Product appearance detection and automatic sorting device

Abstract

The utility model relates to a product appearance detection automatic sorting device relates to the field of industrial automation detection. This technology scheme can arrange and accurately convey products to the separation fixture in the fixed direction through the cooperation of the vibrating disc and the straight vibrator, the all -round detection of product appearance is realized through the setting of double CCD cameras, the first CCD camera can capture the color difference, structural flaw of product front and side, the second CCD camera completes bottom detection under the cooperation of the grabbing mechanism, ensures that there is no detection dead angle, compared with artificial visual identification 0.1mm level subtle foreign matter and scratch, significantly improve the detection precision. In addition, the automatic sorting process dispenses with the manual judgment and the sorting link, the detection speed is greatly improved, and through the cooperative control of the IPC controller and the PLC, the instant rejection of defective products can be realized, the product qualified rate is stably improved, the subsequent rework cost is effectively reduced, and the high quality requirement of large -scale production is satisfied.

Description

Technical Field

[0001] This utility model relates to the field of industrial automation testing technology, and in particular to an automatic sorting device for product appearance inspection. Background Technology

[0002] In the production process of injection-molded circuit board connectors, appearance quality inspection is a crucial step in ensuring product performance and reliability. Currently, the industry generally relies on manual labor for this process, inspecting for minor defects such as uniform color, conformity of shape and structure to design standards, and the absence of oil stains and foreign objects on the surface. However, manual inspection has significant efficiency bottlenecks. Due to the small size and intricate structure of connectors, inspectors need to maintain a high level of concentration for extended periods, which can easily lead to visual fatigue and a decrease in inspection speed, making it difficult to meet the high-speed operation requirements of modern production lines.

[0003] More importantly, the accuracy of manual inspection is difficult to guarantee consistently. Due to factors such as differences in the experience of inspectors, subjective judgment biases, and fluctuations in working conditions, false positives and false negatives occur frequently. For example, subtle differences in color depth, tiny scratches, or oil stains and foreign matter hidden in structural gaps are often difficult to accurately identify visually. If these undetected defects flow into the next process, they not only increase subsequent rework costs but may also affect the overall performance of the final product due to problems such as poor connector contact, and even pose safety hazards, failing to meet the stringent quality requirements of high-end electronic equipment. Summary of the Invention

[0004] The purpose of this invention is to provide an automatic sorting device for product appearance inspection, so as to solve the problems existing in the prior art.

[0005] To achieve the above objectives, the technical solution adopted by this utility model is as follows:

[0006] An automatic product appearance inspection and sorting device includes a frame, a worktable is provided inside the frame, and the automatic product appearance inspection and sorting device further includes:

[0007] A tumbling plate, mounted on the worktable, is used to adjust the scattered products into a fixed arrangement and discharge them from their outlet.

[0008] A straight-pump device is installed on the workbench and located on one side of the pumping plate. Its inlet is connected to the outlet of the pumping plate and is used to transport products neatly arranged from its inlet to its outlet.

[0009] A separation fixture is installed on the workbench and located on one side of the straight pusher. Its positioning groove is connected to the discharge port of the straight pusher, and it can drive the product to move along the first direction.

[0010] The first CCD camera, which is connected to the worktable via a bracket and located above the separation fixture, is used to inspect the top surface of the product;

[0011] A second CCD camera, mounted on the worktable and located on one side of the separation fixture, is used to inspect the bottom surface of the product; and

[0012] The gripping mechanism is mounted on the worktable and located on one side of the separation fixture. It is used to grip the product for bottom surface inspection with the second CCD camera, as well as to classify good and defective products.

[0013] In one possible implementation, the separation fixture further includes:

[0014] A detachable base is mounted on the workbench surface;

[0015] A separation cylinder, mounted on the separation base, with its telescopic end positioned along a first direction; and

[0016] A separation slide is installed at the telescopic end of the separation cylinder;

[0017] The positioning groove is disposed on the separation slide.

