A rapid visual inspection device for recognizing the shape features of precast composite slabs

Abstract

This utility model relates to a rapid visual inspection device for recognizing the shape features of precast composite slabs. The device comprises multiple functional modules, including an overall support structure for supporting the entire inspection setup, an industrial vision sensor array for acquiring image data of the precast composite slabs, a matrix illumination unit for auxiliary imaging, a laser rangefinder sensor array module for acquiring surface contour information, and a transmission actuator for enabling coordinated movement of multiple components. Furthermore, it is equipped with a control unit for centrally controlling the operating status of each module. This device integrates machine vision and laser inspection technologies, enabling efficient and stable rapid inspection and quality assessment of the shape features of precast composite slabs, significantly improving the automation and accuracy of the inspection process while reducing manual intervention and increasing inspection efficiency.

Description

Technical Field

[0001] This utility model relates to a visual rapid detection device for shape feature recognition, and more particularly to a visual rapid detection device for shape feature recognition of prefabricated composite slabs. Background Technology

[0002] Prefabricated construction, as an important means to achieve energy conservation, emission reduction, and improve building quality, is being rapidly promoted nationwide. Compared with traditional cast-in-place construction methods, prefabricated construction has advantages such as shorter construction period, controllable quality, high safety, and less environmental pollution. Against this backdrop, the production method of building components is gradually transitioning from on-site processing to factory prefabrication, driving the rapid development of the precast concrete component industry chain.

[0003] In prefabricated concrete building systems, precast composite slabs are among the most common precast components, primarily used as floor structures. These components consist of a bottom precast concrete slab and an upper layer of cast-in-place concrete, connected by reinforcing steel to form an integrated load-bearing system with excellent load-bearing capacity and construction adaptability. With the diversification of engineering needs and the increasing complexity of structural designs, precast composite slabs are gradually exhibiting characteristics such as larger dimensions, irregular structural shapes, and abundant embedded parts, placing higher demands on production quality and testing processes.

[0004] Because precast composite slabs need to be transported to the construction site for direct installation after prefabrication in the factory, their dimensions, edge integrity, and the location of embedded parts must be strictly controlled. Excessive deviations in the geometric dimensions of the components, or misalignments in the connectors, will lead to difficulties in on-site installation, affect the accuracy of component splicing, and may even cause structural hazards. Therefore, conducting comprehensive, efficient, and accurate shape inspection before the components leave the factory is a crucial step in ensuring the quality of prefabricated construction. Major inspection items include, but are not limited to: The length, width, thickness, and other dimensions of the component; The integrity and straightness of the edge contour; The accuracy of the location of exposed reinforcing bars, embedded parts, or openings; Defects such as surface flatness and warping.

[0005] Currently, the industry still widely uses manual inspection for the quality control of composite slabs before they leave the factory. Inspectors use tools such as tape measures, calipers, rulers, or laser rangefinders to measure and record the length, width, thickness, edge lines, angles, and exposed rebar positions of each component. This method relies on human experience and manual operation, which is not only inefficient and time-consuming, but also susceptible to subjective influence from the operator, resulting in poor repeatability and objectivity. Especially when facing large-scale, multi-batch, and highly customized production tasks, manual inspection is no longer sufficient. Furthermore, due to the large size of the components and the compact storage area, inspectors need to frequently climb up and down the components and bend over to measure, posing certain safety hazards.

[0006] With the development of intelligent manufacturing technology, non-contact automatic inspection of prefabricated components using technologies such as computer vision, laser measurement, and image processing has become an industry trend. For example, some companies have already begun to try mounting industrial cameras on fixed brackets to extract the edge contours of components and calculate their dimensions using image recognition algorithms. However, current systems of this type still have the following shortcomings in practical applications: 1) Most image acquisition units use a single-camera layout, which limits the field of view. The working distance needs to be increased to improve the field of view, which makes it difficult to meet the requirements for detection efficiency and accuracy. 2) The testing equipment is fixed in place and lacks the ability to move along tracks, which makes it impossible to achieve flexible testing at multiple workstations and limits its applicability in assembly line or multi-production line scenarios. 3) Most current systems are semi-automatic and still require manual intervention, making it impossible to achieve truly unmanned intelligent detection.

