjustment mechanism installed inside the cavity, through holes on both sides of the detection chamber, a wire body inserted through the through holes, a first limiting mechanism attached to the top of the wire body, and a second limiting mechanism attached to the bottom of the wire body. The adjustment mechanism includes a base installed inside the cavity, a motor housing installed on one side of the base, a drive motor installed inside the motor housing, and a lead screw fixedly connected to the output end of the drive motor. A support frame is threaded onto the surface of the rod. An extension plate is fixedly connected to the middle of the support frame. A motor box is fixedly connected to one side of the extension plate. A servo motor is installed inside the motor box. A lead screw is fixedly connected to the output end of the servo motor. A support block is threaded onto the surface of the lead screw. A high-resolution camera is mounted on the surface of the support block. The first limiting mechanism includes a limiting wheel A that overlaps the top of the wire body. A threaded rod is fixedly connected to one side of the limiting wheel A. A positioning nut is threaded onto the surface of the threaded rod. The second limiting mechanism includes a limiting wheel B that overlaps the bottom of the wire body. A connecting rod is fixedly connected to the bottom of the limiting wheel B.

[0008] As a further embodiment of this utility model, a fixed rod is slidably connected to the bottom of the connecting rod, and extension blocks are fixedly connected to both sides of the connecting rod. The extension blocks serve to support the electric push rod.

[0009] As a further embodiment of this utility model, an electric push rod is fixedly connected to the bottom of the extension block, and a battery is electrically connected to one side of the electric push rod via a power line. The battery provides continuous power supply.

[0010] As a further embodiment of this utility model, a fixing block is fixedly connected to the bottom of the electric push rod. The fixing block is fixedly connected to the upper surface of the fixing rod, and the fixing block serves to support the electric push rod.

[0011] As a further embodiment of this utility model, a storage compartment is fixedly connected to the bottom of the testing chamber, and the storage compartment has a placement slot inside, which serves to store miscellaneous items.

[0012] As a further embodiment of this utility model, the surface edge of the placement groove is hinged to a sealing door, and a handle is installed on the surface of the sealing door, which serves to open the sealing door.

[0013] As a further embodiment of this utility model, an image processor is electrically connected to one side of the high-resolution camera via a power line, and a control terminal is electrically connected to one side of the image processor via a power line. The image processor is configured to process images.

[0014] (III) Beneficial Effects

[0015] This invention provides a wire flaw detection device based on a vision camera, which has the following advantages:

[0016] 1. This vision camera-based wire flaw detection device, through the adjustment mechanism, allows a high-resolution camera on one side to photograph the surface of the wire body during use. The drive motor inside the bottom motor box is activated, causing the lead screw at the bottom to rotate. This, in turn, moves the support frame threaded onto the lead screw back and forth, adjusting the distance between the high-resolution camera on one side of the support frame and the wire body. Then, based on the desired photographing position on the wire body surface, a servo motor inside the motor box on one side can be activated. The servo motor drives the lead screw at the end to rotate, causing the high-resolution camera mounted on the lead screw to move left and right along the lead screw. This achieves the effect of moving the high-resolution camera left and right and back and forth, improving the comprehensiveness, accuracy, and adaptability of flaw detection.

[0017] 2. This vision camera-based wire flaw detection device, through the setting of a first limiting mechanism and a second limiting mechanism, typically uses limiting wheels to prevent the wire body from deviating during transportation. However, since the wire body has different thicknesses, the positions of the top and bottom limiting wheels A and B can be adjusted according to the thickness of the wire body. After adjusting the threaded rod on one side of the limiting wheel A to the appropriate position, it is then fixed with a positioning nut. Next, the power is turned on, and the electric push rod is controlled to drive the top limiting wheel B to rise and fall, thereby adapting to the detection of wire bodies of different thicknesses and improving the flexibility and convenience of the equipment during use. Attached Figure Description

[0018] Figure 1 is a schematic diagram of the overall structure of this utility model;

[0019] Figure 2 is a schematic diagram of the adjustment mechanism of this utility model;

[0020] Figure 3 is a schematic diagram of the first limiting mechanism of this utility model;

[0021] Figure 4 is a schematic diagram of the structure of the testing chamber of this utility model.

