A capacitor lead wire testing device

Abstract

This application relates to a capacitor conductor detection device, specifically in the technical field of conductor quality inspection. The device includes a housing, a main camera, and two side cameras. The housing has detection holes for the capacitor conductor to be inspected to move to the detection station within the housing. A mounting plate is fixedly installed inside the housing, and the main camera and two side cameras are respectively mounted on the mounting plate, with the two side cameras positioned to the side of the main camera. A coaxial light source corresponding to the main camera is mounted on the mounting plate, and two strip light sources are installed inside the housing. For each side camera, a reflector is provided to reflect the light path towards that side camera. This application, through the arrangement of the main camera and two side cameras with reflectors, provides a three-field-of-view coverage of the entire outer surface of the conductor, significantly reducing the false negative rate and improving the detection efficiency and accuracy of the capacitor conductor.

Description

Technical Field

[0001] This application relates to the technical field of conductor quality inspection, and in particular to a capacitor conductor inspection device. Background Technology

[0002] In the field of automated production of electronic components, capacitor leads are core conductive components, and their appearance, dimensions, and surface defects directly determine the electrical stability and service life of the capacitor. In actual production, leads need to be inspected simultaneously for multiple indicators, including total length, dimensions of each segment, diameter, shoulder shape, solder joint protrusion, missing corners, scratches, delamination, deformation, and breakage. The inspection items are numerous and the precision requirements are high.

[0003] Currently, the inspection of capacitor leads for appearance and dimensional defects still largely relies on manual visual inspection within the industry. In this manual inspection mode, inspectors must observe the appearance of each lead on a high-speed production line to determine the presence of defects such as dimensional deviations, protruding solder joints, missing corners, scratches, delamination, deformation, and breakage. However, manual inspection has several inherent drawbacks: firstly, it is inefficient and difficult to match the pace of high-speed production lines, easily becoming a production bottleneck; secondly, manual judgment standards are highly subjective, with inconsistent results from different personnel at different times, and prolonged operation can lead to visual fatigue, resulting in high rates of missed or false detections of minor defects. Furthermore, manual inspection can only observe the leads from a single perspective, failing to simultaneously cover critical areas such as the top and sides, making it easy to miss defects such as missing corners, edge damage, and asymmetrical solder joints.

[0004] Therefore, given the low efficiency, poor stability, and high false negative rate of manual inspection, developing a dedicated capacitor pin defect detection device with stable structure, multi-view synchronous imaging, and comprehensive detection capabilities has become an urgent technical problem to be solved in this field. Utility Model Content

[0005] To improve the detection efficiency and accuracy of capacitor conductors, this application provides a capacitor conductor detection device.

[0006] A capacitor guide pin testing device includes a housing, a main camera for capturing a global image of the capacitor guide pin, and two side cameras for capturing images of the end sides of the capacitor guide pin. The housing has a detection hole communicating with a testing station for the capacitor guide pin. A mounting plate is fixedly installed inside the housing. The main camera and the two side cameras are respectively mounted on the mounting plate, with each side camera positioned to the side of the main camera. A coaxial light source corresponding to the main camera is mounted on the mounting plate. Two strip light sources are installed inside the housing. For each side camera, a reflector is provided for reflecting light onto that side camera. The main camera and the two side cameras are arranged vertically downwards and above the testing station. The strip light sources and reflectors are... The detection device is not located below the detection station; the housing also includes a protective structure that physically isolates the detection station from the optical elements. The protective structure includes a first transparent protective plate located below the detection station and above the strip light source and the reflector, and a second transparent protective plate located above the detection station and below the main camera and the two side cameras. The detection device also includes a detection sensor, which outputs a positioning signal when the capacitor guide needle is detected to be in position, so as to trigger the main camera and the two side cameras to synchronously acquire images. The metal processing surface inside the housing corresponding to the space where the guide needle is located includes a diffuse reflection layer treated by sandblasting or shot peening. The surface roughness Ra value of the metal corresponding to the diffuse reflection layer ranges from 0.8 μm to 3.2 μm.

[0007] Optionally, the main camera and two side cameras are arranged vertically downwards and located above the inspection station; the strip light source and the reflector are respectively located below the inspection station; the housing also includes a first base plate, and a bottom backlight is installed on the surface of the first base plate facing the inspection station.

[0008] Optionally, the housing further includes a front lower assembly located below the detection station, wherein a sensor bracket is fixed to the inner sidewall of the front lower assembly near the mounting plate, and the detection sensor is mounted on the sensor bracket.

[0009] Optionally, the first transparent protective plate is fixedly connected between the upper surface of the front lower component away from the mounting base and the mounting plate, and the first transparent protective plate is located above the strip light source, the reflector and the bottom backlight.

[0010] Optionally, the first transparent protective plate is a first float glass plate.

[0011] Optionally, the housing further includes a front upper component located above the testing station, wherein the lower surface of the front upper component near the mounting base is fixedly connected to the second transparent protective plate, and the second transparent protective plate is horizontally arranged.

[0012] Optionally, the second transparent protective plate is a second float glass plate.

[0013] Optionally, the first base plate is fixedly connected to the lower surface of the front lower assembly near the mounting base; a height adjustment assembly is connected below the first base plate, the height adjustment assembly including an adjustment upper plate, a second base plate, multiple connecting rods, multiple adjusting screws, and a first fixing screw; multiple connecting rods are fixedly connected between the adjustment upper plate and the second base plate, and the second base plate is connected to the mounting base; multiple adjusting screws are respectively threaded to the adjustment upper plate through external threads, and multiple adjusting screws are respectively threaded to their respective first fixing screws through internal threads, and the end of each first fixing screw away from the mounting base is respectively threaded to the first base plate.

[0014] Optionally, the second base plate is provided with a first adjustment hole for adjusting the relative position of the second base plate and the mounting base surface.

