Hardware missing detection mechanism and defective product distinguishing device for plastic products

Abstract

The embodiment of the utility model discloses a hardware missing detection mechanism for a plastic product, and the mechanism comprises a housing which is provided with a first through hole in the center of the wall surface of the detection side; the plane light source is fixedly arranged on the wall surface of the detection side, the area is larger than or equal to twice of the area of the to-be-detected product, and a second through hole is formed in the center; and the shooting device is fixedly arranged in the shell, and a lens of the shooting device sequentially penetrates through the first through hole and the second through hole and is over against the to-be-detected product. By arranging the plane light source and the shooting device, the nut on the bottom shell of the LED display screen can be automatically detected, the imaging quality is good, and the detection efficiency is greatly improved; the area of the plane light source is larger than or equal to twice of the area of the to-be-detected product, sufficient and uniform illumination can be provided, shot images are further ensured to be clear, and detection accuracy is improved; the shooting device shoots the to-be-detected product through the first through hole and the second through hole, and a clear product image can be obtained.

Description

Technical Field

[0001] This utility model relates to the field of product quality testing equipment, specifically to a hardware missing detection mechanism and defective product identification device for plastic products. Background Technology

[0002] With the widespread application of LED displays in various electronic devices, quality control during their production process has become particularly important. In the production of the LED display's base shell, the nut, as a key hardware component, directly affects the overall performance and lifespan of the product due to its installation quality.

[0003] However, existing hardware component missing detection technologies still have some problems. When using in-mold vision inspection devices to inspect molded products, the enclosed structure and spatial constraints of the mold cavity inside the plastic molding equipment (injection molding machine) force the imaging device to use an inclined angle for image acquisition, while also requiring a corresponding inclined lighting scheme. These imaging conditions lead to:

[0004] 1. Decreased image quality: The acquired product images are prone to defects such as distortion, shadows, uneven reflection, and blurred features.

[0005] 2. Increased false positive rate: The decline in image quality directly affects the accuracy and robustness of image processing algorithms, leading to a significant increase in the false positive rate for product defects (such as rough edges, missing materials, stains, etc.) or qualified status.

[0006] 3. Difficult debugging: Since the shooting device and light source are located inside the small and inaccessible mold cavity, it is extremely inconvenient and time-consuming to debug and optimize key parameters such as imaging angle, light intensity, light angle, and focal length on site, which further exacerbates the instability of the system and the difficulty of maintenance.

[0007] Therefore, there is an urgent need for a hardware missing detection mechanism and defective product identification device for plastic products, in order to improve the stability of detection results and reduce the complexity of the debugging process. Utility Model Content

[0008] The technical problem to be solved by this utility model embodiment is to provide a hardware missing detection mechanism for plastic products, so as to improve the stability of detection results.

[0009] To address the aforementioned technical problems, this utility model provides a hardware missing detection mechanism for plastic products, comprising: a housing with a first through hole at the center of the wall on the detection side; a planar light source fixed on the wall on the detection side, having an area greater than or equal to twice the area of ​​the product to be detected, and a second through hole at its center; and an imaging device fixed inside the housing, with its lens passing through the first and second through holes sequentially and facing the product to be detected.

[0010] Furthermore, the planar light source is a uniform illumination source composed of an LED array.

[0011] Furthermore, the imaging device employs an industrial CCD camera, whose optical axis is perpendicular to the plane of the planar light source.

[0012] Furthermore, the operating side of the housing is provided with a display, and below the display is a cabinet with a mouse and / or keyboard placement cavity.

[0013] Furthermore, the display is a touch screen, used to display the detection images and / or analysis results captured by the imaging device in real time.

[0014] Furthermore, the housing contains an image processor, which is electrically connected to the shooting device and the display via cables.

[0015] Furthermore, the housing has multiple mounting holes vertically along its fixed side, through which a mounting bracket is mounted with adjustable height, and the mounting bracket is used to fix the hardware missing parts detection mechanism for plastic products to an external injection molding machine.

