A product surface micro-defect detection device

Abstract

The utility model discloses a product surface tiny defect detection device, include: the profiling tool, the hollow setting of profiling tool is used for placing the profiling groove of workpiece, linear feeding mechanism, the profiling tool sets up in linear feeding mechanism, to receive the drive of moving between the feeding station and detection station, gathers camera, sets up in detection station, the image of the detection surface of workpiece is gathered in the profiling tool's top, scan identification module for scanning and identifying readable link information on workpiece. The automatic drive of profiling tool cooperation linear feeding mechanism and rotating mechanism can execute the automatic detection work of surface defect after workpiece feeding, and the efficiency, stability and precision of comparing artificial detection greatly promote.

Description

Technical Field

[0001] This utility model belongs to the field of visual inspection technology and relates to a device for detecting minute defects on the surface of products. Background Technology

[0002] The manufacturing process of oil coolers for automotive engines, transmissions, new energy vehicle batteries, and electric drive cooling systems mainly includes stamping, cleaning, riveting, assembly, welding, marking, airtightness testing, and dimensional inspection. Airtightness testing, mounting hole position checks, and flatness checks of sealing surfaces, among other dimensional inspections, are now automated using single-machine or integrated testing lines, ensuring product quality. However, defects such as scratches that occur during production and transit are often missed. This is because the surface texture and gloss of the sealing surfaces are inconsistent, and some products may have localized shallow liquid stains or other complex conditions. Furthermore, uneven lighting and localized specular reflections on the product surface under illumination make detection difficult. If these scratches are located in the sealing area, they will worsen the sealing effect, thus affecting the product's cooling performance. Currently, there are no automated testing devices or methods available, and major manufacturers still rely on manual visual inspection to control product quality.

[0003] However, this method has obvious shortcomings, mainly:

[0004] (1) Low testing efficiency. When processing large batches of products, the testing time for testing personnel is relatively fixed, making it difficult to significantly improve efficiency.

[0005] (2) Poor testing stability. Different people may have different judgments about the same product, which relies heavily on the experience of the workers. When the continuous testing time is too long, visual fatigue and low mood may occur. At this time, the product testing is affected by the subjective emotions of the people, and the objectivity of the test results cannot be guaranteed, thus leading to reduced stability.

[0006] (3) Low detection accuracy. Due to the limitations of the human eye's physical conditions, especially under certain special circumstances (such as strong reflection), some short and shallow defects on the product inspection surface may not be detected under continuous visual observation, which can easily lead to fatigue detection and reduced accuracy. Utility Model Content

[0007] In order to overcome the shortcomings of the prior art, this utility model provides a device for detecting minute defects on the surface of products.

[0008] To achieve the above objectives, the present invention adopts the following technical solution:

[0009] A device for detecting minute defects on the surface of a product, comprising:

[0010] The copying fixture has a hollow interior with a copying groove for placing the workpiece.

[0011] A linear feeding mechanism, wherein the copying tooling is disposed on the linear feeding mechanism and is driven to move between the loading / unloading station and the inspection station;

[0012] A camera is set at the inspection station to capture images of the inspection surface of the workpiece above the profiling fixture;

[0013] The barcode scanning and recognition module is used to scan and recognize readable link information on the workpiece.

[0014] Furthermore, it also includes a rotating mechanism, which includes an outer ring base, an inner ring rotating platform, and a rotating motor. The outer ring base is connected to the linear feeding mechanism, and the inner ring rotating platform is connected to the copying tooling and driven by the rotation of the rotating motor. The inner ring rotating platform has a hollow structure that communicates with the copying groove.

[0015] Furthermore, it also includes a frame, on which a horizontal plate is provided, the linear feeding mechanism is provided on the horizontal plate, the barcode scanning and identification module is provided below the horizontal plate, and a viewing window is provided through the horizontal plate.

[0016] Furthermore, the linear feeding mechanism includes a feeding cylinder and feeding guide rails respectively disposed on opposite sides of the viewing window, and the rotating mechanism is connected to the feeding guide rails and driven to move by the feeding cylinder.

[0017] Furthermore, the contouring fixture includes a bottom fixture and a top fixture, the top fixture and the bottom fixture forming a detachable connection, and the contouring groove is disposed on the top fixture.

[0018] Furthermore, it also includes a through-beam photoelectric sensor, which is set at the loading and unloading station and forms through-beam light. The copying fixture has a slot along the radial direction for the through-beam light to pass through, and the slot is connected to the copying groove.