[0018] In one possible implementation, an optical fiber sensor is also installed on one side of the separation slide located in the positioning groove to confirm the product's position within the positioning groove.

[0019] In one possible implementation, the grasping mechanism includes:

[0020] A gripping base is mounted on the worktable surface;

[0021] A sliding cylinder is mounted on the gripping base along a first direction;

[0022] A telescopic cylinder, mounted on the sliding block of the sliding cylinder along a second direction perpendicular to the first direction; and

[0023] A lifting cylinder is installed vertically on the telescopic end of the telescopic cylinder, and a suction cup is installed on its lifting end;

[0024] The suction cup is capable of adsorbing or releasing the product.

[0025] In one possible implementation, the automatic product appearance inspection and sorting device further includes:

[0026] The control cabinet is located inside the frame and below the workbench, and is electrically connected to the jacking plate, the straight jack, the separation fixture, the first CCD camera, the second CCD camera, and the gripping mechanism.

[0027] The control cabinet includes at least a PLC programmable controller and an IPC controller.

[0028] In one possible implementation, the automatic product appearance inspection and sorting device further includes:

[0029] Good product boxes and defective product boxes are both located on the workbench, and are used to place qualified products and unqualified products respectively.

[0030] In one possible implementation, the automatic product appearance inspection and sorting device further includes:

[0031] An LCD display is mounted on the front side of the rack and is electrically connected to the control cabinet.

[0032] In one possible implementation, the product in the positioning slot, the first CCD camera, and the second CCD camera are located on the same straight line in a first direction.

[0033] The beneficial effects of the technical solution provided by this utility model include at least the following:

[0034] This technical solution utilizes the synergistic action of a vibratory feeder and a linear vibrator to automatically arrange products in a fixed orientation and precisely transport them to a separation fixture. The dual CCD camera setup enables comprehensive inspection of the product's appearance. The first CCD camera captures color differences and structural defects on the front and sides of the product, while the second CCD camera, in conjunction with the gripping mechanism, inspects the bottom surface, ensuring no blind spots. Compared to manual visual inspection, it can identify minute foreign objects and scratches as small as 0.1mm, significantly improving inspection accuracy. Furthermore, the automated sorting process eliminates manual judgment and sorting steps, greatly increasing inspection speed. Through the coordinated control of the IPC controller and PLC, defective products can be immediately rejected, resulting in a stable increase in product pass rate, effectively reducing subsequent rework costs, and meeting the high-quality requirements of large-scale production. Attached Figure Description

[0035] The accompanying drawings are provided to further understand the present invention and form part of the specification. They are used together with the embodiments of the present invention to explain the present invention and do not constitute a limitation thereof.

[0036] Figure 1 A schematic diagram of the front axle side structure of an automatic sorting device for product appearance inspection provided in an exemplary embodiment of the present invention is shown.

[0037] Figure 2 A schematic diagram of the rear axle side structure of an automatic sorting device for product appearance inspection provided in an exemplary embodiment of the present invention is shown.

[0038] Figure 3 This diagram illustrates the internal structure of an automatic product appearance inspection and sorting device provided in an exemplary embodiment of the present invention.

[0039] Figure 4 This diagram illustrates the structure of the separation fixture, first CCD camera, second CCD camera, and gripping mechanism of an automatic sorting device for product appearance inspection provided in an exemplary embodiment of the present invention.

[0040] Figure 5 A schematic diagram of the separation fixture of an automatic sorting device for product appearance inspection provided in an exemplary embodiment of the present invention is shown.

[0041] In the picture:

[0042] 1. Rack;

[0043] 2. Work surface;

[0044] 3. Rotate the plate;

[0045] 4. Vertical swing arm;

[0046] 5. Separation fixture; 51. Positioning groove; 52. Separation base; 53. Separation cylinder; 54. Separation slide; 55. Fiber optic sensor;

[0047] 6. The first CCD camera;

[0048] 7. Second CCD camera;

[0049] 8. Gripping mechanism; 81. Gripping base; 82. Sliding cylinder; 821. Sliding block; 83. Telescopic cylinder; 84. Lifting cylinder; 85. Suction cup;

[0050] 9. Control cabinet;

[0051] 10. Good quality box;

[0052] 11. Defective product boxes;

[0053] 12. LCD display. Detailed Implementation

[0054] The technical solutions of the present utility model will be clearly and completely described below with reference to the accompanying drawings of the embodiments. Obviously, the described embodiments are only some embodiments of the present utility model, and not all embodiments. Based on the embodiments of the present utility model, all other embodiments obtained by those of ordinary skill in the art without creative effort are within the protection scope of the present utility model.

