Appearance detection device

Abstract

The embodiment of the utility model provides an appearance detection device which comprises a rack, a shooting mechanism and a lighting mechanism, and the rack comprises lower platforms arranged on the two sides of a conveying track, an upper platform arranged above the lower platforms and a plurality of supporting parts; the supporting component is connected with at least one of the upper platform and the lower platform; the shooting mechanism comprises a first camera used for shooting a first side surface of the to-be-detected material, a plurality of second cameras used for shooting a second side surface of the to-be-detected material, and a third camera used for shooting a third side surface of the to-be-detected material; the plurality of second cameras are connected with a liftable first supporting component through a first mounting frame; the first supporting part penetrates through the lower platform and is connected with the lifting driving mechanism; the lighting mechanism comprises a top lamp used for irradiating the first side face, a plurality of side lamps used for irradiating the second side face and a bottom lamp used for irradiating the third side face. The top lamp is connected with the upper platform, the side lamps are connected with the first installation frame so that the side lamps and the corresponding second cameras can move synchronously, and the bottom lamp is connected with the lower platform. According to the technical scheme, the shooting height of the shooting mechanism is automatically adjusted, and the adaptability and universality of the external inspection equipment are improved.

Description

Technical Field

[0001] This disclosure relates to the field of chemical fiber production technology, and in particular to an appearance inspection device. Background Technology

[0002] In the field of chemical fiber production, rigorous visual inspection of different types of chemical fiber yarn cakes or spools, such as POY (pre-oriented yarn), DTY (draw textured yarn), and FDY (fully drawn yarn), is a crucial step in ensuring product quality and promptly identifying and eliminating defective products. Visual inspection equipment typically includes industrial cameras that use image acquisition and analysis technology to examine the yarn cake's shape, color, and surface defects. These different types of yarn products vary in size, winding density, and surface characteristics due to their diverse processing techniques and applications.

[0003] Existing appearance inspection equipment typically integrates multiple industrial cameras and matching light sources to capture images of products from different angles to obtain comprehensive appearance information. These cameras and light sources are often independently positioned and fixed during installation according to specific product specifications, and their positions and angles are usually not adjustable during equipment operation. Utility Model Content

[0004] This disclosure provides an appearance inspection device to solve or alleviate one or more technical problems in the prior art.

[0005] As one aspect of this disclosure, an embodiment provides an appearance inspection device, including:

[0006] The frame includes a lower platform disposed on both sides of the conveyor track, an upper platform disposed above the lower platform, and multiple equipment support components; the equipment support components are connected to at least one of the upper platform and the lower platform.

[0007] The imaging mechanism includes a first camera for photographing a first side of the material to be inspected, a plurality of second cameras for photographing a second side of the material to be inspected, and a third camera for photographing a third side of the material to be inspected; the plurality of second cameras are connected to a liftable first support component via a first mounting bracket; the first support component passes through the lower platform and is connected to a lifting drive mechanism.

[0008] The second side is a circumferential surface, and the plurality of second cameras are arranged around the circumferential surface at intervals; the plurality of second cameras are at the same shooting height, which is determined according to the type or size of the material to be detected;

[0009] The lighting mechanism includes a top light for illuminating the first side, a plurality of side lights for illuminating the second side, and a bottom light for illuminating the third side; the top light is connected to the upper platform, the plurality of side lights are connected to the first mounting bracket, such that the side lights move synchronously with the corresponding second camera, and the bottom light is connected to the lower platform.

[0010] In one implementation, the plurality of second cameras includes side cameras disposed in the side region of the lower platform, with two side cameras disposed on each side of the lower platform; the side cameras are disposed facing the detection station on the conveying track, and the detection station is equidistant from the plurality of second cameras.

[0011] In one implementation, the plurality of second cameras includes a center camera, at least one center camera is provided on the lower platform, and the center camera is positioned facing the detection station on the conveyor track; the angle formed between each pair of adjacent second cameras and the detection station is the same.

[0012] In one implementation, the first support component includes a first vertical rod that passes through the lower platform via a bushing and is connected to the lifting drive mechanism disposed below the lower platform; the top of the first vertical rod corresponding to the edge camera is slidably connected to the upper platform.

[0013] In one implementation, the first support component for mounting the edge camera further includes a first crossbar connected to the first vertical bar via a connector, with a first end of the first crossbar closer to the conveyor track and the first end connected to the first mounting bracket.

[0014] In one implementation, the first mounting bracket includes a base plate and side plates disposed on both sides of the base plate, and the second camera is disposed on the base plate; both sides of the second camera are respectively connected to a side light through the side plates.

[0015] In one implementation, the outer surfaces of the two side plates of each first mounting bracket have a first included angle of 1° to 30°, and a pair of side lamps connected to the side plates have a second included angle, the second included angle being complementary to the first included angle.

[0016] In one implementation, the top light is a ring light, and the first camera takes a picture of the material to be inspected below through the hollow part of the ring light.

[0017] In one implementation, the bottom light includes a pair of arc-shaped lights respectively disposed on the two lower platforms.

[0018] In one implementation, the arc-shaped light is connected to the slide rail of the lower platform via a connecting component, the slide rail extending perpendicular to the material conveying direction; the end of the arc-shaped light extends above the conveying track; wherein the distance between the ends of the pair of arc-shaped lights is greater than the diameter of the corresponding part of the tray used to carry the material to be tested.

