A high-precision coating flaw and alignment degree automatic detection platform

Abstract

The utility model discloses a kind of high-precision coating flaw and alignment degree automatic detection platform, including rack, conveying system, detection system, alignment degree detection device and control system being sequentially arranged on rack.The application integrates conveying, detection, alignment degree detection and control system, can realize the high-precision, automated flaw detection and alignment degree detection to coating material, significantly improve detection efficiency and quality, reduce artificial cost.Through high-resolution linear array camera combined with multispectral LED light source, full-coverage detection of surface defects (scratches, bubbles, foreign matter) is realized, while using three-dimensional laser range finder to monitor coating thickness distribution in real time, the reliability, precision, image acquisition quality, flaw detection capability of the correction function of conveying system are enhanced, and the stability of detection result is ensured.

Description

Technical Field

[0001] This utility model relates to the field of testing equipment technology, specifically a high-precision automatic detection platform for coating defects and alignment. Background Technology

[0002] In industrial manufacturing, defect detection and alignment control of coated materials (such as lithium battery separators, optical films, and flexible circuit substrates) are core aspects of ensuring product quality. During the coating process, coating thickness uniformity, surface defects (such as bubbles, scratches, and foreign matter), and pattern alignment directly affect product performance (such as battery energy density and the light transmittance of optical devices). Traditional detection technologies have the following limitations:

[0003] 1. Single inspection dimension: Most equipment relies solely on optical cameras for surface inspection, failing to acquire coating thickness data, leading to missed defects such as bubbles and uneven coating; 2. Insufficient correction accuracy: Mechanical correction systems have slow response speeds (≥0.1mm accuracy), causing material misalignment and subsequent inspection errors; 3. Weak anti-interference capability: Industrial vibrations can easily blur the images from line scan cameras, affecting the defect recognition rate. Utility Model Content

[0004] To overcome the shortcomings of existing technical solutions, this utility model provides a high-precision automatic detection platform for coating defects and alignment, which can effectively solve the problems raised in the background technology.

[0005] The technical solution adopted by this utility model to solve its technical problem is:

[0006] A high-precision automatic detection platform for coating defects and alignment includes a frame, a conveying system, a detection system, an alignment detection device, and a control system arranged sequentially on the frame.

[0007] The frame is provided with a frame, and the top of the frame is provided with a precision slide, a transverse guide rail and a longitudinal guide rail for connecting the detection system. The conveying system includes a coating material conveying roller group with an anti-static coating on the surface, a correction roller group driven by a motor and a tension sensor. The correction roller group achieves ±0.02mm level transverse displacement compensation through closed-loop control.

[0008] The control system is connected to the detection system and the alignment detection device. The detection system includes a high-resolution line scan camera group and a three-dimensional laser rangefinder that uses triangulation to acquire coating thickness data in real time. The three-dimensional laser rangefinder is located directly above the coating material conveying roller group. The alignment detection device includes a line laser emitter and a feature point matcher that implements real-time template comparison of coating patterns based on FPGA hardware.

[0009] As a further description of the above technical solution, the correction roller group includes an active roller, a driven pressure roller, and an edge detection sensor using an infrared photoelectric tube array. The active roller is connected to a motor, and the driven pressure roller is equipped with a pneumatic pressure regulator.

[0010] As a further description of the above technical solution, the high-resolution line scan camera group includes three 12k pixel line scan cameras, a multispectral LED light source, and a polarizing filter. The line scan cameras are arranged orthogonally along the direction of the coating material conveying roller group.

[0011] As a further description of the above technical solution, the bottom of the frame is provided with a base, the base is provided with a shock-absorbing base, the shock-absorbing base is a honeycomb aluminum alloy structure, and the shock-absorbing base is filled with damping gel.

[0012] As a further description of the above technical solution, the coating material conveying roller group is made of transparent material, and a backlight is installed at the bottom of the coating material conveying roller group.

[0013] As a further description of the above technical solution, the control system includes a motion control module and an image processing unit. The motion control module includes a multi-axis motion controller, which synchronously drives the movement of the precision slide of the detection system via an EtherCAT bus. The image processing unit has a built-in GPU accelerator card and a dedicated defect feature extraction ASIC chip.