[0015] Optionally, each of the reflectors is fixedly connected to a rotating shaft, which is rotatably connected to the mounting plate. A rotating block is fixedly connected to the end of the rotating shaft away from the reflector. A second adjustment hole is provided on the rotating block, and a second fixing screw is inserted into the second adjustment hole. The second fixing screw passes through the second adjustment hole and is threadedly connected to the mounting plate.

[0016] Compared with the prior art, the beneficial effects of this utility model are as follows: 1. By using a combination of a main camera and two side cameras with a reflector, the system achieves 360-degree synchronous acquisition of the guide needle from three cameras within a confined space. The three fields of view cover the entire outer surface of the guide needle, significantly reducing the false negative rate and improving the detection efficiency and accuracy of the capacitor guide needle.

[0017] 2. The main camera and side camera are located above the inspection station, while the light source and reflector are located below. The vertically opposed layout is compact, and the guide pin movement area is isolated from the optical components by a transparent protective plate, which effectively prevents guide pin splashes from damaging the lens and light source and improves the reliability of equipment operation.

[0018] 3. The equipment integrates height adjustment components, horizontal adjustment holes, reflector rotation adjustment, and coaxial light source vertical adjustment structure, which can compensate for height, horizontal and light path deviations between different production equipment and achieve rapid and accurate deployment on site. Attached Figure Description

[0019] Figure 1 This is a schematic diagram of the structure of a capacitor lead needle detection device according to one embodiment of this application.

[0020] Figure 2This is a schematic diagram illustrating the camera structure in one embodiment of this application.

[0021] Figure 3 This is an exploded view illustrating the rotating block structure in one embodiment of this application.

[0022] In the diagram, 1. Housing; 11. Mounting plate; 12. First side plate; 13. First bottom plate; 131. Bottom backlight; 14. Front lower assembly; 141. Front lower plate; 142. First corner plate; 15. Front upper assembly; 151. Front upper plate; 152. Second corner plate; 16. Top plate; 17. Back plate; 18. Second side plate; 2. Main camera; 21. Coaxial light source; 3. Side camera; 31. Strip light source; 32. Reflector; 4. Detection hole; 5. First transparent protective plate; 6. Second transparent protective plate; 7. Height adjustment assembly; 71. Adjustment upper plate; 72. Second bottom plate; 73. Connecting rod; 74. Adjustment screw; 75. First adjustment hole; 8. Rotating block; 81. Second adjustment hole; 9. Third adjustment hole. Detailed Implementation

[0023] The principles and features of this utility model are described below. The examples given are only for explaining this utility model and are not intended to limit the scope of this utility model.

[0024] The present application will be further described in detail below with reference to the accompanying drawings.

[0025] like Figure 1 and Figure 2 As shown in the figure, this application provides a capacitor guide pin detection device, including a housing 1, a main camera 2, and two side cameras 3. The housing 1 has a detection hole 4, which is connected to the detection station of the capacitor guide pin. A mounting plate 11 is fixedly installed inside the housing 1. The main camera 2 and the two side cameras 3 are respectively mounted on the mounting plate 11, and the two side cameras 3 are respectively located on the side of the main camera 2. A coaxial light source 21 corresponding to the main camera 2 is installed on the mounting plate 11. Two strip light sources 31 are installed inside the housing 1. For each side camera 3, there is a reflector 32 for reflecting the light path to that side camera 3. The main camera 2 is used to capture a global image of the capacitor guide pin, and the two side cameras 3 are used to capture images of the end side of the capacitor guide pin.

[0026] It is easy to understand that the guide pin can be divided into regions such as section A, section E, section B, section Y, and the CP line. Section A is located at the very top of the guide pin; section E is located in the narrow transition section between section A and section B; section B is located in the middle section of the guide pin; section Y is located in the connection area between the end of section B and the CP line, which is the solder joint for resistance welding or laser welding; the CP line is located at the very end of the guide pin and is a thin, needle-like lead (usually called a lead or pin), used to insert the capacitor into the printed circuit board (PCB) to achieve electrical connection. In this embodiment, the main camera 2 can be a 12-megapixel high-resolution area array camera, vertically arranged above the guide pin, used to capture a top-down global image of the guide pin. The global image can cover all parts of the guide pin, including section A, section E, section B, section Y, and the CP line, and the field of view can meet the measurement requirements of dimensions such as the total length L.

[0027] The two side cameras 3 can be 5-megapixel area scan cameras, respectively positioned on the left and right sides of the main camera 2, to capture partial side images of the left or right side of the guide pin. Since the side view is mainly used to detect local details such as B-section defects and Y-section corner defects, and does not need to cover the entire length, a camera with lower resolution and a smaller field of view can meet the requirements, while reducing hardware costs.

[0028] The housing 1 forms a relatively enclosed detection chamber, reducing interference from external ambient light and dust pollution. The detection hole 4 on the housing 1 connects to the guide needle conveying mechanism on the guide needle production line, allowing the capacitor guide needle to be tested to move from outside the housing 1 to the detection station inside. In this embodiment, the guide needle can rotate from the central space of the housing 1 into the detection station, stop upon reaching its position, and be photographed by the main camera 2 and two side cameras 3.

[0029] The main camera 2 and the two side cameras 3 shoot simultaneously. This simultaneous shooting ensures the consistency of the three images in the time dimension, meaning that the three images capture the same guide needle from different perspectives at the same instant.

[0030] like Figure 2 As shown, a coaxial light source 21 corresponding to the main camera 2 is installed on the mounting plate 11. The coaxial light source 21 is arranged in the imaging optical path of the main camera 2. The light beam emitted by it is coaxial or approximately coaxial with the optical axis of the main camera 2. It is used to uniformly illuminate the area to be detected by the guide needle and suppress shadows, thereby improving the imaging quality of the global image.

[0031] The housing 1 includes two first side plates 12, which are fixedly connected to the two sides of the mounting plate 11 along its length. In this embodiment, two strip light sources 31 can be provided. One strip light source 31 is fixedly installed on the inner side of the two first side plates 12 that are close to each other, and the strip light sources 31 are located at the bottom end of the first side plates 12 near the mounting base. The strip light sources 31 are distributed near the inspection station, and their illumination direction can be adjusted according to the actual situation on site. They are used to provide supplementary illumination from the side to highlight the longitudinal defects and fine textures on the surface of the guide needle.