[0055] In this specification, identical components are represented by the same reference numerals. It should be noted that the terms "front," "rear," "left," "right," "upper," and "lower" used in the following description refer to directions in the accompanying drawings of this utility model, while the terms "bottom surface," "top surface," "inner," and "outer" refer to directions towards or away from a specific component, respectively. 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 indicated technical features. Therefore, a feature defined as "first" or "second" may explicitly or implicitly include one or more of that feature. In the description of this utility model, "multiple" means two or more.

[0056] The present invention will be further described below with reference to the accompanying drawings and embodiments.

[0057] Figure 1 This diagram shows a front axle side structure of an automatic product appearance inspection and sorting device provided in an exemplary embodiment of the present invention. Figure 2 This diagram shows a rear axle side structure of an automatic product appearance inspection and sorting device provided in an exemplary embodiment of the present invention. Figure 3 This diagram illustrates the internal structure of an automatic product appearance inspection and sorting device according to an exemplary embodiment of the present invention. The device includes a frame 1 with a worktable 2 inside. It further includes: a chuck 3 mounted on the worktable 2 for adjusting scattered products into a fixed arrangement and exporting them from their outlet; a straight feeder 4 mounted on the worktable 2 and located to one side of the chuck 3, with its inlet connected to the outlet of the chuck 3 for neatly conveying products from its inlet to its outlet; and a separating fixture 5 mounted on the worktable 2 and located to one side of the straight feeder 4. (See reference...) Figure 5Its positioning groove 51 is connected to the discharge port of the straight-pinch device 4, which can drive the product to move along the first direction; the first CCD camera 6 is connected to the worktable 2 through the bracket and is located above the separation fixture 5, which is used to detect the top surface of the product; the second CCD camera 7 is installed on the worktable 2 and is located on one side of the separation fixture 5, which is used to detect the bottom surface of the product; and the gripping mechanism 8 is installed on the worktable 2 and is located on one side of the separation fixture 5, which is used to grip the product to cooperate with the bottom surface detection of the second CCD camera 7, as well as to classify good and defective products.

[0058] It is worth mentioning that the product in the positioning slot 51, the first CCD camera 6, and the second CCD camera 7 are located on the same straight line in the first direction.

[0059] In this embodiment, the vibratory feeder 3 arranges scattered products in a uniform posture via a spiral track. The straight vibrator 4 receives the output from the vibratory feeder 3 and further regulates the product spacing using high-frequency micro-vibration, ensuring that the products entering the separation fixture 5 are in a single, orderly row. The positioning groove 51 of the separation fixture 5 precisely aligns with the output port of the straight vibrator 4. The first CCD camera 6 is vertically positioned above the separation fixture 5, capturing the entire top surface of the product from a top-view angle. Combined with the fixed posture of the positioning groove 51, it ensures that no color or structural defect is missed during detection. The second CCD camera 7 is positioned laterally, forming a detection cooperation with the gripping mechanism 8. When the gripping mechanism suspends the product above it, it can clearly capture the details of the bottom surface. Since the three cameras are collinear in the first direction, the product can be inspected from a dual-view perspective without secondary positioning, significantly shortening the inspection cycle.

[0060] In this embodiment, the gripping mechanism 8 achieves three-dimensional motion through a combination of multi-axis cylinders, and the suction cup 85 accurately adsorbs the product. It not only works with the second CCD camera to complete the posture adjustment for bottom surface detection, but also diverts the product to different bins according to the detection results. The overall structural design eliminates the subjective bias of manual inspection. Through the combination of mechanical collaboration and visual recognition, it achieves full automation from material handling to quality sorting.