[0014] Compared with the prior art, the beneficial effects of this utility model are:

[0015] This utility model discloses a high-precision automatic detection platform for coating defects and alignment, which has at least one of the following beneficial effects during use:

[0016] Integrating conveying, inspection, alignment detection, and control systems, this system enables high-precision, automated defect and alignment detection of coated materials, significantly improving inspection efficiency and quality while reducing labor costs. It achieves full-coverage detection of surface defects (scratches, bubbles, foreign matter) using a high-resolution linear scan camera combined with a multispectral LED light source. Simultaneously, a 3D laser rangefinder monitors the coating thickness distribution in real time, enhancing the reliability, accuracy, image acquisition quality, and defect detection capabilities of the conveying system's correction function, and ensuring the stability of the inspection results. Attached Figure Description

[0017] Figure 1 This is a schematic diagram of the overall structure of a high-precision automatic detection platform for coating defects and alignment according to this utility model.

[0018] Figure 2 This is a side view of the high-precision automatic detection platform for coating defects and alignment according to the present invention.

[0019] Figure 3 This is a perspective structural diagram of a high-precision automatic detection platform for coating defects and alignment according to the present invention.

[0020] Numbering on the map:

[0021] 1. Frame; 101. Control system; 102. Base; 103. Frame; 104. Transverse guide rail; 105. Longitudinal guide rail; 2. Conveying system; 201. Coating material conveying roller assembly; 202. Correcting roller assembly; 203. Tension sensor; 204. Edge detection sensor; 205. Driven roller; 206. Pneumatic pressure regulator; 207. Driven pressure roller; 3. Detection system; 301. High-resolution line scan camera assembly; 302. Three-dimensional laser rangefinder; 303. Precision slide; 4. Alignment detection device; 401. Line laser emitter. Detailed Implementation

[0022] 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.

[0023] like Figure 1-3 As shown, this utility model provides a high-precision automatic detection platform for coating defects and alignment, including a frame 1, a conveying system 2, a detection system 3, an alignment detection device 4 and a control system 101 arranged sequentially on the frame 1.

[0024] The main frame 103 of this embodiment adopts a welded steel structure with a hard anodized coating on the surface, and has a load-bearing capacity of ≥500kg. The top integrates a precision slide 303 with a repeatability of ±1μm and a stroke range of 2000mm on the X-axis, 1200mm on the Y-axis, and 200mm on the Z-axis. The transverse guide rail 104 and the longitudinal guide rail 105 adopt pre-tensioned roller linear guide rails with a friction coefficient of ≤0.001.

[0025] The frame 1 is provided with a frame 103. The top of the frame 103 is provided with a precision slide 303, a transverse guide rail 104 and a longitudinal guide rail 105 for connecting the detection system 3. The conveying system 2 includes a coating material conveying roller group 201 with an anti-static coating, a correction roller group 202 driven by a motor and a tension sensor 203. The correction roller group 202 achieves ±0.02mm level transverse displacement compensation through closed-loop control.

[0026] In this embodiment, the surface of the coating material conveying roller group 201 is coated with an antistatic coating (surface resistance 10^6-10^8Ω) to eliminate static electricity and dust adsorption. The correction roller group 202 is driven by a servo motor and works with the tension sensor 203 to achieve closed-loop control. The lateral correction accuracy is ±0.02mm, the material transmission speed range is 5-120m / min, and the applicable material width is 300-1500mm.

[0027] The control system 101 is connected to the detection system 3 and the alignment detection device 4 respectively. The detection system 3 includes a high-resolution line scan camera group 301 and a three-dimensional laser rangefinder 302 that uses triangulation to acquire coating thickness data in real time. The three-dimensional laser rangefinder 302 is located directly above the coating material conveying roller group 201. The alignment detection device 4 includes a line laser emitter 401 and a feature point matcher that implements real-time template comparison of coating patterns based on FPGA hardware.