[0032] For each side camera 3, a reflector 32 is correspondingly installed inside the housing 1. The reflector 32 is arranged in the imaging optical path of the corresponding side camera 3 to reflect the light from the side of the guide pin tip to that side camera 3, so that the side camera 3 can still obtain a clear image of the side of the guide pin tip even when the internal space of the device is limited. The reflection angle of the reflector 32 and its relative position in the housing 1 can be adjusted according to the on-site optical path requirements to make the formed reflected optical path most favorable for the side camera 3 to acquire images.

[0033] In this embodiment, the metal processing surface inside the housing 1 corresponding to the space where the guide needle is located includes a diffuse reflection layer treated by sandblasting or shot peening. Combined with the metal wrapping structure around the housing 1, the light from the light source forms diffuse reflection on the inner metal wall, achieving a soft light environment, thereby better highlighting the minute defects on the surface of the guide needle and improving the defect detection rate.

[0034] Specifically, the inner metal walls of the housing 1 that directly face the space where the guide needle is located, including the surface of the mounting plate 11 facing the detection station, the inner surface of the upper front assembly 15, the inner surface of the lower front assembly 14, and the inner surface of the first side plate 12 facing the detection station, are all treated with sandblasting or shot peening to form a diffuse reflection layer. In a specific process embodiment, 80-150 mesh quartz sand or cast steel shot can be used as the blasting medium, and the metal surface can be uniformly blasted at a blasting pressure of 0.4 MPa to 0.6 MPa to form a uniformly distributed micro-pits and raised rough morphology on the metal surface, which is the diffuse reflection layer. The surface roughness Ra value of the treated metal is controlled within the range of 0.8 μm to 3.2 μm. This roughness range can ensure that the incident light undergoes sufficient diffuse reflection on the surface without accumulating dust or being difficult to clean due to excessive surface roughness.

[0035] In the illumination state, the light emitted by the coaxial light source 21, the strip light source 31, and the bottom backlight 131 not only directly illuminates the surface of the guide pin, but also projects a considerable portion of the light onto the surrounding metal inner walls. Because the inner wall surface has a diffuse reflection layer, the incident light no longer forms a glaring specular reflection spot along a specific direction like on a smooth metal surface; instead, it is uniformly scattered in all directions within the metal cavity. After multiple diffuse reflections by the surrounding inner walls, a soft light environment with uniform brightness and no obvious directionality is formed around the inspection station. This soft light environment effectively suppresses the high-gloss glare and local overexposure caused by directional strong light irradiation on the slender metal surface of the guide pin, making minor defects such as scratches, indentations, and oxide spots on the guide pin surface appear more clearly in the image with varying grayscale differences, thereby significantly improving the imaging contrast and detection rate of defects.

[0036] The guide needle is fed into the detection station inside the housing 1 through the detection hole 4 by an external conveying mechanism. The coaxial light source 21 and the strip light source 31 are illuminated, simultaneously triggering the main camera 2 and two side cameras 3 to expose and capture images. The main camera 2 directly acquires a global image of the guide needle; the two side cameras 3 acquire reflected images of the side surfaces of the guide needle ends through their respective reflectors 32. The three images collectively cover the entire outer surface of the guide needle. After capturing the images, the guide needle is conveyed out by the conveying mechanism, and the next guide needle enters, thus cyclically detecting the needle. It should be noted that image analysis and processing after acquisition can be achieved using existing image processing techniques in the field; this invention only relates to improvements in the hardware structure of the detection equipment.

[0037] In a preferred embodiment, the main camera 2 and the two side cameras 3 are arranged vertically downwards and above the inspection station. The three cameras are mounted on the mounting plate 11, with their lenses facing downwards and directly towards the inspection station. The main camera 2 acquires a global image of the guide pin from directly above, while the two side cameras 3 acquire images of the side of the guide pin's tip from an oblique angle above. Arranging the cameras uniformly above the inspection station shortens the camera's suspended optical path, making the overall structure more compact in the horizontal direction, and also facilitates docking with guide pin conveying mechanisms located above or to the side of the equipment.

[0038] The strip light source 31 and the reflector 32 are respectively disposed below the inspection station. The strip light source 31 is arranged on both sides below the inspection station, with its illumination direction facing the inspection station, and is used to illuminate the surface of the guide needle from the side; the reflector 32 is also disposed below the inspection station, and is located directly below or diagonally below the corresponding side camera 3, and is used to reflect the light from the side of the guide needle end upward to the corresponding side camera 3, so that the side camera 3 can obtain a clear image of the side of the end without having to be on the same horizontal level as the guide needle.

[0039] like Figure 2As shown, the housing 1 also includes a first base plate 13, which is located below the inspection station and forms the bottom support of the housing 1. A bottom backlight 131 is also installed on the surface of the first base plate 13 facing the inspection station. The bottom backlight 131 provides illumination from below the inspection station to enhance the contrast of the guide pin outline and assist the camera in acquiring images with clear edges.

[0040] In other embodiments, the main camera 2 and two side cameras 3 can be vertically arranged below the inspection station, while the strip light source 31, reflector 32, and backlight are correspondingly positioned above the inspection station. However, after comparing actual working conditions, this arrangement has obvious shortcomings: First, the guide pin usually enters the inspection station from the top or upper side of the equipment. When the camera is positioned below, its lens and body are prone to spatial interference with the guide pin conveying mechanism. Second, the guide pin is a slender metal part. If it accidentally falls or breaks during the inspection process, the camera lens positioned below will be directly in the fall path, posing a risk of impact damage. Third, when the reflector 32 and strip light source 31 are positioned above, top space needs to be left for the guide pin feeding, resulting in a loose structure of the equipment in the vertical direction. Moreover, the reflector 32 above is more prone to accumulating dust, affecting the stability of the reflected light path. In addition, if the bottom backlight 131 is moved to the top, the backlight effect of outlining the guide pin from the bottom is lost, which is not conducive to global imaging.