[0019] In one implementation, the third camera is connected to a second support component via a second mounting bracket; the second support component includes a second horizontal bar and a second vertical bar, the second vertical bar passing through the lower platform via a bushing and connected to a lifting drive mechanism disposed below the lower platform; the third camera rotates around the second vertical bar.

[0020] In one implementation, the conveying track includes a conveying roller for carrying and conveying the material to be tested and a guide rail connected to the end of the conveying roller; there is a gap between the lower platform and the guide rail.

[0021] The embodiments of this disclosure employ the above-described technical solution to automatically adjust the shooting height of the shooting mechanism according to changes in the material to be tested, enabling one testing device to be compatible with the testing needs of multiple products, improving the adaptability and versatility of external testing equipment, reducing the hassle of replacing or adjusting the entire set of equipment due to product switching, and improving production efficiency.

[0022] The above overview is for illustrative purposes only and is not intended to be limiting in any way. Further aspects, embodiments, and features of this disclosure will become readily apparent from the accompanying drawings and the following detailed description, in addition to the illustrative aspects, embodiments, and features described above. Attached Figure Description

[0023] In the accompanying drawings, unless otherwise specified, the same reference numerals throughout the various drawings denote the same or similar parts or elements. These drawings are not necessarily drawn to scale. It should be understood that these drawings depict only some embodiments provided according to this disclosure and should not be construed as limiting the scope of this disclosure.

[0024] Figure 1 This is a schematic diagram of the appearance inspection device according to an embodiment of the present disclosure;

[0025] Figure 2 This is a top view schematic diagram of an appearance inspection device according to an embodiment of the present disclosure;

[0026] Figure 3 This is a structural schematic diagram of the first mounting bracket portion according to an embodiment of the present disclosure.

[0027] Explanation of reference numerals in the attached drawings: 100, frame; 110, lower platform; 111, bushing; 120, upper platform; 130, equipment support component; 131, first support component; 131a, first vertical rod; 131b, first horizontal rod; 131c, connector; 132, second support component; 132a, second horizontal rod; 132b, second vertical rod; 200, conveyor track; 201, conveyor roller; 202, guide rail; 21 0. Inspection station; 300. Shooting mechanism; 310. First camera; 320. Second camera; 320a. Side camera; 320b. Center camera; 321. First mounting bracket; 321a. Base plate; 321b. Side plate; 330. Third camera; 331. Second mounting bracket; 400. Lighting mechanism; 410. Top light; 420. Side light; 430. Bottom light; 432. Connecting components; 433. Slide rail. Detailed Implementation

[0028] In the following description, only certain exemplary embodiments are briefly described. As those skilled in the art will recognize, the described embodiments can be modified in various ways without departing from the spirit or scope of this disclosure. Therefore, the drawings and description are to be considered exemplary in nature and not restrictive.

[0029] In the description of this application, unless otherwise expressly specified and limited, the terms "connection," "fixed," etc., should be interpreted broadly. For example, "fixed" can mean a fixed connection, a detachable connection, or an integral part; it can mean a mechanical connection or an electrical connection; it can mean a direct connection or an indirect connection through an intermediate medium; it can mean the internal communication of two components or the interaction between two components. Those skilled in the art can understand the specific meaning of the above terms in this application according to the specific circumstances.

[0030] Furthermore, in the description of this application, unless otherwise stated, "a plurality of" means two or more. The terms "upper," "lower," "left," "right," "inner," "outer," etc., indicate the orientation or positional relationship based on the orientation or positional relationship shown in the accompanying drawings, and are only for the convenience of describing this application and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation, and therefore should not be construed as a limitation of this application.

[0031] The main types of yarn involved in the embodiments of this disclosure may include one or more of the following: partially oriented yarns (POY), fully drawn yarns (FDY), and drawn textured yarns (DTY) (or low-elasticity yarn). For example, the specific types of yarn may include polyester partially oriented yarns, polyester fully drawn yarns, polyester drawn yarns, and polyester drawn textured yarns.

[0032] This embodiment provides an appearance inspection device that can be used to inspect the appearance of POY, DTY, FDY and other yarn cakes or spindles (hereinafter collectively referred to as "materials to be inspected") in chemical fiber production.

[0033] Figure 1 A schematic diagram of the appearance inspection device according to an embodiment of the present disclosure is shown. Figure 2 A top view schematic diagram of an appearance inspection apparatus according to an embodiment of the present disclosure is shown. (In conjunction with...) Figure 1 and Figure 2 As shown, the appearance inspection device includes a frame 100, a shooting mechanism 300, and a lighting mechanism 400.

[0034] The frame 100 includes a lower platform 110 disposed on both sides of the conveyor track 200, an upper platform 120 disposed above the lower platform 110, and multiple equipment support components 130. The equipment support components 130 support the imaging mechanism 300 and the lighting mechanism 400, and are connected to at least one of the upper platform 120 and the lower platform 110 to ensure equipment stability and rigidity. The conveyor track 200 is used to convey the material to be tested.