[0028] In this embodiment, the high-resolution line scan camera 301 consists of 3 orthogonally arranged 12k pixel cameras with a single-line scanning frequency of 80kHz and a pixel size of 3.5μm×3.5μm. Its three-dimensional laser rangefinder 302 is based on triangulation, with a laser wavelength of 650nm, a sampling rate of 10kHz, and a thickness measurement accuracy of ±0.5μm. The line laser emitter 401 projects 405nm blue light with a line width of 0.01mm. It works in conjunction with a high-speed CMOS sensor to capture edge contours. The FPGA-implemented feature point matcher supports a template library of 1000 sets, with a matching speed of ≤1ms / frame and an alignment detection accuracy of ±0.01mm.

[0029] In this embodiment, the motion control module of the control system 101 synchronously drives the three-axis slide table via EtherCAT bus with a bus cycle of 1ms. The image processing unit integrates an NVIDIA Jetson AGX Orin GPU and a custom ASIC chip, with a processing speed of ≥200fps. It supports the Modbus TCP / IP protocol and communicates with the production line PLC in real time.

[0030] Furthermore, the correction roller group 202 includes an active roller 205, a driven pressure roller 207, and an edge detection sensor 204 using an infrared photoelectric tube array. The active roller 205 is connected to a motor, and the driven pressure roller 207 is equipped with a pneumatic pressure regulator 206.

[0031] 205 surface coating of the drive roller The ceramic layer has a hardness ≥ HV1500 and a diameter tolerance of ±0.002mm. The driven pressure roller 207 is equipped with an SMC pneumatic pressure regulator 206 with a pressure control accuracy of ±0.01MPa. The edge detection sensor 204 uses an Omron EE-SX671 infrared phototransistor with a detection frequency of 10kHz and a resolution of ±5μm.

[0032] Furthermore, the high-resolution line scan camera group 301 includes three 12k pixel line scan cameras, a multispectral LED light source, and a polarizing filter. The line scan cameras are orthogonally arranged along the direction of the coating material conveying roller group 201.

[0033] The multispectral LED light source includes three wavelength bands: ultraviolet (365nm): to excite the fluorescence properties of materials and detect microcracks; visible (550nm): for standard bright-field detection; and near-infrared (850nm): to penetrate the surface and detect internal foreign objects. The polarizing filter has an extinction ratio ≥1000:1 to suppress specular reflection from the metal coating.

[0034] Furthermore, the frame 1 has a base 102 at its bottom, and the base 102 has a shock-absorbing base 102. The shock-absorbing base 102 has a honeycomb aluminum alloy structure, and the shock-absorbing base 102 is filled with damping gel.

[0035] The honeycomb aluminum alloy structure has a pore size of 2mm, a wall thickness of 0.1mm, a compressive strength of ≥50MPa, a damping gel made of silicon-based composite material with a loss factor of ≥0.8, an operating temperature of -20℃ to 80℃, a natural frequency of 4.5Hz, and a vibration attenuation rate of ≥90%@100Hz.

[0036] Furthermore, the coating material conveying roller assembly 201 is made of transparent material, and a backlight is installed at the bottom of the coating material conveying roller assembly 201.

[0037] The conveyor roller is made of polycarbonate with a light transmittance of ≥92% and a bending strength of 120MPa. The backlight uses an OSRAM LED module with a brightness of 50,000 lux, a color temperature of 5,000K, and a uniformity of ≥95%.

[0038] Furthermore, the control system 101 includes a motion control module and an image processing unit. The motion control module includes a multi-axis motion controller, which synchronously drives the precision slide 303 of the detection system 3 to move via an EtherCAT bus. The image processing unit has a built-in GPU accelerator card and a dedicated defect feature extraction ASIC chip.

[0039] The multi-axis motion controller (601) uses Beckhoff CX2040, supports 32-axis synchronous control, has wavelet transform algorithm embedded in ASIC chip, supports real-time extraction of 20 types of defect features, has a data throughput of 2.4Gbps, and supports real-time storage of 4K video streams.