[0016] This utility model embodiment also provides a defective product identification device, including an injection molding machine, a nut feeder for supplying nuts to the injection molding machine, and a robot arm connected to the injection molding machine for picking up and placing products to be inspected after injection molding. It also includes a hardware missing detection mechanism for plastic products as described above, and the detection mechanism is connected to the robot arm.

[0017] Furthermore, the product to be tested is the bottom shell of an LED display screen after the nuts are assembled.

[0018] The beneficial effects of this utility model are as follows: By setting up a planar light source and an imaging device, the nuts on the bottom shell of the LED display screen can be automatically detected, resulting in good image quality and greatly improving detection efficiency; the area of ​​the planar light source is greater than or equal to twice the area of ​​the product to be detected, providing sufficient and uniform illumination, further ensuring clear images and improving detection accuracy; the imaging device captures images of the product to be detected through the first and second through holes, obtaining clear product images; the detection mechanism is connected to the robotic arm, enabling automatic classification and processing of defective and good products based on the detection results, reducing manual operation and improving production efficiency; the installation height of the detection mechanism can be flexibly adjusted through the mounting holes and fixing brackets on the shell to adapt to the needs of different production lines; the entire detection process is highly automated, reducing the workload of manual inspection and lowering production costs. Attached Figure Description

[0019] Figure 1 This is an overall structural diagram of a hardware missing parts detection mechanism for plastic products according to an embodiment of the present invention.

[0020] Figure 2 This is a partially exploded structural diagram of the detection mechanism described in another embodiment of the present invention.

[0021] Figure 3 This is a schematic diagram of the defective product distinguishing device according to an embodiment of the present invention.

[0022] Explanation of icon numbers Detailed Implementation

[0023] It should be noted that, in the absence of conflict, the embodiments and features in the embodiments of this application can be combined with each other. The present invention will be further described in detail below with reference to the accompanying drawings and specific embodiments.

[0024] In this embodiment of the invention, directional indicators (such as up, down, left, right, front, back, etc.) are only used to explain the relative positional relationship and movement of the components in a specific posture (as shown in the attached figure). If the specific posture changes, the directional indicators will also change accordingly.

[0025] Furthermore, in this utility model, descriptions involving "first," "second," etc., are for descriptive purposes only and should not be construed as indicating or implying their relative importance or implicitly specifying the number of technical features indicated. Therefore, a feature defined with "first" or "second" may explicitly or implicitly include at least one of those features. Example

[0026] Please refer to Figures 1-2 A hardware missing detection mechanism for plastic products includes a housing 1, a planar light source 2, and an imaging device 3.

[0027] A first through hole 11 is provided at the center of the detection side wall of the housing 1. A planar light source 2 is fixed on the detection side wall, with an area greater than or equal to twice the area of ​​the product to be detected, and a second through hole 21 is provided at its center. An imaging device 3 is fixed inside the housing 1, and its lens passes through the first through hole 11 and the second through hole 21 in sequence, and is directly facing the detection surface of the product to be detected.

[0028] The housing 1 is made of metal, possessing good rigidity and stability, and is generally rectangular in shape. The detection side wall of the housing 1 is the front, with a circular first through hole 11 at its center for the lens of the imaging device 3 to pass through. Inside the housing 1 is a bracket for fixing the imaging device 3; the bracket is made of aluminum alloy and is fixedly connected to the inner wall of the housing 1 by bolts.

[0029] The planar light source 2 is fixed to the wall of the detection side of the housing 1, covering the outside of the first through hole 11. The planar light source 2 is a uniform illumination source composed of an LED array, and its overall shape is square. The corresponding illumination surface not only completely covers the detection surface of the product to be detected, but its area is also more than twice the area of ​​the product to be detected. The second through hole 21 is coaxially arranged with the first through hole 11 of the housing 1, and is used for the lens of the imaging device 3 to pass through. The planar light source 2 is fixed to the detection side wall of the housing 1 with screws and can be removed and replaced. The LED array of the planar light source 2 consists of multiple low-power LED beads, which are arranged closely and uniformly to provide a stable and consistent illumination effect. The color temperature is 5500K, and the brightness is adjustable.