[0035] The imaging mechanism 300 is used to photograph the material to be inspected from multiple angles. The imaging mechanism 300 includes:

[0036] A first camera 310 is used to photograph a first side of the material to be detected (e.g., the top side of the filament cake).

[0037] Multiple second cameras 320 are used to capture the second side surface of the material to be inspected (e.g., the circumferential surface of a silk cake). The multiple second cameras 320 are connected to a liftable first support member 131 via a first mounting bracket 321. The first support member 131 passes through the lower platform 110 and is connected to a lifting drive mechanism (e.g., an electric cylinder, a servo motor with a lead screw, etc.) located below the lower platform 110. The lifting drive mechanism drives the first support member 131 to rise and fall, thereby synchronously raising and lowering the first mounting bracket 321 and the multiple second cameras 320 mounted thereon. The second side surface is a circumferential surface, and the multiple second cameras 320 are arranged at intervals around the circumference of the material to be inspected to achieve complete imaging of the circumferential surface. The multiple second cameras 320 are at the same shooting height, which can be determined and adjusted according to the type (e.g., POY, DTY, or FDY) or specific dimensions (e.g., diameter, height) of the material to be inspected.

[0038] The third camera 330 is used to photograph the third side of the material to be inspected (e.g., the bottom side of the filament cake).

[0039] Lighting mechanism 400 provides illumination for shooting mechanism 300. Lighting mechanism 400 includes:

[0040] A top light 410 is used to illuminate the first side of the material to be tested, and the top light 410 is connected to the upper platform 120.

[0041] Multiple side lights 420 are used to illuminate the second side of the material to be inspected. Crucially, the multiple side lights 420 are connected to the first mounting bracket 321. This design ensures that when the first mounting bracket 321 rises and falls with the first support member 131, the side lights 420 and the corresponding second camera 320 move synchronously, guaranteeing that the second camera 320 always receives stable and suitable illumination from the side lights 420 regardless of changes in shooting height.

[0042] The bottom light 430 is used to illuminate the third side of the material to be tested, and the bottom light 430 is connected to the lower platform 110.

[0043] According to the scheme of this disclosure embodiment, by setting multiple second cameras 320 for photographing the circumferential surface of the material to be inspected and their corresponding multiple side lights 420 on a liftable first support component 131 and driving them by a lifting drive mechanism, automatic adjustment of the shooting height is achieved. This means that when it is necessary to inspect different types (such as POY, DTY, FDY) or different sizes of yarn cakes, the height of the second cameras 320 and the side lights 420 can be easily adjusted to adapt to changes in the material. Thus, one device can be compatible with the inspection needs of multiple products, improving the adaptability and versatility of external inspection equipment, reducing the trouble of replacing or adjusting the entire set of equipment due to product switching, and improving production efficiency. At the same time, the side lights and the second cameras are raised and lowered synchronously, maintaining the consistency of their relative positions and angles, which can avoid light problems caused by changes in position, such as the second camera being directly illuminated by the side light on the opposite side.

[0044] It should be noted that, in terms of overall structure, the entire appearance inspection device is preferably housed entirely within a chassis. This chassis provides necessary protection for the internal inspection mechanism, imaging mechanism, lighting mechanism, and control system, and helps to create a relatively closed and controlled inspection environment. The upper platform 120 and lower platform 110 of the device are fixedly connected to the inner wall or internal frame structure of this chassis to ensure the stability and rigidity of the overall structure. To achieve continuous passage and automated inspection of the material to be inspected, the chassis has notches at the inlet and outlet of the material conveying path. The shape and size of these notches are designed to roughly match the outline of the material to be inspected (e.g., POY, DTY, FDY, etc., yarn cakes or spindles). This matching notch design ensures that the material to be inspected can smoothly enter and leave the inspection area, and also helps to minimize the interference of external light entering the chassis and affecting the lighting environment, and can to some extent prevent external dust and other contaminants from entering, thereby ensuring the accuracy of the inspection results and the long-term stable operation of the equipment. Furthermore, the appearance inspection device can be installed on the side of an existing conveyor track, meaning the conveyor track 200 can be part of an existing production line.

[0045] In one possible implementation, the plurality of second cameras 320 include side cameras 320a disposed in the side region of the lower platform 110. In a preferred arrangement, two side cameras 320a are provided on each side of the lower platform 110 (i.e., each side of the conveyor track 200). The side cameras 320a are positioned facing the inspection station 210 on the conveyor track 200 (which is part of the production line transport mechanism). The inspection station is a predetermined position on the conveyor track 200 where the material to be inspected is placed. Importantly, the shooting distance from the inspection station to the plurality of second cameras 320 (including the side cameras 320a) is designed to be the same to ensure consistent imaging.

[0046] According to the scheme of this disclosure embodiment, by symmetrically arranging side cameras 320a on both sides of the inspection station and ensuring that the distance from each second camera 320 to the inspection station is the same, image information of the circumferential surface of the material to be inspected can be captured more comprehensively and evenly. This symmetrical and equidistant arrangement helps to eliminate image distortion or information omissions that may be caused by inconsistent shooting angles or distances. In particular, it has higher coverage and accuracy for detecting defects (such as lint, oil stains, etc.) on the circumferential surface, thereby improving the inspection quality of the circumferential surface of the material.