[0022] In the diagram: 1. Testing chamber; 2. Adjustment mechanism; 201. Base; 202. Motor box; 203. Drive motor; 204. Lead screw; 205. Stand; 206. Extension plate; 207. Motor box; 208. Servo motor; 209. Lead screw; 210. Support block; 211. High-resolution camera; 3. Wire body; 4. First limiting mechanism; 401. Limiting wheel A; 402. Threaded rod; 403. Positioning nut; 5. Second limiting mechanism; 501. Limiting wheel B; 502. Connecting rod; 6. Fixing rod; 7. Extension block; 8. Electric push rod; 9. Battery; 10. Fixing block; 11. Storage compartment; 12. Sealed door; 13. Image processor; 14. Control terminal. Detailed Implementation

[0023] The technical solutions of the present utility model will be clearly and completely described below with reference to the accompanying drawings of the embodiments. All other embodiments obtained by those skilled in the art based on the embodiments of the present utility model without creative effort are within the scope of protection of the present utility model.

[0024] Please refer to Figures 1 to 4. This utility model provides a technical solution: a wire flaw detection device based on a vision camera, including a detection chamber 1. The detection chamber 1 has an internal cavity, and an adjustment mechanism 2 is installed inside the cavity. By adjusting the mechanism 2, the high-resolution camera 211 can be moved left and right and forward and backward, improving the comprehensiveness, accuracy, and adaptability of flaw detection. Through holes are provided on both sides of the detection chamber 1, and a wire body 3 is inserted through the through holes. A first limiting mechanism 4 is attached to the top of the wire body 3, and a second limiting mechanism 5 is attached to the bottom of the wire body 3. The first limiting mechanism 4 and the second limiting mechanism 5 are used to adapt to the detection of wire bodies 3 of different thicknesses, improving the flexibility and convenience of the equipment during use.

[0025] The adjustment mechanism 2 includes a base 201 installed inside the cavity. A motor housing 202 is installed on one side of the base 201. A drive motor 203 is installed inside the motor housing 202. A lead screw 204 is fixedly connected to the output end of the drive motor 203. A support frame 205 is threadedly connected to the surface of the lead screw 204. An extension plate 206 is fixedly connected to the middle of the support frame 205. A motor box 207 is fixedly connected to one side of the extension plate 206. A servo motor 208 is installed inside the motor box 207. A lead screw 209 is fixedly connected to the output end of the servo motor 208. A support block 210 is threadedly connected to the surface of the lead screw 209. A high-resolution camera 211 is installed on the surface of the support block 210.

[0026] The first limiting mechanism 4 includes a limiting wheel A401 that overlaps the top of the wire body 3. A threaded rod 402 is fixedly connected to one side of the limiting wheel A401, and a positioning nut 403 is threadedly connected to the surface of the threaded rod 402.

[0027] The second limiting mechanism 5 includes a limiting wheel B501 that overlaps the bottom of the wire body 3, and a connecting rod 502 is fixedly connected to the bottom of the limiting wheel B501.

[0028] A fixed rod 6 is slidably connected to the bottom of the connecting rod 502, and extension blocks 7 are fixedly connected to both sides of the connecting rod 502. The extension blocks 7 serve to support the electric push rod 8.

[0029] An electric push rod 8 is fixedly connected to the bottom of the extension block 7. One side of the electric push rod 8 is electrically connected to a storage battery 9 via a power line. The storage battery 9 provides continuous power supply.

[0030] A fixing block 10 is fixedly connected to the bottom of the electric push rod 8. The fixing block 10 is fixedly connected to the upper surface of the fixing rod 6. The fixing block 10 serves to support the electric push rod 8.

[0031] A storage compartment 11 is fixedly connected to the bottom of the testing chamber 1. The storage compartment 11 has a placement slot inside, which serves to store miscellaneous items.

[0032] A sealing door 12 is hinged to the surface edge of the placement slot. A handle is installed on the surface of the sealing door 12, which serves to open the sealing door 12.

[0033] An image processor 13 is electrically connected to one side of the high-resolution camera 211 via a power cord, and a control terminal 14 is electrically connected to one side of the image processor 13 via a power cord. The image processor 13 is configured to process images.

[0034] In this invention, the working steps of the device are as follows:

[0035] First step: When in use, the high-resolution camera 211 on one side takes a picture of the surface of the wire body 3. The drive motor 203 inside the bottom motor box 202 is started. The drive motor 203 drives the bottom lead screw 204 to rotate, which causes the stand 205 threaded on the surface of the lead screw 204 to move back and forth. This adjusts the distance between the high-resolution camera 211 on one side of the stand 205 and the wire body 3. Then, according to the position that needs to be photographed on the surface of the wire body 3, the servo motor 208 inside the motor box 207 on one side can be started. The servo motor 208 drives the end lead screw 209 to rotate, which causes the high-resolution camera 211 mounted on the surface of the lead screw 209 to move left and right on the lead screw 209.