[0061] For details, please refer to Figure 5 The separation fixture 5 further includes: a separation base 52, which is mounted on the worktable 2; a separation cylinder 53, which is mounted on the separation base 52, with its telescopic end arranged along a first direction; and a separation slide 54, which is mounted on the telescopic end of the separation cylinder 53; wherein, a positioning groove 51 is provided on the separation slide 54. A fiber optic sensor 55 is also installed on one side of the separation slide 54 located in the positioning groove 51 to confirm the positioning status of the product in the positioning groove 51.

[0062] In this embodiment, the separating cylinder 53 is arranged along the first direction, and its telescopic end is connected to the separating slide 54. It can accurately push the product in the positioning groove 51 into the detection area, realizing the switching between the detection station and the conveying station. The positioning groove 51 is located on the separating slide 54, and the groove design that matches the discharge port of the vibrator 4 can limit the product displacement and ensure uniform posture during detection. The fiber optic sensor 55 is installed on one side of the positioning groove 51 and confirms whether the product is in place in real time through optical signal feedback. It forms a linkage logic with the separating cylinder 53. The cylinder only starts the pushing action when the fiber optic sensor 55 detects the product, avoiding empty detection or misaligned detection, and providing an accurate trigger signal for the CCD camera.

[0063] For more details, see [link to relevant documentation]. Figure 4 The gripping mechanism 8 includes: a gripping base 81, which is mounted on the worktable 2; a sliding cylinder 82, which is mounted on the gripping base 81 along a first direction; a telescopic cylinder 83, which is mounted on the sliding block 821 of the sliding cylinder 82 along a second direction, the second direction being perpendicular to the first direction; and a lifting cylinder 84, which is mounted on the telescopic end of the telescopic cylinder 83 along a vertical direction, and a suction cup 85 is mounted on its lifting end; wherein, the suction cup 85 is capable of adsorbing or releasing the product.

[0064] In this embodiment, the sliding cylinder 82 is arranged along the first direction, driving the component to translate along the X direction, thereby switching the product between the detection and sorting areas. The telescopic cylinder 83 is installed along the second direction perpendicular to the first direction, adjusting the Y-axis position of the suction cup 85 to adapt to the gripping needs of different workstations. The lifting cylinder 84 is set along the vertical Z-axis, controlling the up and down movement of the suction cup 85 to complete the picking and placing of products. The suction cup 85 uses negative pressure to adsorb products, enabling stable picking and placing and avoiding product damage. The coordinated action of each cylinder enables the suction cup 85 to achieve three-dimensional spatial movement, precisely coordinating with the detection process. This ensures stable posture during bottom surface detection and efficiently completes the classification and placement of good and defective products, improving sorting efficiency and accuracy.

[0065] Further, see Figure 2 The automatic sorting device for product appearance inspection also includes: a control cabinet 9, which is set inside the frame 1 and located below the workbench 2. It is electrically connected to the tumbling plate 3, the straight tumbling device 4, the separation fixture 5, the first CCD camera 6, the second CCD camera 7, and the gripping mechanism 8. The control cabinet 9 includes at least a PLC programmable controller and an IPC controller.

[0066] In this embodiment, the PLC programmable controller undertakes the underlying logic control. With its fast response characteristics, it accurately executes timing control tasks. For example, after receiving the arrival signal from the fiber optic sensor 55, it immediately triggers the action of the separation cylinder 53. Based on the position feedback of the gripping mechanism 8, it coordinates the linkage sequence of the sliding cylinder 82, the telescopic cylinder 83 and the lifting cylinder 84 to ensure that the picking and placing actions of the suction cup 85 are accurately connected and to avoid collisions of mechanical parts.

[0067] In this embodiment, the IPC controller focuses on complex data processing and decision-making. By receiving image data transmitted from the first CCD camera 6 and the second CCD camera 7, it runs a preset visual detection algorithm to analyze and judge product appearance defects, and converts the detection results into control commands to send to the PLC.