[0047] In one possible implementation, the plurality of second cameras 320 include not only side cameras 320a but also a center camera 320b. At least one center camera 320b is provided on the lower platform 110 (the lower platforms 110 on both sides of the conveyor track 200), and the center camera 320b is also positioned facing the detection station 210 on the conveyor track 200. Furthermore, the angle formed between any two adjacent second cameras 320 (including side cameras 320a and center cameras 320b) and the center of the detection station 210 is the same. This means that the plurality of second cameras 320 (including side cameras and center cameras) are distributed in a uniform circular array centered on the detection station 210. For example, two side cameras 320a and one center camera 320b are installed on each side of the conveyor track 200, with the six second cameras spaced 60° apart from the detection station 210. It should be noted that... Figure 1 Only three second cameras on one side of the transport track 200 are shown; the three second cameras on the other side are not shown. Figure 2 The image shows three second cameras on the other side.

[0048] According to the scheme of this embodiment, all the second cameras 320 (edge ​​and center positions) are arranged at equal angular intervals around the inspection station 210, resulting in more uniform and complete information acquisition of the circumferential surface of the material to be inspected. By capturing images from multiple optimized angles, blind spots are reduced, ensuring effective imaging of any position on the circumferential surface. This is crucial for identifying and locating subtle defects that are easily detected only at specific angles, thereby further improving the comprehensiveness and accuracy of the inspection and ensuring product quality.

[0049] In one possible implementation, the first support component 131 includes at least one first vertical rod 131a. The first vertical rod 131a passes through the lower platform 110 via a bushing 111 (set on the lower platform 110) and is connected to the lifting drive mechanism located below the lower platform 110. For the center camera 320b, the corresponding first mounting bracket is directly set at the top of the first vertical rod 131a, meaning the first vertical rod 131a directly supports the center camera 320b and the bottom of the first mounting bracket, resulting in better stability. Even during lifting movements, the center camera 320b will not experience significant swaying. For the edge camera 320a, since the conveyor track 200 has a certain width, the edge camera 320a needs to extend towards the conveyor track 200 via a crossbar, creating a certain distance between the edge camera 320a and the corresponding first vertical rod 131a. To increase stability during the lifting process, the top of the first vertical rod 131a corresponding to the side camera 320a is preferably slidably connected to the upper platform 120, for example, by a slider cooperating with the guide rail on the upper platform 120.

[0050] According to the scheme of this embodiment, the first vertical rod 131a passes through the bushing 111 and connects to the lifting drive mechanism, providing a stable and reliable vertical lifting guide for the side camera 320a. Simultaneously, its top sliding connection with the upper platform 120 forms a stable support similar to a gantry structure, significantly enhancing the rigidity and vibration resistance of the first support component 131 during lifting. This ensures that even after adjusting the shooting height, the side camera 320a can maintain accurate focus and a stable imaging posture, avoiding image blurring or detection errors caused by vibration or tilting. This is of great significance for ensuring the consistency and reliability of detection results for different batches and specifications of products.

[0051] In one possible implementation, the first support member 131 for mounting the edge camera 320a includes a first vertical rod 131a and a first horizontal rod 131b. The first horizontal rod 131b is connected to the first vertical rod 131a via a connector 131c (e.g., an L-shaped connecting plate or welding). The first end of the first horizontal rod 131b is designed to be closer to the conveyor track 200, and the first mounting bracket 321 (for fixing the edge camera 320a) is connected to this first end of the first horizontal rod 131b.

[0052] According to the embodiments of this disclosure, by adding a first horizontal bar 131b and connecting it to the first vertical bar 131a, the position of the edge camera 320a relative to the first vertical bar 131a in the horizontal direction can be adjusted more flexibly. In particular, by extending its first end toward the conveyor track, the edge camera 320a can be more precisely positioned at an ideal shooting point, such as closer to the edge of the material to be inspected, or avoiding interference from other structures. This structure optimizes the camera layout, helps to obtain the best shooting angle and working distance, thereby improving the detection capability of defects in specific areas (such as the edge of a silk cake).

[0053] In one possible implementation, such as Figure 3 As shown, the first mounting bracket 321 includes a base plate 321a and two side plates 321b symmetrically arranged on both sides of the base plate 321a. The second camera 320 (whether it is a side camera 320a or a center camera 320b) is mounted and fixed on the base plate 321a. The two side lights 420 that cooperate with the second camera 320 are respectively connected to the base plate 321a through the side plates 321b.

[0054] According to the embodiments of this disclosure, the integrated design of mounting the second camera 320 on the base plate 321a and the side light 420 on the side plate 321b makes each second camera 320 and its corresponding lighting unit (side light 420) constitute a compact module. Since the side light 420 is fixed to the first mounting bracket 321 integrated with the camera, the relative position of the camera and the light source remains unchanged when the height of the first mounting bracket 321 is adjusted by raising and lowering with the first support member 131. This ensures that regardless of the shooting height adjustment, the illumination angle of the light source and its coordination with the camera can be maintained at an optimal state, thereby ensuring stable lighting conditions and high-quality image acquisition, which is highly advantageous for identifying subtle defects sensitive to lighting conditions.