[0030] The imaging device 3 is fixed inside the housing 1 and uses an industrial CCD camera, model MV-CA050-10GM. The lens of the imaging device 3 passes through the first through hole 11 and the second through hole 21 in sequence, and its optical axis is perpendicular to the plane of the planar light source 2. The imaging device 3 is fixed inside the housing 1 by a bracket, and its position can be finely adjusted to ensure that the lens is directly facing the center of the detection area. The imaging device 3 is equipped with an industrial lens with a focal length of 16mm and an aperture range of F1.4-F16, which can be adjusted according to actual detection needs.

[0031] The operating side of the housing 1 is equipped with a display 4, which is preferably a touch screen that supports multi-touch operation, used to display the detection images and analysis results captured by the imaging device 3 in real time. The touch screen allows operators to intuitively view the detection results and perform related operations. The display 4 can also be an LCD display 4. Below it is a cabinet 5 with a mouse and keyboard storage compartment. The width of the cabinet 5 is the same as the width of the housing 1, providing storage space for the mouse and keyboard, and also providing convenient operating space for the operator.

[0032] The housing 1 houses an image processor, which is electrically connected to the imaging device 3 and the display 4 via cables. Preferably, the image processor is connected to the imaging device 3 via a USB 3.0 interface to ensure high-speed and stable image transmission; and to the display 4 via an HDMI interface to provide high-definition image display. The image processor can quickly identify whether hardware parts are missing in plastic products, with a detection accuracy of over 99.5% and a detection speed of less than 0.5 seconds per piece.

[0033] Preferably, the top of the housing 1 is provided with a laser alignment device for positioning the product to be inspected or the external robot arm 30. The laser alignment device uses a red laser diode to emit a crosshair laser, which is used to accurately position the product to be inspected or the external robot arm 30, thereby enabling rapid and accurate imaging. The laser alignment device is fixed to the top of the housing 1 by an adjustable bracket, which can rotate 360 ​​degrees horizontally and adjust the angle by ±30 degrees vertically, so as to adjust the laser irradiation position according to actual inspection needs.

[0034] The housing 1 has a vertically recessed mounting groove or multiple evenly spaced mounting holes on its fixed side, allowing for the height-adjustable mounting of the mounting bracket 6. The mounting bracket 6, made of steel, is connected to the mounting groove or holes of the housing 1 via bolts. The mounting bracket 6 allows the hardware missing parts detection mechanism for plastic products to be fixed to the external injection molding machine 10. The height of the mounting bracket 6 is adjustable within a predetermined range to accommodate the detection needs of different product models or the installation requirements of injection molding machines 10 of varying heights.

[0035] In practical applications, the product to be inspected is placed in the inspection area in front of the planar light source 2, which provides uniform backlight illumination. The imaging device 3 captures an image of the product. The image is transmitted to an image processor for analysis and processing to determine whether any hardware components in the plastic product are missing. The inspection results are displayed in real time on a touchscreen, and operators can perform related operations and parameter adjustments via the touchscreen or keyboard and mouse. A laser alignment device assists the product to be inspected or the robotic arm 30 in precise positioning, ensuring the accuracy of the inspection position. By mounting the inspection mechanism on the injection molding machine 10 using a mounting bracket 6, online visual inspection outside the mold can be achieved, improving the stability of the inspection results and reducing the complexity of the debugging process. Example

[0036] Please refer to the above as well. Figure 3 A defective product identification device includes an injection molding machine 10, a nut feeder 20 that supplies nuts to the injection molding machine 10, and a robot arm 30 connected to the injection molding machine 10 for picking up and placing injection-molded products to be inspected. It also includes the hardware missing detection mechanism for plastic products described in Embodiment 1, wherein the detection mechanism is connected to the robot arm 30.

[0037] Injection molding machine 10 is used for the production of medium to large-sized plastic products. It is equipped with a PLC control system, enabling automated production control and allowing signal exchange with external devices via a communication interface.