[0019] Furthermore, gratings that form opposing beams are respectively provided on both sides of the loading and unloading station.

[0020] Furthermore, it also includes a light source, which includes a first aperture and a second aperture. The first aperture and the second aperture are arranged sequentially from top to bottom above the profiling fixture. The first aperture and the second aperture are coaxial. The diameter of the first aperture is smaller than the diameter of the second aperture. LED beads are evenly distributed on the inner circumference of the first aperture and the inner circumference of the second aperture, respectively. The light emission angle of the LED beads is 0°.

[0021] Furthermore, it also includes an NG marking module, which includes a stamp and a Z-axis cylinder for driving the movement of the stamp.

[0022] Furthermore, it also includes a display module, which includes a touch screen.

[0023] In summary, the advantages of this utility model are as follows:

[0024] The automatic drive of the contouring tooling, combined with the linear feeding mechanism and the rotary mechanism, enables automatic detection of surface defects after the workpiece is loaded, which greatly improves the efficiency, stability and accuracy compared with manual inspection.

[0025] It features a low-angle, two-layer lighting scheme, which effectively avoids uneven lighting and localized specular reflection on the product surface, making scratches and other appearance defects more prominent and easier to identify.

[0026] Equipped with automatic barcode scanning, after the product is placed on the fixture and the start button is pressed, the product reaches the inspection position, and the barcode scanner set at the inspection station can effectively sense and identify the QR code.

[0027] The detection image data is linked to the product's QR code information, which can be queried through a database or by scanning the code to trace quality issues.

[0028] It has the function of automatically marking the product inspection surface with a stamp indicating that the inspection result is unqualified.

[0029] The detachable top and bottom fixtures make the device highly compatible. Within the field of view, products of different sizes and shapes can be tested simply by changing the matching top fixture and switching the product formula. Attached Figure Description

[0030] Figure 1 This is a schematic diagram of the product surface micro-defect detection device of this utility model.

[0031] Figure 2 for Figure 1 A structural diagram from the bottom middle view.

[0032] Figure 3 for Figure 1 A schematic diagram of the structure above the horizontal plate.

[0033] Figure 4 for Figure 3 The top view in the image.

[0034] Figure 5 for Figure 3 A structural diagram from another perspective.

[0035] Figure 6This is an exploded structural diagram of the rotating mechanism and the copying tooling.

[0036] Figure 7 This is a schematic diagram of the light source structure.

[0037] The diagram shows the following components: 11. Horizontal plate; 12. Window; 13. Feeding guide rail; 14. Electrical control board box; 15. Industrial computer; 16. Touch screen display; 2. Detection surface; 21. Rotating mechanism; 211. Rotary motor; 22. Bottom fixture; 221. Screw hole; 23. Top fixture; 231. Pattern groove; 232. Slot; 233. Gap; 234. Support; 3. Photoelectric sensor; 31. Grating; 4. Light source; 41. Acquisition camera; 42. First aperture; 43. Second aperture; 51. Barcode scanner; 52. NG marking module. Detailed Implementation

[0038] The following specific examples illustrate the implementation of this utility model. Those skilled in the art can easily understand other advantages and effects of this utility model from the content disclosed in this specification. This utility model can also be implemented or applied through other different specific embodiments, and various details in this specification can also be modified or changed based on different viewpoints and applications without departing from the spirit of this utility model. It should be noted that, unless otherwise specified, the following embodiments and features described therein can be combined with each other.

[0039] It should be noted that the illustrations provided in the following embodiments are only schematic representations of the basic concept of the present invention. Therefore, the drawings only show the components related to the present invention and are not drawn according to the number, shape and size of the components in actual implementation. In actual implementation, the form, quantity and proportion of each component can be arbitrarily changed, and the layout of the components may also be more complex.

[0040] In this embodiment of the invention, all directional indicators (such as up, down, left, right, front, back, horizontal, vertical, etc.) are only used to explain the relative positional relationship and movement of each component in a specific posture. If the specific posture changes, the directional indicator will also change accordingly.

[0041] Due to installation errors and other reasons, the parallel relationship referred to in the embodiments of this utility model may actually be an approximate parallel relationship, and the perpendicular relationship may actually be an approximate perpendicular relationship.