[0055] In a preferred design, a predetermined first angle is formed between the outer surfaces (or their symmetrical center lines) of the two side plates 321b of each set of first mounting brackets 321, typically ranging from 1° to 30°. Correspondingly, a second angle is also formed between the pair of side lamps 420 (i.e., the two side lamps surrounding the second camera 320) connected to the pair of side plates 321b. The design of the second angle complements the first angle; for example, the first and second angles are complementary, and their sum is 180°. If the side plates 321b are tilted inward, the optical axes of the side lamps 420 are adjusted accordingly to achieve optimal illumination; complementarity can also be understood as synergistic optimization of the lighting effect. For example, the optical axes of the side lamps can be designed to converge slightly towards the center of the camera's field of view.

[0056] According to the embodiments of this disclosure, by setting a specific first angle for the side plate 321b and coordinating it with a second angle between the side lamps 420, the illumination angle and range of the side lamps 420 on the detection area can be finely controlled. This minute angle adjustment, especially for the circumferential surface of the material to be inspected with a certain curvature, can effectively converge light, reduce reflection, or produce specific shadow effects, enhancing the contrast and visibility of defects and improving the detection sensitivity and accuracy of the second camera 320. For example, a smaller angle can make the light more concentrated, suitable for detecting small defects; while a slightly larger angle can provide more uniform coverage.

[0057] In one embodiment, an angle adjustment mechanism is provided at the connection between the base plate 321a and the side plate 321b of the first mounting bracket 321, or for the side plate 321b itself. This angle adjustment mechanism can be configured to allow one or both side plates 321b to deflect slightly relative to the base plate 321a (or relative to the central axis of the second camera 320). This means that the aforementioned first included angle (i.e., the included angle between the outer surfaces of the two side plates 321b) is no longer fixed, but can be automatically adjusted within a certain range (e.g., 0° to 45°).

[0058] The angle adjustment mechanism can take many forms, for example:

[0059] Electric adjustment: The deflection angle of the side plate 321b is precisely controlled by a micro servo motor or stepper motor driving a worm gear mechanism or a small linkage mechanism. The control system can automatically command the motor to drive the side plate 321b to the optimal angle according to the type of material to be tested, surface characteristics (such as reflectivity), or a preset testing program.

[0060] Pneumatic adjustment: The side plate 321b is pushed by a micro cylinder to switch between several preset angles.

[0061] When the angle of the side plate 321b changes, the illumination direction and angle of the side lamps 420 fixed thereon also change. Therefore, the second included angle between the side lamps 420 will also change accordingly, thereby achieving dynamic optimization of the lighting conditions of the second side surface (circumferential surface).

[0062] This embodiment introduces an automatic angle adjustment mechanism for the side plate 321b (and side lamp 420), giving the appearance inspection device greater lighting flexibility and adaptability. For materials to be inspected with different types, gloss levels, and texture characteristics (such as highly reflective FDY yarn and relatively diffuse-reflective DTY yarn), the system can automatically adjust the illumination angle of the side lamp 420 to achieve the best defect display effect. For example, for materials prone to specular reflection, the side lamp angle can be adjusted to avoid areas of strong reflection, or specific grazing light can be used to highlight minor surface irregularities. This dynamic and intelligent lighting adjustment capability can significantly improve the detection rate of complex surface defects, reduce the limitations caused by fixed lighting angles, and further enhance the versatility and inspection accuracy of the equipment.

[0063] In one possible implementation, the top light 410 is preferably a ring light. The first camera 310 is disposed in the central hollow portion of the ring light and takes downward images of the first side (top surface) of the material to be detected through this hollow portion.

[0064] According to the scheme of this disclosure embodiment, a ring light is used as the top light, and the first camera 310 passes through its center to take pictures, realizing coaxial or near-coaxial illumination. This illumination method can provide a very uniform and shadowless illumination effect for the top surface of the material to be inspected, and is especially suitable for inspecting flat or complex textured surfaces. It can effectively eliminate the shadow interference that may be caused by side light sources, clearly showing the molding state, label information, surface dirt, color difference and other defects of the top surface, and improving the accuracy and reliability of the first side surface inspection.

[0065] In one possible implementation, the bottom light 430 includes a pair of arc-shaped lights respectively disposed on the two lower platforms 110.

[0066] According to the embodiment of this disclosure, the bottom lights 430 are designed as a pair of arc-shaped lights, respectively arranged on the lower platforms 110 on both sides of the conveyor track. This allows for enveloping, wider-angle illumination of the third side (bottom surface) of the material to be inspected from below. Compared to a single point light source or a linear light source, the arc-shaped lights better adapt to the bottom contour of cylindrical or near-cylindrical materials such as silk cakes, providing more uniform illumination and reducing dark areas caused by the material itself or the tray supporting the material. This helps to clearly photograph and inspect defects on the bottom surface, such as damaged bottom tubes, oil stains, and poor forming.

[0067] In one possible implementation, the curved light is connected to a slide rail 433 on the lower platform 110 via a connecting component 432. The slide rail 433 extends perpendicularly to the material conveying direction (i.e., perpendicular to the extension direction of the conveyor track 200). The ends of the curved lights are designed to slightly intrude into the space above the conveyor track 200. Furthermore, if the material to be detected is carried by a tray 220, the distance between the ends of the pair of curved lights is designed to be greater than the diameter or width of the corresponding portion of the tray 220.