[0041] Therefore, considering structural compactness, on-site safety, optical path stability, and imaging effect, a more preferred implementation is to vertically arrange the main camera 2 and two side cameras 3 above the inspection station, while concentrating the strip light source 31, reflector 32, and bottom backlight 131 below the inspection station. This vertically opposed layout can form a complete inspection optical path within a very small space, effectively avoiding interference with the guide needle conveying mechanism and reducing the risk of camera damage.

[0042] like Figure 1 and Figure 2 As shown, the housing 1 also includes a lower front assembly 14 located below the detection station. The lower front assembly 14 constitutes the main support structure of the lower part of the housing 1, used to support optical components such as the strip light source 31 below the detection station. A sensor bracket is fixed to the inner wall of the lower front assembly 14 near the mounting plate 11. The sensor bracket can be, for example, an L-shaped or Z-shaped bent plate, with one side wall fastened to the inner wall of the lower front assembly 14 by screws, and the other side wall used to support the detection sensor. To improve adaptability, an adjustment elongated hole can be provided on the sensor bracket to finely adjust the installation position of the detection sensor in the horizontal or vertical direction, so that its detection window is accurately aligned with the detection station.

[0043] A detection sensor is mounted on the sensor bracket to detect whether the capacitor lead has moved into position at the detection station. In this embodiment, the detection sensor can be a diffuse reflection photoelectric sensor, such as an infrared diffuse reflection sensor; in other embodiments, a fiber optic sensor or an inductive proximity switch can also be used. The detection sensor is arranged in the area below the detection station and close to the inner wall of the mounting plate 11. This position can make full use of the lower space of the housing 1, avoid spatial interference with the main camera 2, side camera 3 and coaxial light source 21 located above the detection station, and at the same time, it does not block the light path of the strip light source 31 and the reflector 32, so that the equipment maintains a compact structure in a very small space.

[0044] The installation height of the detection sensor can be adaptively adjusted according to the actual stopping position of the guide pin after it is in place. For example, the sensor bracket can be designed with a multi-step mounting surface, or a vertical oblong hole can be opened on the bracket to make the height of the detection sensor adjustable within a certain range, thereby adapting to the arrival height deviation of different types of guide pins or different conveying mechanisms.

[0045] During the inspection process, the guide pin enters the housing 1 through the inspection hole 4 and moves to the inspection station. When the guide pin reaches the preset inspection position, the inspection sensor senses the guide pin and outputs a positioning signal. This positioning signal is used to trigger the main camera 2 and the two side cameras 3 to synchronously acquire images, thereby realizing online inspection of the guide pin. Integrating the inspection sensor inside the equipment housing 1 enables the inspection equipment to have an independent positioning detection function, eliminating the need to rely entirely on the position feedback of the external conveying mechanism. This helps to improve the response speed and synchronization accuracy of the inspection action, ensuring that the camera completes the image capture at the optimal moment when the guide pin is stably stationary.

[0046] A first transparent protective plate 5 is fixedly connected between the upper surface of the front lower component 14 away from the mounting base and the mounting plate 11. The first transparent protective plate 5 is located above the strip light source 31, the reflector 32, and the bottom backlight 131. In this embodiment, the upper surface of the front lower component 14 away from the mounting base is the top surface of the front lower component 14 facing the detection station. The first transparent protective plate 5 spans between this top surface and the mounting plate 11, vertically separating the space above the detection station from the space below where the strip light source 31, the reflector 32, and the bottom backlight 131 are located.

[0047] As a specific installation method, one edge of the first transparent protective plate 5 is detachably fixed to the upper surface of the lower front assembly 14 by screws, and the other edge is fixed to the corresponding position of the mounting plate 11 by screws or snap-fit ​​structures, thereby stably suspending the first transparent protective plate 5 above the lower optical element. To improve connection reliability, right-angle connectors or reinforcing ribs can also be added between the first transparent protective plate 5 and the mounting plate 11 to enhance the impact resistance of the transparent protective plate.

[0048] The first transparent protective plate 5 can be set horizontally, or it can be set slightly inclined according to the internal spatial layout of the housing 1 and the movement trajectory of the guide needle, for example, at an angle of 0° to 15° with the horizontal plane. The tilt direction can be towards the detection hole 4, so that accidentally dropped debris or dust can slide off naturally under gravity, avoiding accumulation on the first transparent protective plate 5 and affecting the detection environment. The first transparent protective plate 5 maintains an appropriate vertical distance from the strip light source 31, the reflector 32 and the bottom backlight 131 below. This distance provides sufficient structural deformation buffer space for the first transparent protective plate 5, and also leaves room for adjustment, heat dissipation and maintenance of the optical components below.

[0049] The first transparent protective plate 5 is a first float glass plate. The first transparent protective plate 5 is set as a transparent plate so that it can block the guide needle and foreign objects while allowing light to pass through, thereby avoiding obstruction of the illumination path of the strip light source 31 below and the reflection path of the reflector 32, ensuring that the side camera 3 can normally receive the side image of the guide needle end reflected by the reflector 32, and the light from the bottom backlight 131 can also pass through the first float glass plate to illuminate the inspection station.

[0050] In this embodiment, the first float glass plate is preferably made of float glass. Float glass has the characteristics of high surface flatness, excellent optical transmittance, wear resistance, and resistance to aging. It can maintain stable light transmission performance for a long time in industrial environments, and its high hardness can effectively resist the impact of guide needle splashing. The thickness of the float glass plate can be, for example, from 3mm to 8mm. This thickness range provides sufficient mechanical protection for the underlying optical components without causing light attenuation or a significant increase in the overall weight of the equipment due to excessive thickness.