[0036] The second step: During use, to prevent the main body 3 of the wire from deviating during transportation, limit wheels are usually set for positioning. However, the thickness of the main body 3 varies, so the positions of the top and bottom limit wheels A401 and B501 of the main body 3 can be adjusted according to the thickness of the main body 3. After adjusting the threaded rod 402 on one side of the limit wheel A401 to a suitable position, it is then fixed with the positioning nut 403. Next, the power is turned on, and the electric push rod 8 is controlled to drive the top limit wheel B501 to rise and fall. It should be noted that the device structure and drawings of this utility model mainly describe the principle of this utility model. In terms of the technical aspects of this design principle, the setting of the power mechanism, power supply system and control system of the device is not fully described. However, under the premise that those skilled in the art understand the principle of the above utility model, the specific details of its power mechanism, power supply system and control system can be clearly understood. The control method in the application document is automatic control through a controller. The control circuit of the controller can be implemented by those skilled in the art through simple programming.

[0037] All standard parts used can be purchased from the market, and can be customized according to the instructions and drawings. The specific connection methods of each part adopt conventional methods such as bolts, rivets, and welding that are mature in the existing technology. The machinery, parts and equipment adopt conventional models in the existing technology, and the structure and principle of the components known to those skilled in the art can be known by those skilled in the art through technical manuals or conventional experimental methods.

[0038] Although embodiments of the present invention have been shown and described, it will be understood by those skilled in the art that various changes, modifications, substitutions and alterations can be made to these embodiments without departing from the principles and spirit of the present invention, the scope of which is defined by the appended claims and their equivalents.

Claims

1. A wire flaw detection device based on a vision camera, comprising a detection chamber (1), characterized in that: The testing chamber (1) has an internal cavity, and an adjustment mechanism (2) is installed inside the cavity. Through holes are provided on both sides of the testing chamber (1), and a wire body (3) is inserted through each through hole. A first limiting mechanism (4) is attached to the top of the wire body (3), and a second limiting mechanism (5) is attached to the bottom of the wire body (3). The adjustment mechanism (2) includes a base (201) installed inside the cavity. A motor housing (202) is installed on one side of the base (201). A drive motor (203) is installed inside the motor housing (202). A lead screw (204) is fixedly connected to the output end of the drive motor (203). A support frame (205) is threaded onto the surface of the lead screw (204). An extension plate (206) is fixedly connected to the middle of the support frame (205). A motor box (207) is fixedly connected to one side of the servo motor (208), and a lead screw (209) is fixedly connected to the output end of the servo motor (208). A support block (210) is threadedly connected to the surface of the lead screw (209), and a high-resolution camera (211) is installed on the surface of the support block (210). The first limiting mechanism (4) includes a limiting wheel A (401) that overlaps the top of the wire body (3). A threaded rod (402) is fixedly connected to one side of the limiting wheel A (401), and a positioning nut (403) is threadedly connected to the surface of the threaded rod (402). The second limiting mechanism (5) includes a limiting wheel B (501) that overlaps the bottom of the wire body (3), and a connecting rod (502) is fixedly connected to the bottom of the limiting wheel B (501).

2. The wire flaw detection device based on a vision camera according to claim 1, characterized in that: The bottom of the connecting rod (502) is slidably connected to a fixing rod (6), and extension blocks (7) are fixedly connected to both sides of the connecting rod (502).

3. The wire flaw detection device based on a vision camera according to claim 2, characterized in that: An electric push rod (8) is fixedly connected to the bottom of the extension block (7), and a battery (9) is electrically connected to one side of the electric push rod (8) via a power line.

4. The wire flaw detection device based on a vision camera according to claim 3, characterized in that: The bottom of the electric push rod (8) is fixedly connected to a fixing block (10), which is fixedly connected to the upper surface of the fixing rod (6).

5. The wire flaw detection device based on a vision camera according to claim 1, characterized in that: The bottom of the testing chamber (1) is fixedly connected to a storage compartment (11), and the storage compartment (11) has a placement slot inside.

6. The wire flaw detection device based on a vision camera according to claim 5, characterized in that: The surface edge of the placement slot is hinged to a sealing door (12), and a handle is installed on the surface of the sealing door (12).

7. The wire flaw detection device based on a vision camera according to claim 1, characterized in that: One side of the high-resolution camera (211) is electrically connected to an image processor (13) via a power line, and the other side of the image processor (13) is electrically connected to a control terminal (14) via a power line.

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