[0068] According to the embodiment of this disclosure, the curved lamp is mounted on the slide rail 433 via a connecting component 432, allowing its position to be adjusted along the slide rail 433 (i.e., perpendicular to the material conveying direction). This adjustability allows for optimization of the curved lamp's illumination position based on the width or size of the material to be inspected or the tray 220, ensuring optimal bottom lighting. Its end extends above the conveyor track, allowing it to be closer to the bottom of the material to be inspected, providing more direct illumination. Simultaneously, ensuring the distance between the lamp ends is greater than the tray diameter prevents collisions and interference between the curved lamp and the tray 220, and ensures that the light effectively illuminates the bottom surface of the material on the tray, enhancing the adaptability and practicality of the bottom lighting.

[0069] In one possible implementation, the third camera 330 is connected to a second support member 132 via a second mounting bracket 331. The second support member 132 includes a second horizontal bar 132a and a second vertical bar 132b. The second vertical bar 132b passes through the lower platform 110 via a bushing 112 (set on the lower platform 110) and is connected to a lifting drive mechanism disposed below the lower platform 110 (this lifting drive mechanism can be independent, or it can be linked with or share some components with the mechanism driving the first support member). Furthermore, the third camera 330 (or its connected second mounting bracket 331) is designed to be able to rotate about the axis of the second vertical bar 132b, for example, by providing a rotation mechanism.

[0070] According to the embodiments of this disclosure, the third camera 330 is equipped with an independent second support component 132 that includes lifting and rotation functions, greatly improving its detection flexibility. The lifting function allows the vertical position of the third camera 330 to be precisely adjusted according to the height of the material to be detected, so as to obtain a clear bottom image. The rotation function allows the third camera 330 to adjust the shooting angle in the horizontal plane, which can be used to focus on scanning specific areas at the bottom or to adapt to the bottom features of materials with different shapes. This multi-degree-of-freedom adjustment capability ensures comprehensive and blind-spot-free detection of the third side (bottom surface) of the material, enhancing the adaptability of the equipment to complex detection tasks.

[0071] In one possible implementation, the conveyor track 200 includes a plurality of conveyor rollers 201 for carrying and conveying the material to be tested, and guide rails 202 connected to (or serving as support and guide) the ends of the conveyor rollers 201. Crucially, an appropriate gap is designed between the lower platform 110 and the guide rails 202.

[0072] According to the embodiments of this disclosure, the conveyor track 200 employs a structure of conveyor rollers 201 and guide rails 202, providing stable and reliable transport for the material to be inspected. The gap between the lower platform 110 and the guide rails 202 is an important vibration reduction and isolation measure. This gap effectively prevents vibrations generated by the conveyor track 200 during operation from being directly transmitted to the lower platform 110 and the high-precision imaging mechanism 300 and lighting mechanism 400 mounted thereon. By reducing this mechanical vibration interference, the stability of the camera at the moment of shooting is ensured, thereby obtaining clearer, shake-free images. This is crucial for accurately identifying minute defects, improving the overall stability of the inspection system, and enhancing the reliability of the inspection results.

[0073] In one possible implementation, each of the plurality of side lights 420 employs a rectangular array light panel composed of a plurality of independently controllable LED beads. These LED beads are arranged regularly on the rectangular light panel (e.g., M rows and N columns). The rectangular array light panel is equipped with a bead control module, which can independently or in groups control the on / off state and brightness of any one or a portion of the LED beads on the rectangular light panel.

[0074] Thus, this embodiment can adaptively adjust the lighting area according to the height of the material to be tested: before or during testing, the system can acquire the height information of the material to be tested (e.g., through the lifting position sensor of the first support component 131, or through preset product parameters). Based on this height information, the LED control module only illuminates the LEDs in those rows (or areas) on the rectangular array light panel that correspond to the actual height of the material. For example, if the material is short, only a few rows of LEDs at the bottom of the light panel are illuminated; if the material is tall, more rows or even all LEDs are illuminated. This ensures that the second camera is not directly illuminated by the side lights on the opposite side, thus affecting the imaging effect on the material to be tested.

[0075] On the other hand, this example can eliminate misjudgments due to reflections through multiple exposures and zoned illumination: To distinguish between genuine surface defects and bright spots or dark spots caused by surface reflections (especially on smooth or oily surfaces) (which may be misjudged as defects), the LED control module can control the LEDs on the rectangular array light board to illuminate in different areas sequentially within a very short time, and perform multiple rapid exposures in conjunction with the second camera 320. For example, for the same inspection, the following operations can be performed:

[0076] First time revealed: Only the upper half of the LED beads on the array light panel are lit.

[0077] Second exposure: Only the lower half of the LED beads on the array light panel are lit.

[0078] Third exposure: Only the left half of the LED beads on the array light panel are lit.

[0079] Fourth exposure: Only the right half of the LEDs in the array panel are illuminated. (Alternatively, a more detailed partitioning method can be used, such as scanning and illuminating row by row or column by column). By comparing the image information obtained from these multiple exposures at the same location, it can be seen that genuine defects (such as dents, fuzz, and blemishes) typically retain their inherent characteristics under different illumination angles, while the position and intensity of reflective points change significantly with the direction of the light source. Image processing algorithms can leverage this difference to effectively identify and filter out reflective false defects, extracting the true defect information.