[0068] Furthermore, see Figure 3 The automatic sorting device for product appearance inspection also includes a good product box 10 and a defective product box 11, both of which are located on the workbench 2 and are used to place qualified products and unqualified products, respectively.

[0069] Specifically, see Figure 1 The automatic sorting device for product appearance inspection also includes an LCD display 12, which is installed on the front side of the frame 1 and electrically connected to the control cabinet 9. By receiving signals transmitted from the control cabinet 9, it can intuitively display the inspection progress, yield rate, etc., helping to quickly judge the status of the device, handle abnormalities in a timely manner, and improve the convenience of operation and maintenance efficiency.

[0070] Next, the working principle of the automatic product appearance inspection and sorting device involved in the embodiments of this utility model will be explained.

[0071] The vibratory feeder 3 starts first, and through the directional vibration of the spiral track, it gradually adjusts the disorderly stacked scattered products to a uniform orientation, so that they move in an orderly manner along the guide rail and finally smoothly enter the feeding guide rail of the straight vibrator 4. The straight vibrator 4 further regulates the product spacing with the help of high-frequency micro-vibration, ensuring that the products are arranged in a single row and are accurately conveyed into the positioning groove 51 of the separation fixture 5.

[0072] Once the fiber optic sensor 55 detects that the product has fully entered the positioning slot 51 and is in position, it will immediately send a signal to the control cabinet 9. The PLC controller in the control cabinet 9 will then drive the separation cylinder 53 to move, causing the separation slide 54 to extend along the first direction, so that the product in the positioning slot 51 is precisely positioned in the detection area directly below the first CCD camera 6;

[0073] At this time, the IPC controller triggers the first CCD camera 6 to start the preset visual inspection program to perform high-definition shooting and defect identification of the color uniformity and structural integrity of the top surface of the product.

[0074] If the first CCD camera 6 determines that the top surface of the product is qualified, the control cabinet 9 will instruct the gripping mechanism 8 to perform the next operation. The sliding cylinder 82 and the telescopic cylinder 83 will work together to adjust the position, and the lifting cylinder 84 will drive the suction cup 85 to descend and adsorb the product. Then, the product will be taken out from the positioning slot 51 and moved to hover above the detection area of ​​the second CCD camera 7. The second CCD camera 7 will then perform a comprehensive inspection of the bottom surface of the product.

[0075] If the first CCD camera 6 detects a defect on the top surface of the product, the gripping mechanism 8 will directly transfer the product to the defective product box 11 and release it.

[0076] If the second CCD camera 7 detects that the bottom surface is qualified, the gripping mechanism will put the product into the good product box 10.

[0077] If the bottom surface fails the inspection, the product will also be sent to the defective product box 11;

[0078] Throughout the process, the LCD display 12 synchronously displays the testing progress, yield rate, and equipment operating status in real time, achieving full-process automation and visual monitoring.

[0079] In summary, this technical solution, through the synergistic action of the vibratory feeder and the linear vibrator, automatically arranges products in a fixed direction and precisely transports them to the separation fixture. The dual CCD camera setup enables comprehensive inspection of the product's appearance. The first CCD camera captures color differences and structural defects on the front and sides of the product, while the second CCD camera, in conjunction with the gripping mechanism, completes bottom surface inspection, ensuring no blind spots. Compared to manual visual inspection, it can identify minute foreign objects and scratches as small as 0.1mm, significantly improving inspection accuracy. Furthermore, the automated sorting process eliminates manual judgment and sorting steps, greatly increasing inspection speed. Through the coordinated control of the IPC controller and PLC, defective products can be immediately rejected, resulting in a stable increase in product pass rate, effectively reducing subsequent rework costs, and meeting the high-quality requirements of large-scale production.