[0038] The nut feeder 20 is a vibratory feeder. It delivers nuts to the mold of the injection molding machine 10 via a pneumatic conveying pipe, achieving automatic nut supply. The nut feeder 20 is connected to the injection molding machine 10 via a signal line, and automatically controls the feeding rhythm according to the working status of the injection molding machine 10.

[0039] A robotic arm 30 is installed next to the injection molding machine 10 to pick up and place products to be inspected after injection molding. The robotic arm 30 is equipped with pneumatic grippers, and different gripper heads can be changed according to different products to adapt to the gripping needs of products of different shapes and sizes. The robotic arm 30 is connected to the injection molding machine 10 via a signal cable and automatically performs pick-up and place actions according to the working status of the injection molding machine 10.

[0040] The inspection mechanism is mounted near the discharge area of ​​the injection molding machine 10 via a mounting bracket 6, with its position matching the working range of the robot arm 30. The inspection mechanism is connected to the robot arm 30 via a signal line, and can send inspection result signals to the robot arm 30 to guide the robot arm 30 in classifying and processing the products.

[0041] The product to be tested is the LED display screen base shell after the nuts are assembled, with a matte black paint coating. The base shell has multiple nut mounting positions inside, and each base shell requires multiple nuts for subsequent assembly and fixation with the display screen panel.

[0042] In practical applications, the injection molding machine 10 performs injection molding production according to a preset program, and the nut feeder 20 delivers the nuts to the preset positions within the mold. After injection molding is completed, the robot arm 30 removes the molded product and suspends it in the inspection area of ​​the inspection mechanism. The planar light source 2 of the inspection mechanism provides uniform backlighting, and the imaging device 3 captures images of the product. The image processor analyzes the images to determine whether any nuts are missing from the product. The inspection results are transmitted to the robot arm 30 via signal lines, and the robot arm 30 places the products onto the production line 40 or into the defective product area based on the inspection results. The entire process is highly automated and efficient, significantly improving production efficiency and product quality. In summary, the use of external visual inspection with the lens facing the product being inspected overcomes the technical shortcomings of existing technologies, such as poor imaging quality, high misjudgment rate, and difficult debugging.

[0043] 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 hardware component missing detection mechanism for plastic products, characterized in that, include: The housing has a first through hole at the center of the wall on the detection side; A planar light source is fixed on the wall on the detection side, with an area greater than or equal to twice the area of ​​the product to be detected, and a second through hole is opened in the center; The imaging device is fixed inside the housing, and its lens passes through the first through hole and the second through hole in sequence and is facing the product to be inspected.

2. The testing mechanism according to claim 1, characterized in that, The planar light source is a uniform illumination source composed of an LED array.

3. The testing mechanism according to claim 1, characterized in that, The imaging device uses an industrial CCD camera, whose optical axis is perpendicular to the plane of the planar light source.

4. The testing mechanism according to claim 1, characterized in that, The operating side of the housing is equipped with a display, and below the display is a cabinet with a mouse and / or keyboard placement cavity.

5. The testing mechanism according to claim 4, characterized in that, The display is a touch screen, used to display the detection images and / or analysis results captured by the imaging device in real time.

6. The testing mechanism according to claim 4, characterized in that, The housing contains an image processor, which is electrically connected to the shooting device and the display via cables.

7. The testing mechanism according to claim 1, characterized in that, The housing has multiple mounting holes along its fixed side, through which a mounting bracket can be mounted at an adjustable height. The bracket is used to fix the hardware missing parts detection mechanism for plastic products to an external injection molding machine.

8. A defective product identification device, comprising an injection molding machine, a nut feeder for supplying nuts to the injection molding machine, and a robotic arm connected to the injection molding machine for picking up and placing injection-molded products to be inspected, characterized in that, It also includes a hardware missing detection mechanism for plastic products as described in any one of claims 1 to 7, wherein the detection mechanism is signal-connected to a robotic arm.

9. The defective product distinguishing device according to claim 8, characterized in that, The product to be tested is the bottom shell of an LED display screen after the nuts are assembled.

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