[0051] In other embodiments, the first float glass sheet can also be made of plexiglass (acrylic sheet) or polycarbonate (PC sheet). Plexiglass sheets are lightweight, have good impact resistance and toughness, and are easy to process and replace on-site; polycarbonate sheets have higher impact resistance and are suitable for working conditions with a high risk of guide needle splashing. However, compared to float glass, plexiglass sheets and polycarbonate sheets have lower surface hardness, are more prone to scratches after long-term use, and have a tendency to attract dust by electrostatics, thus requiring more frequent surface cleaning and maintenance.

[0052] To improve optical performance, at least one of the upper and lower surfaces of the first float glass plate may be coated, such as with an anti-reflective coating to increase the transmittance of light in a specific wavelength band and reduce light loss; or with an anti-fouling coating to reduce the adhesion of oil stains and dust to the plate surface, facilitating on-site cleaning and keeping the optical path clean. The first transparent protective plate 5 may be a non-porous structure.

[0053] like Figure 1As shown, in this embodiment, the front lower assembly 14 includes a front lower plate 141 and two first corner plates 142. The front lower plate 141 is fixedly connected to the two first corner plates 142, and the ends of the two first corner plates 142 away from the front lower plate 141 are fixedly connected to their respective first side plates 12. A sensor bracket is installed on the inner side of the front lower plate 141 near the mounting plate 11. A first transparent protective plate 5 is installed on the upper surfaces of the front lower plate 141 and the two first corner plates 142.

[0054] The housing 1 also includes a front upper assembly 15 located above the inspection station, which constitutes the upper support structure of the housing 1. The front upper assembly 15 is located on the lower surface near the mounting base, i.e., the bottom surface of the front upper assembly 15 facing the inspection station, and is fixedly connected to the mounting plate 11 with a second transparent protective plate 6. In this embodiment, the front upper assembly 15 includes a front upper plate 151 and two second corner plates 152. The front upper plate 151 is fixedly connected to each of the two second corner plates 152, and the ends of the two second corner plates 152 away from the front upper plate 151 are fixedly connected to their respective first side plates 12.

[0055] The second transparent protective plate 6 is horizontally positioned, with its surface roughly parallel to the plane of the inspection station, thus forming a horizontal physical barrier below the main camera 2 and the two side cameras 3. As a specific installation method, one edge of the second transparent protective plate 6 is detachably fixed to the lower surface of the upper front assembly 15 with screws, and the other edge is fixed to the corresponding position on the mounting plate 11 with screws or a snap-fit ​​structure, allowing the second transparent protective plate 6 to be stably suspended between the inspection station and the upper camera. To improve connection reliability, a right-angle connector can also be added between the second transparent protective plate 6 and the mounting plate 11 to enhance impact resistance in the suspended state.

[0056] The second transparent protective plate 6 is located below the main camera 2 and the two side cameras 3, and maintains an appropriate vertical distance from the bottom of the camera lens. This distance balances the camera's field of view and protection requirements, preventing the second transparent protective plate 6 from entering the camera's imaging field of view and causing obstruction, while ensuring that it can effectively intercept upward-flying foreign objects in the event of abnormal splashing of the guide pin, preventing the guide pin or debris from directly impacting the lens and body of the main camera 2 and the two side cameras 3, thereby protecting the precision imaging components.

[0057] The second transparent protective plate 6 corresponds vertically to the first transparent protective plate 5, forming a relatively enclosed detection chamber area between them. When the guide pin is being tested at the detection station, its movement is restricted within the space between the upper and lower transparent protective plates, thereby isolating the movement area of ​​the guide pin from the camera area above and the light source and reflector 32 area below, significantly reducing the risk of damage to the internal functional modules of the equipment due to abnormal detachment or breakage of the guide pin.

[0058] In other embodiments, buffer pads or shock-absorbing strips may be provided at the connection between the second transparent protective plate 6 and the mounting plate 11 and the front upper component 15 to absorb the impact energy when the guide needle splashes, reduce the transmission of vibration to the camera mounting structure, and ensure the positional stability and imaging clarity of the camera during long-term use.

[0059] The second transparent protective plate 6 can be a second float glass plate. By setting the second transparent protective plate 6 as a transparent plate, the main camera 2 and the two side cameras 3 can directly photograph the guide pin at the inspection station through the plate surface, achieving physical protection without obstructing the imaging optical path of the camera, thus balancing protection function and imaging quality.

[0060] In this embodiment, the second float glass sheet is preferably made of float glass. The thickness of this float glass sheet can be, for example, from 3 mm to 8 mm. This thickness range provides sufficient mechanical strength to withstand the impact of accidental splashing of the guide needle, without causing significant light attenuation or excessive weight increase on the upper part of the device due to excessive thickness. In other embodiments, the second float glass sheet may also be made of plexiglass (acrylic sheet) or polycarbonate (PC sheet).

[0061] To improve optical performance, at least one of the upper and lower surfaces of the second float glass plate may also be treated with an anti-reflective coating. The second float glass plate and the first float glass plate described above can be identical in material and optical performance, and together they form an opposing transparent protective layer.

[0062] like Figure 1 As shown, in this embodiment, the second transparent protective plate 6 can adopt a one-piece, hole-free structure. This one-piece, hole-free structure is a continuous, complete plate surface, forming a complete physical isolation between the inspection station and the camera area in the horizontal direction. The three camera lenses can directly photograph the guide pins at the inspection station below through the transparent plate surface without the need to open any through holes in the plate surface. This ensures the integrity of the camera imaging optical path and avoids edge chipping or stress concentration problems that may exist at the openings. At the same time, it maximizes the interception area of ​​the transparent protective plate for guide pin splashes, providing the most rigorous protection for the camera lenses above.

[0063] In other embodiments, the second transparent protective plate 6 may also have openings along the three camera shooting paths. Specifically, through holes or clearance holes are provided on the second transparent protective plate 6 corresponding to the imaging optical axes of the main camera 2 and the two side cameras 3, respectively. The diameter of the opening is slightly larger than the field of view cone cross-section of the corresponding camera lens to ensure that the imaging optical path is not blocked, and the camera lens is directly aligned with the detection station through the opening.