[0080] In the embodiments disclosed in this utility model, the terms "installation," "connection," "linking," and "fixing" should be interpreted broadly. For example, "connection" can be a fixed connection, a detachable connection, or an integral connection; "linking" can be a direct connection or an indirect connection through an intermediate medium. Those skilled in the art can understand the specific meaning of the above terms in the embodiments disclosed in this utility model according to the specific circumstances.

[0081] The above description is only a preferred embodiment of the present utility model. It should be noted that for those skilled in the art, several improvements and modifications can be made without departing from the principle of the present utility model, and these improvements and modifications should also be considered within the protection scope of the present utility model.

Claims

1. An automatic sorting device for product appearance inspection, comprising a frame (1), wherein a worktable (2) is provided inside the frame (1), characterized in that, The automatic sorting device for product appearance inspection also includes: A tumbling plate (3), which is installed on the worktable (2), is used to adjust the products in a scattered state to a fixed direction and to discharge them from their outlet; A straight feeder (4) is installed on the workbench (2) and located on one side of the actuating plate (3). Its feed inlet is connected to the discharge port of the actuating plate (3) and is used to transport products from its feed inlet to its discharge port in an orderly manner. The separation fixture (5) is installed on the workbench (2) and located on one side of the straight feeder (4). Its positioning groove (51) is connected to the discharge port of the straight feeder (4), and it can drive the product to move along the first direction. The first CCD camera (6) is connected to the worktable (2) via a bracket and is located above the separation fixture (5), and is used to inspect the top surface of the product; A second CCD camera (7), mounted on the worktable (2) and located on one side of the separation fixture (5), is used to inspect the bottom surface of the product; and The gripping mechanism (8) is mounted on the worktable (2) and located on one side of the separation fixture (5). It is used to grip the product for bottom surface inspection in conjunction with the second CCD camera (7) and to classify good and bad products.

2. The automatic product appearance inspection and sorting device according to claim 1, characterized in that, The separation fixture (5) also includes: Separate base (52), which is mounted on the worktable (2); A separation cylinder (53), which is mounted on the separation base (52), has its telescopic end arranged along a first direction; and Separating slide (54), which is installed at the telescopic end of the separating cylinder (53); The positioning groove (51) is disposed on the separation slide (54).

3. The automatic product appearance inspection and sorting device according to claim 2, characterized in that, A fiber optic sensor (55) is also installed on one side of the positioning groove (51) on the separation slide (54) to confirm the product's position in the positioning groove (51).

4. The automatic product appearance inspection and sorting device according to claim 1, characterized in that, The grasping mechanism (8) includes: A gripping base (81) is mounted on the worktable (2); A sliding cylinder (82) is mounted on the gripping base (81) along a first direction; A telescopic cylinder (83) is mounted on a sliding block (821) of the sliding cylinder (82) along a second direction perpendicular to the first direction; and A lifting cylinder (84) is installed vertically on the telescopic end of the telescopic cylinder (83), and a suction cup (85) is installed on its lifting end. The suction cup (85) is capable of adsorbing or releasing the product.

5. The automatic product appearance inspection and sorting device according to claim 1, characterized in that, The automatic sorting device for product appearance inspection also includes: The control cabinet (9) is located inside the frame (1) and below the workbench (2). It is electrically connected to the jacking plate (3), the straight jack (4), the separation fixture (5), the first CCD camera (6), the second CCD camera (7), and the gripping mechanism (8). The control cabinet (9) includes at least a PLC programmable controller and an IPC controller.

6. The automatic product appearance inspection and sorting device according to claim 1, characterized in that, The automatic sorting device for product appearance inspection also includes: Good product box (10) and defective product box (11) are both located on the workbench (2) and are used to place qualified products and unqualified products respectively.

7. The automatic product appearance inspection and sorting device according to claim 5, characterized in that, The automatic sorting device for product appearance inspection also includes: An LCD display (12) is mounted on the front side of the rack (1) and is electrically connected to the control cabinet (9).

8. The automatic product appearance inspection and sorting device according to any one of claims 1 to 7, characterized in that, The product in the positioning slot (51), the first CCD camera (6), and the second CCD camera (7) are located on the same straight line in the first direction.

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