[0040] In summary, the coating material is conveyed by an anti-static roller assembly, and the tension sensor 203 monitors the material tension in real time (adjustable from 5-50N). An infrared photoelectric array scans the edge position at a frequency of 10kHz, and the deviation data is calculated by a PID algorithm to drive the correction roller for lateral compensation. A linear array camera continuously captures images in the material's travel direction, and three sets of cameras process different spectral data respectively. A three-dimensional laser rangefinder 302 generates a thickness distribution heat map, and the data and image information are spatiotemporally aligned. The FPGA feature matcher compares the current pattern with a preset template and outputs the X / Y direction offset.

[0041] The detection results are transmitted to the motion controller via EtherCAT bus, driving the three-axis slide to adjust the camera focus. Severe defects trigger audible and visual alarms, while the robotic arm marks the defect location. Historical data is stored in the database, and SPC statistical charts are generated. It simultaneously detects 6 types of surface defects (scratches, bubbles, foreign objects, etc.), 3 types of thickness anomalies, and 2 types of alignment deviations, with a false negative rate of ≤0.01% and a false positive rate of ≤0.1%. It can operate stably in industrial environments with vibration acceleration of 0.5g and ambient temperatures ranging from -10℃ to 45℃.

[0042] It will be apparent to those skilled in the art that this invention is not limited to the details of the exemplary embodiments described above, and that it can be implemented in other specific forms without departing from the spirit or essential characteristics of this invention. Therefore, the embodiments should be considered illustrative and non-limiting in all respects, and the scope of this invention is defined by the appended claims rather than the foregoing description. Thus, it is intended that all variations falling within the meaning and scope of equivalents of the claims be included within this invention. No reference numerals in the claims should be construed as limiting the scope of the claims.

Claims

1. A high-precision automatic detection platform for coating defects and alignment, characterized in that: It includes a frame, a conveying system sequentially mounted on the frame, a detection system, an alignment detection device, and a control system; The frame is provided with a frame, and the top of the frame is provided with a precision slide, a transverse guide rail and a longitudinal guide rail for connecting the detection system. The conveying system includes a coating material conveying roller group with an anti-static coating on the surface, a correction roller group driven by a motor and a tension sensor. The correction roller group achieves ±0.02mm level transverse displacement compensation through closed-loop control. The control system is connected to the detection system and the alignment detection device. The detection system includes a high-resolution line scan camera group and a three-dimensional laser rangefinder that uses triangulation to acquire coating thickness data in real time. The three-dimensional laser rangefinder is located directly above the coating material conveying roller group. The alignment detection device includes a line laser emitter and a feature point matcher that implements real-time template comparison of coating patterns based on FPGA hardware.

2. The high-precision automatic detection platform for coating defects and alignment according to claim 1, characterized in that: The correction roller assembly includes an active roller, a driven pressure roller, and an edge detection sensor using an infrared photoelectric tube array. The active roller is connected to a motor, and the driven pressure roller is equipped with a pneumatic pressure regulator.

3. The high-precision automatic detection platform for coating defects and alignment according to claim 1, characterized in that: The high-resolution line scan camera group includes three 12k pixel line scan cameras, a multispectral LED light source, and a polarizing filter. The line scan cameras are orthogonally arranged along the direction of the coating material conveying roller group.

4. The high-precision automatic detection platform for coating defects and alignment according to claim 1, characterized in that: The frame has a base at the bottom, and the base has a shock-absorbing base. The shock-absorbing base has a honeycomb aluminum alloy structure and is filled with damping gel.

5. The high-precision automatic detection platform for coating defects and alignment according to claim 1, characterized in that: The coating material conveying roller assembly is made of transparent material, and a backlight is installed at the bottom of the coating material conveying roller assembly.

6. The high-precision automatic detection platform for coating defects and alignment according to claim 1, characterized in that: The control system includes a motion control module and an image processing unit. The motion control module includes a multi-axis motion controller, which synchronously drives the precision slide of the detection system via an EtherCAT bus. The image processing unit has a built-in GPU accelerator card and a dedicated defect feature extraction ASIC chip.

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