[0042] This utility model provides a device for detecting minute defects on the surface of a product, including a frame, a contouring fixture, a linear feeding mechanism, a rotating mechanism 21, a vision inspection module, a barcode scanning and recognition module, an NG marking module 52, a display module, an industrial computer 15, and an electrical control system.

[0043] Reference Figure 1 and Figure 2 The frame includes a square frame structure composed of multiple crossbeams and columns. An electrical control board box 14 and an industrial computer 15 are located at the bottom of the frame. A horizontal plate 11 is fixedly installed in the middle of the frame for mounting a contouring fixture, a linear feeding mechanism, and a rotating mechanism 21. The linear feeding mechanism includes a feeding guide rail 13 and a feeding cylinder. A window 12 is provided on the horizontal plate 11, with a set of feeding guide rails 13 mounted on opposite sides of the window 12. The bottom of the rotating mechanism 21 is slidably connected to the feeding guide rails 13 on both sides. The feeding cylinder is connected to the rotating mechanism 21 to drive it to move along the feeding guide rails 13. The contouring fixture is mounted on the rotating mechanism 21. The rotating mechanism 21 includes... The system comprises an outer ring base, an inner ring rotating platform, and a rotary motor 211. The inner ring rotating platform and the outer ring base form a coaxial hollow structure. The outer ring base is connected to the feeding guide rail 13. The rotary motor 211 is mounted on the outer ring base and drives the rotation of the inner ring rotating platform through a gearbox. The copying fixture is connected to the inner ring rotating platform, allowing it to rotate under drive. The linear movement of the copying fixture can be achieved by driving the rotating mechanism 21 through a feeding cylinder. The two ends in the linear direction form a loading / unloading station and a detection station. The copying fixture moves to the loading / unloading station to set up the workpiece loading / unloading. The copying fixture carries the workpiece to the detection station for the workpiece detection process.

[0044] Specifically, refer to Figure 6 The copying fixture includes a bottom fixture 22 and a top fixture 23. Both the bottom fixture 22 and the top fixture 23 are hollow. Their hollow parts are connected to the hollow parts of the rotating platform. The hollow part of the top fixture 23 is set as a copying groove 231 for setting the workpiece. The copying groove 231 is provided with a support part 234 for supporting the edge of the workpiece, and also with a gap part 233 for facilitating the removal of the workpiece. In some embodiments, the workpiece can also form an interference fit with the inner circumference of the copying groove 231 to achieve a snap-fit.

[0045] The top fixture 23 and the bottom fixture 22 are provided with connecting screw holes 221. The top fixture 23 and the bottom fixture 22 are detachably connected and fixed by inserting long screws. The contour groove 231 of the top fixture 23 is set to adapt to the set model of workpiece. When it is necessary to change to other models of workpiece for inspection, the detachable connection allows for quick switching of adaptation by simply replacing the top fixture 23.

[0046] Furthermore, refer to Figures 3 to 5The top fixture 23 has slots 232 on its radially opposite sides. The slots 232 are radially through and connected to the hollow part of the top fixture 23. A set of through-beam photoelectric sensors 3 are set at the loading and unloading station. The photoelectric sensors 3 are mounted on the frame and through-beam photoelectric sensors 3 form through-beam light. When the copying fixture is at the loading and unloading station, the rotating mechanism 21 rotates the copying fixture to the initial angle position. At this time, the slots 232 are located on the path of the through-beam light. When no workpiece is placed, the through-beam light can pass through the slots 232 on both sides to form effective through-beam light. When a workpiece is placed on the top fixture 23, the workpiece will block the through-beam light.

[0047] The presence or absence of material feeding is automatically detected by the photoelectric sensor 3, which detects whether the transmitted light is blocked. The signal line of the photoelectric sensor 3 is electrically connected to the I / O port interface of the electronic control system. The electronic control system monitors this interface in real time. When the copying fixture is at the loading / unloading station, the transmitted light is blocked, and the signal of the photoelectric sensor 3 changes from low to high or from high to low (in this embodiment, the electronic control system preferably captures the signal changing from low to high), the electronic control system starts the current overall inspection process after setting a delay time, and starts the linear feeding mechanism to send the copying fixture from the loading / unloading station to the inspection station for defect detection. After the inspection is completed, when the copying fixture returns from the inspection station to the loading / unloading station, it will block the transmitted light again, and the photoelectric sensor 3 will generate a sensing signal again. At this time, the electronic control system ignores the sensing signal of the photoelectric sensor 3 because the current overall inspection process has not ended. During the process of retracting the loading and unloading station, the copying fixture will be rotated back to its initial angle position. When the inspection result in the current overall inspection process is OK, the copying fixture rotates back to its initial angle position. After it reaches its final position, a delay time is set, and the current overall inspection process ends. When the inspection result in the current overall inspection process is NG, the copying fixture rotates back to its initial angle position. After it reaches its final position, the NG marking module 52 is started to perform the marking process. After the marking is completed, a delay time is set, and the current overall inspection process ends.