[0080] According to the solution of this disclosure, on the one hand, it can accurately match the illumination area with the actual size of the material to be inspected, avoiding ineffective illumination of non-inspection areas (such as the air above or below the material), thereby saving energy. More importantly, it reduces unnecessary stray light entering the camera lens, improves the signal-to-noise ratio and contrast of the image, and makes defect detection of the effective area of ​​the material clearer and more accurate.

[0081] On the other hand, multiple exposures and zoned illumination are used to address the challenges of inspecting highly reflective material surfaces. By actively changing the lighting conditions and performing multiple imaging operations, it is possible to reliably distinguish between genuine surface defects and artifacts formed by specular reflection, significantly reducing the false positive rate (including missed detections and false alarms) caused by reflection. This significantly improves the robustness and accuracy of the appearance inspection device for various complex surfaces (especially smooth, high-gloss, or non-uniformly reflective surfaces).

[0082] The lifting drive mechanism (e.g., the lifting drive mechanism corresponding to the first support component 131, or the lifting drive mechanism corresponding to the second support component 132 of the third camera) can be implemented in the following preferred ways:

[0083] Servo / stepper motor with ball screw mechanism: The lifting drive mechanism can mainly include a precision motor, such as a servo motor or a stepper motor. The output shaft of the motor is connected to a ball screw via a coupling (not shown). The ball screw is mounted vertically. A ball nut is threaded into the ball screw, and the bottom or side of the ball nut is firmly connected to the lower end of the first vertical rod 131a (or the second vertical rod 132b). When the motor rotates, it drives the ball screw to rotate. Since the ball nut is restricted from rotation by its connection with the vertical rod, the ball nut will move linearly along the axial direction of the ball screw, thereby driving the first vertical rod 131a (or the second vertical rod 132b) and the camera components (such as the first mounting bracket 321 or the second mounting bracket 331) carried on it to achieve precise vertical lifting. To ensure the smoothness and guidance of the movement, a linear guide rail can be used near the lower end of the vertical rod or outside the ball nut for auxiliary support and guidance. This linear guide rail is fixed below the lower platform 110. A motor can be connected to the first vertical rod of all the first support components simultaneously through a linkage mechanism, or each first support component corresponding to the second camera can be connected to a motor individually.

[0084] Electric Cylinder (Linear Actuator): Another approach is to directly use an electric cylinder as the lifting drive mechanism. An electric cylinder is a modular product that directly converts the rotary motion of a servo motor or stepper motor into linear reciprocating motion through a built-in lead screw or other mechanical structure. In this solution, the cylinder body of the electric cylinder is fixed below the lower platform 110 or at a suitable position on the frame, and the end of its extension rod (piston rod) is connected to the lower end of the first vertical rod 131a (or the second vertical rod 132b). By controlling the rotation of the electric cylinder's built-in motor, the extension rod can be driven to perform precise linear lifting and lowering motion, thereby raising and lowering the camera components.

[0085] Other configurations of the above embodiments can be adopted from various technical solutions that are now and will be known to those skilled in the art, and will not be described in detail here.

[0086] In the description of this specification, it should be understood that the terms "center," "longitudinal," "transverse," "length," "width," "thickness," "upper," "lower," "front," "rear," "left," "right," "vertical," "horizontal," "top," "bottom," "inner," "outer," "clockwise," "counterclockwise," "axial," "radial," and "circumferential" indicate the orientation or positional relationship based on the orientation or positional relationship shown in the accompanying drawings. They are used only for the convenience of describing this disclosure and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation. Therefore, they should not be construed as limitations on this disclosure.

[0087] Furthermore, the terms "first" and "second" are used for descriptive purposes only and should not be construed as indicating or implying relative importance or implicitly specifying the number of technical features indicated. Thus, a feature defined as "first" or "second" may explicitly or implicitly include one or more of that feature. In the description of this disclosure, "multiple" means two or more, unless otherwise explicitly specified.

[0088] In this disclosure, unless otherwise expressly specified and limited, the terms "installation," "connection," "linking," "fixing," etc., should be interpreted broadly. For example, they can refer to a fixed connection, a detachable connection, or an integral part; they can refer to a mechanical connection, an electrical connection, or a communication connection; they can refer to a direct connection or an indirect connection through an intermediate medium; they can refer to the internal communication of two components or the interaction between two components. Those skilled in the art can understand the specific meaning of the above terms in this disclosure according to the specific circumstances.

[0089] In this disclosure, unless otherwise expressly specified and limited, "above" or "below" the second feature can include direct contact between the first and second features, or contact between the first and second features through another feature between them. Furthermore, "above," "over," and "on top" of the second feature includes the first feature being directly above or diagonally above the second feature, or simply indicates that the first feature is at a higher horizontal level than the second feature. "Below," "below," and "under" the second feature includes the first feature being directly above or diagonally above the second feature, or simply indicates that the first feature is at a lower horizontal level than the second feature.