[0064] If an open structure is adopted, the edges of the opening should preferably be chamfered or rounded to eliminate sharp edges, reduce the risk of guide pin debris getting stuck, reduce stress concentration, and improve the structural strength of the transparent protective plate.

[0065] The first base plate 13 is fixedly connected to the lower surface of the front lower assembly 14 near the mounting base. In this embodiment, the first base plate 13 is a flat plate structure, and its plate surface contour shape is adapted to the front lower assembly 14, for example, it can be designed as an irregularly shaped plate. The upper surface of the first base plate 13 is fastened to the lower surface of the front lower assembly 14 near the mounting base by screws, thereby reliably transferring the weight of the front lower assembly 14 and the entire detection device above it to the support structure below.

[0066] like Figure 1 and Figure 2 As shown, a height adjustment assembly 7 is connected below the first base plate 13. The height adjustment assembly 7 is used to adjust the overall vertical height of the testing equipment relative to the mounting base surface to accommodate height deviations between different on-site production equipment. The height adjustment assembly 7 includes an adjusting upper plate 71, a second base plate 72, multiple connecting rods 73, multiple adjusting screws 74, and a first fixing screw. Multiple connecting rods 73 are fixedly connected between the adjusting upper plate 71 and the second base plate 72. These connecting rods 73 are arranged vertically to maintain a fixed distance between the adjusting upper plate 71 and the second base plate 72, forming a stable frame structure. For example, there can be five connecting rods 73, distributed at the corners of the adjusting upper plate 71 and the second base plate 72 to ensure the frame's anti-overturning capability and structural rigidity. The second base plate 72 is connected to the mounting base surface (e.g., a production line workbench) and serves as the installation reference for the entire height adjustment assembly 7.

[0067] Multiple adjusting screws 74 are threaded to the adjusting upper plate 71 via external threads, and each adjusting screw 74 is threaded to its corresponding first fixing screw via internal threads. Specifically, the adjusting upper plate 71 has threaded through holes corresponding to the number of adjusting screws 74, and the external threaded section of the adjusting screw 74 is screwed into the threaded through hole; the adjusting screw 74 has an internal threaded hole along the axial direction inside, and the external threaded section of the first fixing screw is screwed into the internal threaded hole. The end of each first fixing screw away from the mounting base is threaded to the first base plate 13, for example, the first base plate 13 has a corresponding threaded hole, and the upper end of the first fixing screw is screwed into the threaded hole.

[0068] The height adjustment process is as follows: rotate the adjusting screw 74 to adjust its upward extension length relative to the adjusting upper plate 71; after the extension length reaches the standard, screw the first fixing screw into the internal thread hole of the adjusting screw 74 from bottom to top; continue to rotate the first fixing screw so that its upper end (the end away from the mounting base) is screwed into the first base plate 13 and tightened.

[0069] The number of adjusting screws 74 is preferably multiple, for example, three adjusting screws 74 can be used. By turning multiple adjusting screws 74, the vertical distance between the upper adjusting plate 71 and the first base plate 13 is changed using the thread transmission principle, thereby driving the first base plate 13, which is fixedly connected to the front lower assembly 14, and the entire housing 1 above it to rise and fall relative to the mounting base surface, realizing the coarse adjustment of the overall height of the equipment. The pitch of the adjusting screws 74 can be designed to be relatively fine (e.g., 1mm to 2mm) to improve the accuracy of height adjustment.

[0070] With the height adjustment component 7 described above, the testing equipment in this embodiment can quickly adapt to the height differences between different models of production equipment or different workstations without changing the mounting bracket, thus achieving precise on-site adjustment and rapid deployment.

[0071] The second base plate 72 has a first adjustment hole 75 for adjusting the relative position of the second base plate 72 and the mounting base surface. In this embodiment, the first adjustment hole 75 is an oblong or oval hole, with its major axis arranged horizontally and its minor axis matching the diameter of the fastening bolts used to fix the second base plate 72 to the mounting base surface. The first adjustment hole 75 corresponds to the reserved mounting hole on the mounting base surface.

[0072] As a specific installation method, fastening bolts (such as anchor bolts or expansion bolts) pass through the first adjustment hole 75 to fix the second base plate 72 to the mounting base surface. Before tightening the fastening bolts, the operator can push the second base plate 72 along the long axis of the first adjustment hole 75, causing the second base plate 72 to shift horizontally relative to the mounting base surface, thereby adjusting the installation position of the entire testing equipment in the horizontal plane. After the second base plate 72 is adjusted to the target position, the fastening bolts are tightened, and the friction between the bolt head or washer and the second base plate 72 is used to lock the second base plate 72 to the mounting base surface, completing the horizontal fixation.

[0073] In other embodiments, the major axis of the first adjusting hole 75 can be designed to be arranged along different directions of the second base plate 72. For example, some of the major axes of the first adjusting holes 75 are arranged along the front-back direction (corresponding to the guide needle conveying direction) to adjust the docking gap between the testing equipment and the upstream conveying mechanism; other major axes of the first adjusting holes 75 are arranged along the left-right direction to adjust the lateral centering position of the testing equipment. By coordinating the multi-directional first adjusting holes 75, independent position adjustment of the testing equipment in two orthogonal directions in the horizontal plane can be achieved, improving the flexibility of on-site adaptation.

[0074] In addition, to facilitate observation of displacement during adjustment, the second base plate 72 can also be equipped with scale markings or reference lines, with the scale markings arranged along the long axis of the first adjustment hole 75. Operators can refer to the scale markings for quantitative adjustment, avoiding repeated adjustments caused by relying solely on visual estimation, thereby shortening on-site deployment time and improving installation efficiency.

[0075] By opening the first adjustment hole 75, the height adjustment component 7 of this embodiment not only achieves vertical height adjustment, but also has the ability to fine-tune the horizontal position, enabling the detection equipment to simultaneously compensate for height deviation and horizontal installation deviation between different production equipment, significantly improving the equipment's adaptability to on-site working conditions and ease of deployment.