[0048] After the current overall inspection process is completed, the workpiece can be unloaded and removed. At this time, the beam of light re-penetrates through the slot 232 to reset the photoelectric sensor 3, so as to monitor the next loading of the workpiece onto the copying fixture.

[0049] Furthermore, a set of gratings 31 are installed on both sides of the loading and unloading station. The gratings 31 are fixedly installed on the profiles on both sides of the frame to form a beam pattern, and their signal lines are electrically connected to the I / O port interface of the electrical control system. When the profiling fixture loads the material and the linear feeding mechanism begins to enter the inspection station, the electrical control system monitors this interface in real time until the linear feeding mechanism returns from the inspection station to the loading and unloading station and the current overall inspection process is completed. If any object blocks the beam pattern area of ​​the gratings 31 during this process, the electrical control system will be triggered to stop the equipment, thereby effectively preventing accidental hand placement and injury during the operation of each mechanism in the entire inspection process.

[0050] Furthermore, a magnetic switch can be installed at the inspection station. When the copying fixture moves to the inspection station, it will trigger the magnetic switch and generate a corresponding arrival signal.

[0051] The visual inspection module includes a camera 41 and a light source 4. The camera 41 is positioned above the inspection station and its position is fixed by a frame. Figure 3 and Figure 5 The camera 41 is positioned downwards to capture images of the upper surface of the workpiece on the copying fixture, thereby enabling defect detection on the workpiece surface based on the captured images. The light source 4 can be directly positioned above the copying fixture, and the light source 4 illuminates the copying fixture, which can highlight the defects on the workpiece surface, thus facilitating defect identification and detection in the images captured by the camera.

[0052] Preferred, refer to Figure 7 The light source 4 is set as a ring and is positioned between the acquisition camera 41 and the workpiece. The light source 4 includes a first aperture 42 and a second aperture 43. LED beads are evenly arranged in a ring around the inner circumference of both the first aperture 42 and the second aperture 43. The light generated by the first aperture 42 and the second aperture 43 will partially shine downwards onto the surface of the workpiece on the copying fixture, which can effectively highlight defects.

[0053] Preferably, the LED light bead has a light emission angle of 0°, that is, the light emission direction is parallel to the plane of the aperture ring, so that the generated light is the softest and will not shine too brightly on the workpiece surface, nor will it interfere with the shooting of the acquisition camera 41.

[0054] The first aperture 42 and the second aperture 43 are distributed vertically at a set height interval. Specifically, the first aperture 42 is higher than the second aperture 43. The second aperture 43 is 10mm above the contouring fixture, and the first aperture 42 is 20mm above the contouring fixture. The first aperture 42 and the second aperture 43 are coaxially arranged in a stacked manner. The diameter of the first aperture 42 is smaller than the diameter of the second aperture 43, so that the light from the second aperture 43 is within the light range of the first aperture 42, which strengthens the illumination of the central area and thus highlights the defect.

[0055] The LED beads are round-headed high-brightness LED beads, which emit blue light. The wavelength range of blue light is 440-490nm, which is shorter than the wavelength of green and red light. It has higher energy and can penetrate metal materials more easily and be absorbed, which can reduce the reflection of metal surfaces and make the details of metal surfaces clearer.

[0056] The barcode scanning module includes a barcode scanner 51. In this embodiment, the workpiece includes a front and a back. The front is the inspection surface 2 that needs to be inspected for defects, while the back has a QR code that can be affixed for scanning by the barcode scanner 51. The QR code serves as the identification of the corresponding workpiece and stores various information about the workpiece, thus allowing for identification and differentiation via the barcode scanner 51. When the workpiece is placed on a copying fixture, its front is the upper surface and its back is the lower surface, as shown in the reference... Figure 2 The barcode scanner 51 is fixedly installed on the frame, located below the horizontal plate 11. The hollow setting of the copying fixture and the rotating platform, combined with the open setting of the window 12, ensures that there is no obstruction between the lower surface of the workpiece and the barcode scanner 51, allowing the barcode scanner 51 to directly scan and identify the information on the reverse side of the workpiece.