[0090] The foregoing disclosure provides many different implementations or examples for carrying out different structures of this disclosure. To simplify the disclosure, specific examples of components and arrangements have been described above. Of course, these are merely examples and are not intended to limit the scope of this disclosure. Furthermore, reference numerals and / or letters may be repeated in different examples; such repetition is for simplification and clarity and does not in itself indicate a relationship between the various implementations and / or arrangements discussed.

[0091] The above description is merely a specific embodiment of this disclosure, but the scope of protection of this disclosure is not limited thereto. Any person skilled in the art can easily conceive of various variations or substitutions within the technical scope disclosed in this disclosure, and these should all be included within the scope of protection of this disclosure. Therefore, the scope of protection of this disclosure should be determined by the scope of the claims.

Claims

1. An appearance inspection device, comprising: The frame (100) includes a lower platform (110) disposed on both sides of the conveyor track (200), an upper platform (120) disposed above the lower platform (110), and a plurality of equipment support components (130); the equipment support components (130) are connected to at least one of the upper platform (120) and the lower platform (110); The imaging mechanism (300) includes a first camera (310) for imaging a first side of the material to be inspected, a plurality of second cameras (320) for imaging a second side of the material to be inspected, and a third camera (330) for imaging a third side of the material to be inspected; the plurality of second cameras (320) are connected to a liftable first support member (131) via a first mounting bracket (321); the first support member (131) passes through the lower platform (110) and is connected to a lifting drive mechanism; The second side is a circumferential surface, and the plurality of second cameras (320) are arranged around the circumferential surface at intervals; the plurality of second cameras (320) are at the same shooting height, which is determined according to the type or size of the material to be detected; The lighting mechanism (400) includes a top light (410) for illuminating the first side, a plurality of side lights (420) for illuminating the second side, and a bottom light (430) for illuminating the third side; the top light (410) is connected to the upper platform (120), the plurality of side lights (420) are connected to the first mounting bracket (321), such that the side lights (420) move synchronously with the corresponding second camera (320), and the bottom light (430) is connected to the lower platform (110).

2. The appearance inspection device according to claim 1, wherein, The plurality of second cameras (320) include side cameras (320a) disposed in the side region of the lower platform (110), with two side cameras (320a) disposed on each side of the lower platform (110); the side cameras (320a) are disposed facing the detection station (210) on the conveying track (200), and the detection station (210) is equidistant from the plurality of second cameras (320).

3. The appearance inspection device according to claim 2, wherein, The plurality of second cameras (320) includes a center camera (320b), and at least one center camera (320b) is provided on the lower platform (110). The center camera (320b) is positioned facing the detection station (210) on the conveying track (200). The angle between each pair of adjacent second cameras (320) and the detection station (210) is the same.

4. The appearance inspection device according to claim 2, wherein, The first support component (131) includes a first vertical rod (131a), which passes through the lower platform (110) via a bushing (111) and is connected to the lifting drive mechanism located below the lower platform (110); the top of the first vertical rod (131a) corresponding to the side camera (320a) is slidably connected to the upper platform (120).

5. The appearance inspection device according to claim 4, wherein, The first support component (131) for mounting the side camera (320a) also includes a first crossbar (131b), which is connected to the first vertical bar (131a) via a connector (131c). The first end of the first crossbar (131b) is closer to the conveyor track (200) and is connected to the first mounting bracket (321).

6. The appearance inspection device according to claim 1, wherein, The first mounting bracket (321) includes a base plate (321a) and side plates (321b) disposed on both sides of the base plate (321a). The second camera (320) is disposed on the base plate (321a). The two sides of the second camera (320) are respectively connected to a side lamp (420) through the side plates (321b).

7. The appearance inspection device according to claim 6, wherein, Each set of first mounting brackets (321) has a first included angle of 1° to 30° between the outer surfaces of the two side plates (321b) and a second included angle between a pair of side lamps (420) connected to the side plates (321b), the second included angle being complementary to the first included angle.

8. The appearance inspection device according to claim 1, wherein, The top light (410) is a ring light, and the first camera (310) takes pictures of the material to be tested below through the hollow part of the ring light.

9. The appearance inspection device according to claim 1, wherein, The bottom light (430) includes a pair of arc-shaped lights respectively disposed on the two lower platforms (110).

10. The appearance inspection device according to claim 9, wherein, The arc-shaped lamp is connected to the slide rail (433) of the lower platform (110) via a connecting component (432), the extension direction of the slide rail (433) being perpendicular to the material conveying direction; the end of the arc-shaped lamp extends above the conveying track (200); wherein the distance between the ends of the pair of arc-shaped lamps is greater than the diameter of the corresponding part of the tray used to carry the material to be tested.

11. The appearance inspection device according to claim 1, wherein, The third camera (330) is connected to the second support component (132) via the second mounting bracket (331); the second support component (132) includes a second horizontal bar (132a) and a second vertical bar (132b), the second vertical bar (132b) passes through the lower platform (110) via a bushing (111) and is connected to a lifting drive mechanism located below the lower platform (110); the third camera (330) rotates around the second vertical bar (132b).

12. The appearance inspection device according to claim 1, wherein, The conveying track (200) includes a conveying roller (201) for carrying and conveying the material to be tested and a guide rail (202) connected to the end of the conveying roller (201); there is a gap between the lower platform (110) and the guide rail (202).

Images