[0076] like Figure 1 , Figure 2 and Figure 3 As shown, the housing 1 also includes a top plate 16, a back plate 17, and two second side plates 18. The back plate 17 is arranged parallel to the mounting plate 11, and the bottom of the back plate 17 near the mounting base is fixedly connected to the first base plate 13. The two second side plates 18 are respectively fixedly connected between the back plate 17 and the mounting plate 11. The top plate 16 is fixedly connected to the upper ends of the back plate 17, the mounting plate 11, the first side plate 12, and the second side plates 18, thereby forming a relatively closed detection cavity to reduce interference from external ambient light and dust pollution.

[0077] For each side camera 3, a corresponding reflector 32 is provided inside the housing 1. To achieve precise adjustment of the angle of the reflector 32, each reflector 32 is fixedly connected to a rotating shaft. In this embodiment, the reflector 32 is fixedly connected to the rotating shaft, and one end of the rotating shaft is fixed to the reflector 32 by screws or welding, thereby forming a rigid connection between the rotating shaft and the reflector 32 to rotate synchronously.

[0078] The rotating shaft is rotatably connected to the mounting plate 11. As a specific connection method, a bearing seat or bushing is fixedly mounted on the mounting plate 11, and the rotating shaft is supported within this bearing seat or bushing by rolling or sliding bearings to reduce rotational friction resistance and improve the smoothness and accuracy of angle adjustment. The axis of the rotating shaft is approximately horizontally arranged and is adapted to the relative positions of the imaging optical axis of the corresponding side camera 3 and the detection station, so that when the rotating shaft drives the reflector 32 to pitch within a certain angle range, it can effectively reflect the light from the side of the guide pin tip to the side camera 3.

[0079] A rotating block 8 is fixedly connected to the end of the rotating shaft away from the reflector 32. The rotating block 8 is located in the space formed between the mounting plate 11 and the back plate 17. In this embodiment, the rotating block 8 is a fan-shaped plate or a circular plate, which is fixed to the rotating shaft by a key connection, pin connection, or integral molding to ensure that the rotating block 8 rotates synchronously with the rotating shaft. A second adjustment hole 81 is provided on the rotating block 8. The second adjustment hole 81 is preferably an arc-shaped waist-shaped hole, which extends in an arc shape with the central axis of the rotating shaft as the center. A second fixing screw is inserted into the second adjustment hole 81, and the second fixing screw passes through the second adjustment hole 81 and is threadedly connected to the mounting plate 11. Specifically, a threaded hole or a nut is provided at a corresponding position on the mounting plate 11. The threaded section of the second fixing screw is screwed into the threaded hole, and its nut end or washer end presses against the surface of the rotating block 8 facing away from the mounting plate 11.

[0080] The central angle corresponding to the arc length of the second adjustment hole 81 defines the pitch adjustment range of the reflector 32. For example, the central angle can be 15° to 60°. This angle range is sufficient to cover the optical path offset caused by installation deviation between different production equipment, so that the reflected optical path is most favorable for the side camera 3 to acquire images.

[0081] In the actual adjustment process, the operator first loosens the second fixing screw, releasing the clamping force on the rotating block 8 at its nut end; then, the rotating block 8 is manually rotated, causing the reflector 32 to pitch around the axis of rotation via the rotating shaft; during the adjustment process, the real-time image feedback from the side camera 3 can be observed to determine whether the reflected light path is at the optimal imaging angle; once the angle of the reflector 32 is adjusted to the correct position, the second fixing screw is tightened, causing the nut end of the second fixing screw (with the washer) to press the rotating block 8 firmly against the surface of the mounting plate 11, using friction to lock the rotating block 8 and the rotating shaft, thereby reliably fixing the angle of the reflector 32. This adjustment method is manual, with a simple structure, intuitive operation, and no need for additional driving power, facilitating rapid on-site deployment and maintenance.

[0082] Since each of the two side cameras 3 has its own independent rotating shaft, rotating block 8 and second fixing screw for its corresponding reflector 32, the angles of the two reflectors 32 can be adjusted independently without interfering with each other. This allows them to compensate for the differences in the optical path caused by the asymmetry of the production equipment structure or the installation deviation on both sides, ensuring that all three cameras can obtain clear and complete images of the guide needle.

[0083] like Figure 3As shown, the mounting plate 11 also has a third adjustment hole 9 extending vertically. A third fixing screw is inserted into the third adjustment hole 9 and is threadedly connected to the coaxial light source 21. In this embodiment, the third adjustment hole 9 can be a vertically arranged oblong hole or an elongated hole. Because the third adjustment hole 9 has a relatively long extension length in the vertical direction, the third fixing screw can slide vertically within the third adjustment hole 9, thereby driving the coaxial light source 21 to move up and down relative to the mounting plate 11.

[0084] During the actual adjustment process, the operator first loosens the third fixing screw passing through the third adjustment hole 9 to release the clamping force between the coaxial light source 21 and the mounting plate 11; then, the operator pushes the coaxial light source 21 vertically, allowing it to slide up and down within the guide range of the third adjustment hole 9 to the target height position; finally, the operator retightens the third fixing screw to press and fix the coaxial light source 21 onto the mounting plate 11, thus locking the vertical position of the coaxial light source 21. By adjusting the vertical position of the coaxial light source 21, it is possible to accommodate capacitor guide pins of different lengths or different positioning heights, changing the illumination distance between the light-emitting surface of the coaxial light source 21 and the area to be detected by the guide pin, thereby obtaining a more uniform and suitable illumination effect, resulting in better brightness and contrast in the overall image captured by the main camera 2.