[0057] The NG marking module 52 is located above the loading and unloading station and is fixed to the frame. To prevent the NG marking module 52 from interfering with the visual field, a set of Z-axis cylinders (the Z-axis is vertical in this embodiment) is set up. A stamp is set at the end of the Z-axis cylinder. When a workpiece is detected as defective at the inspection station, the cylinder can move the stamp to the surface of the workpiece to imprint an NG mark, thereby serving as a reminder.

[0058] The display module includes a touch screen 16 for displaying image data, detection data, and user operations.

[0059] The industrial computer 15 is installed in the electrical control board box 14, and the electrical control board box 14 is fixed to the frame. The industrial computer 15 is connected to the linear feeding mechanism, the rotary mechanism 21, the vision inspection module, the barcode recognition module, the NG marking module 52, and the display module to transmit data. It is equipped with an electrical control system to realize the control of each mechanism module.

[0060] Obviously, the described embodiments are only some, not all, of the embodiments of this utility model. All other embodiments obtained by those skilled in the art based on the embodiments of this utility model without inventive effort should fall within the protection scope of this utility model.

Claims

1. A device for detecting minute defects on the surface of a product, characterized in that, include: The copying fixture has a hollow interior with a copying groove for placing the workpiece. A linear feeding mechanism, wherein the copying tooling is disposed on the linear feeding mechanism and is driven to move between the loading / unloading station and the inspection station; A camera is set at the inspection station to capture images of the inspection surface of the workpiece above the profiling fixture; The barcode scanning and recognition module is used to scan and recognize readable link information on the workpiece.

2. The device for detecting minute defects on the surface of a product according to claim 1, characterized in that, It also includes a rotating mechanism, which includes an outer ring base, an inner ring rotating platform, and a rotating motor. The outer ring base is connected to the linear feeding mechanism, and the inner ring rotating platform is connected to the copying tooling and driven by the rotation of the rotating motor. The inner ring rotating platform has a hollow structure that communicates with the copying groove.

3. The device for detecting minute defects on the surface of a product according to claim 2, characterized in that, It also includes a frame, on which a horizontal plate is provided, the linear feeding mechanism is provided on the horizontal plate, the barcode scanning and identification module is provided below the horizontal plate, and a viewing window is provided through the horizontal plate.

4. The device for detecting minute defects on the surface of a product according to claim 3, characterized in that, The linear feeding mechanism includes a feeding cylinder and feeding guide rails respectively disposed on opposite sides of the viewing window. The rotating mechanism is connected to the feeding guide rails and is driven to move by the feeding cylinder.

5. The device for detecting minute defects on the surface of a product according to claim 1, characterized in that, The copying fixture includes a bottom fixture and a top fixture, the top fixture and the bottom fixture are detachably connected, and the copying groove is disposed on the top fixture.

6. A device for detecting minute defects on the surface of a product according to claim 1 or 5, characterized in that, It also includes a through-beam photoelectric sensor, which is set at the loading and unloading station and forms through-beam light. The copying fixture has a slot along the radial direction for the through-beam light to pass through, and the slot is connected to the copying slot.

7. The device for detecting minute defects on the surface of a product according to claim 1, characterized in that, The loading and unloading stations are equipped with light gratings on both sides to form a photoelectric effect.

8. The device for detecting minute defects on the surface of a product according to claim 1, characterized in that, It also includes a light source, which includes a first aperture and a second aperture. The first aperture and the second aperture are arranged sequentially from top to bottom above the profiling tool. The first aperture and the second aperture are coaxial. The diameter of the first aperture is smaller than the diameter of the second aperture. LED beads are evenly distributed on the inner circumference of the first aperture and the inner circumference of the second aperture, respectively. The light emission angle of the LED beads is 0°.

9. A device for detecting minute defects on the surface of a product according to claim 1, characterized in that, It also includes an NG marking module, which includes a stamp and a Z-axis cylinder for driving the movement of the stamp.

10. A device for detecting minute defects on the surface of a product according to claim 1, characterized in that, It also includes a display module, which includes a touch screen.

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