[0085] The number of third adjustment holes 9 can be multiple, for example, two. The two third adjustment holes 9 are arranged horizontally at intervals on the mounting plate 11. The light source bracket of the coaxial light source 21 is connected to the mounting plate 11 through two sets of third fixing screws passing through the corresponding third adjustment holes 9. The arrangement of multiple holes can restrict the rotational freedom of the coaxial light source 21 during the adjustment process, so that it can only translate in the vertical direction, avoiding the optical axis offset caused by the rotation of the coaxial light source 21 around a single point, and ensuring that the illumination direction always maintains a coaxial or approximately coaxial relationship with the imaging optical axis of the main camera 2.

[0086] The terms “comprising,” “including,” or any other variations thereof are intended to cover non-exclusive inclusion, such that a process, method, article, or apparatus that comprises a list of elements includes not only those elements but also other elements not expressly listed, or elements inherent to such process, method, article, or apparatus.

[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 at least one of that feature. In the description of this application, "multiple" means at least two, such as two, three, etc., unless otherwise explicitly specified.

[0088] In the description of this specification, the references to terms such as "one embodiment," "some embodiments," "example," "specific example," or "some examples," etc., refer to specific features, structures, materials, or characteristics described in connection with that embodiment or example, which are included in at least one embodiment or example of this application. In this specification, the illustrative expressions of the above terms do not necessarily refer to the same embodiment or example. Furthermore, the specific features, structures, materials, or characteristics described may be combined in any suitable manner in one or more embodiments or examples. Moreover, without contradiction, those skilled in the art can combine and integrate the different embodiments or examples described in this specification, as well as the features of different embodiments or examples.

[0089] Although embodiments of this application have been shown and described above, it is understood that the above embodiments are exemplary and should not be construed as limiting this application. Those skilled in the art can make changes, modifications, substitutions and variations to the above embodiments within the scope of this application.

Claims

1. A capacitor lead detection apparatus, characterized by, The device includes a housing (1), a main camera (2) for capturing a global image of a capacitor guide pin, and two side cameras (3) for capturing images of the end sides of the capacitor guide pin. The housing (1) has a detection hole (4) connected to a detection station for the capacitor guide pin. A mounting plate (11) is fixedly installed inside the housing (1). The main camera (2) and the two side cameras (3) are respectively mounted on the mounting plate (11), with the two side cameras (3) positioned on the side of the main camera (2). A coaxial light source (21) corresponding to the main camera (2) is mounted on the mounting plate (11). Two strip light sources (31) are installed inside the housing (1). For each side camera (3), a reflector (32) is provided to reflect light onto that side camera (3). The main camera (2) and the two side cameras (3) are arranged vertically downwards and located above the detection station. The strip light source (31) and the reflector (32) are respectively located below the detection station; the housing (1) is also provided with a protective structure that physically isolates the detection station from the optical elements. The protective structure includes a first transparent protective plate (5) located below the detection station and above the strip light source (31) and the reflector (32), and a second transparent protective plate (6) located above the detection station and below the main camera (2) and the two side cameras (3); the detection device also includes a detection sensor, which outputs a positioning signal when the capacitor guide needle is sensed to be in position, so as to trigger the main camera (2) and the two side cameras (3) to synchronously acquire images; the metal processing surface inside the housing (1) corresponding to the space where the guide needle is located includes a diffuse reflection layer treated by sandblasting or shot peening, and the surface roughness Ra value of the metal corresponding to the diffuse reflection layer ranges from 0.8μm to 3.2μm.

2. The capacitor lead inspection apparatus of claim 1, wherein The housing (1) also includes a first base plate (13), and a bottom backlight (131) is installed on the surface of the first base plate (13) facing the detection station.

3. The capacitor lead inspection apparatus of claim 2, wherein The housing (1) also includes a front lower assembly (14) located below the detection station. A sensor bracket is fixed to the inner side wall of the front lower assembly (14) near the mounting plate (11), and the detection sensor is mounted on the sensor bracket.

4. The capacitor lead inspection apparatus of claim 3, wherein The upper surface of the front lower component (14) away from the mounting base is fixedly connected to the first transparent protective plate (5) between the mounting plate (11) and the first transparent protective plate (5) is located above the strip light source (31), the reflector (32) and the bottom backlight (131).

5. The capacitor lead inspection apparatus of claim 4, wherein The first transparent protective plate (5) is a first float glass plate.

6. The capacitor lead inspection apparatus of claim 2, wherein The housing (1) also includes a front upper component (15) located above the testing station. The lower surface of the front upper component (15) near the mounting base is fixedly connected to the second transparent protective plate (6) between the mounting plate (11) and the second transparent protective plate (6) is horizontally arranged.

7. The capacitor lead inspection apparatus of claim 6, wherein The second transparent protective plate (6) is a second float glass plate.

8. The capacitor lead inspection apparatus of claim 4, wherein The first base plate (13) is fixedly connected to the lower surface of the front lower assembly (14) near the mounting base. A height adjustment assembly (7) is connected below the first base plate (13). The height adjustment assembly (7) includes an adjustment upper plate (71), a second base plate (72), multiple connecting rods (73), multiple adjusting screws (74), and a first fixing screw. Multiple connecting rods (73) are fixedly connected between the adjustment upper plate (71) and the second base plate (72). The second base plate (72) is connected to the mounting base. Multiple adjusting screws (74) are threaded to the adjustment upper plate (71) through external threads. Multiple adjusting screws (74) are threaded to their respective first fixing screws through internal threads. The end of each first fixing screw away from the mounting base is threaded to the first base plate (13).

9. The capacitor lead inspection apparatus of claim 8, wherein The second base plate (72) is provided with a first adjustment hole (75) for adjusting the relative position of the second base plate (72) and the mounting base surface.

10. The capacitor lead inspection apparatus of claim 1, wherein Each of the reflectors (32) is fixedly connected to a rotating shaft, which is rotatably connected to the mounting plate (11). A rotating block (8) is fixedly connected to the end of the rotating shaft away from the reflector (32). A second adjustment hole (81) is provided on the rotating block (8). A second fixing screw is inserted into the second adjustment hole (81). The second fixing screw passes through the second adjustment hole (81) and is threadedly connected to the mounting plate (11).

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