[0007] In summary, existing technologies cannot simultaneously achieve high precision, large-area coverage, fully automated control, and system stability, making it difficult to meet the actual quality control requirements of current intelligent manufacturing of precast composite slabs. Therefore, there is an urgent need to develop a visual inspection device for the shape characteristics of precast composite slabs that is compact in structure, highly integrated with inspection modules, and capable of adapting to the inspection needs of components of various specifications. This device should combine multi-row image acquisition, laser array measurement, lighting control, and track-based movement to achieve comprehensive and rapid inspection and data archiving of components, improving inspection efficiency and automation levels, and promoting the development of prefabricated building production lines towards intelligence and standardization. Utility Model Content

[0008] The purpose of this invention is to overcome the shortcomings of the prior art and provide a rapid visual inspection device for recognizing the shape features of prefabricated composite slabs by combining machine vision technology and laser detection technology, so as to realize rapid and accurate automated inspection of the shape features of prefabricated composite slabs.

[0009] This utility model provides a visual rapid detection device for recognizing the shape features of precast composite slabs. The device is equipped with an image data acquisition unit arranged in a multi-row array, and achieves higher coverage and resolution through the collaborative work of multiple rows of industrial vision sensors. A scanning array unit consisting of multiple rows of laser rangefinders arranged in a longitudinal and transverse pattern is provided to acquire surface contour information of the component. An illumination array consisting of multiple high-brightness, uniformly emitting linear illumination elements is used to form a planar light field to optimize the imaging effect; Each unit is integrated and installed on an integrated support structure composed of double transverse reinforcing beams, together forming a data acquisition module; The data acquisition module is supported by a set of dual-drive linear moving platforms. The drive units on both sides adopt a linkage structure and maintain motion consistency through end fixed connection components.

[0010] Furthermore, the multi-row industrial vision sensor array is arranged according to the size range of the component under test and the imaging field of view, and is installed on an integrated bracket structure composed of double transverse reinforcing beams.

[0011] Furthermore, the entire testing device is equipped with a movable bottom wheel assembly, which can move smoothly between different testing stations along a predetermined track.

[0012] Furthermore, the multi-row laser ranging sensors are arrayed according to the size of the component detection area and the point cloud acquisition accuracy requirements, and are fixed along the side of the integrated support structure.

[0013] Furthermore, multiple high-brightness, uniform linear lighting devices are arranged in a matrix according to the image acquisition area and are fixed to the horizontal support parts of the integrated bracket structure and the frame beams, respectively.

[0014] Furthermore, the integrated support structure is mounted on a dual-drive linear sliding platform, which is driven synchronously to move the data acquisition module smoothly along the acquisition path.

[0015] Furthermore, the entire testing device is powered by either a battery storage module or an external power supply.

[0016] On the other hand, this application also provides a method for recognizing the shape features of precast composite slabs. The recognition method is based on the aforementioned rapid visual detection device and includes the following steps: Step 1: System initialization. The control system sends control commands to drive the detection device to move to the preset detection position, while the dual-drive linear sliding platform unit resets to the detection starting point. Step Two: Upon reaching the detection position, the control system sends a start detection signal. The dual-drive linear sliding platform unit moves to the first detection position. The industrial vision sensor array, laser rangefinder array, and illumination array move together with the double transverse reinforced crossbeam integrated support structure unit. After moving to the designated position, the industrial camera group begins to acquire images and upload them to the control system. During the movement, the laser rangefinder array acquires point cloud data at set intervals. After acquisition, the system moves to the second detection position and repeats the above data acquisition process, resulting in multiple sets of image data. Step 3: Fuse multiple sets of image data and combine them with point cloud data analysis to obtain complete images and surface condition data of precast slab components; use machine vision technology and deep learning algorithms to measure the size and recognize features of the images to achieve rapid detection of component shape features; Step 4: Using the precast composite slab standard model database, compare the test results to determine whether the target under test meets the quality standards, generate a test report, and archive the test data. Step 5: After completing the detection of the precast composite slab to be tested at the current position, the control system sends a command to drive the detection system to move to the next detection position, while the dual-drive linear sliding platform unit returns to the detection origin.

[0017] Beneficial effects:

[0018] 1. The multi-row industrial vision sensor array is arranged according to the size range of the component under test and the imaging field of view, and is installed on an integrated bracket structure composed of double transverse reinforcing beams; 2. The multi-row laser ranging sensors are arrayed according to the size of the component detection area and the point cloud acquisition accuracy requirements, and are fixed along the side of the integrated bracket structure; 3. Multiple high-brightness, uniform linear lighting devices are arranged in a matrix according to the image acquisition area and are fixed to the horizontal support parts of the integrated bracket structure and the frame beams respectively; 4. The integrated support structure is mounted on a dual-drive linear sliding platform, which is driven synchronously to move the data acquisition module smoothly along the acquisition path. 5. The entire testing device supports either a battery storage module or an external power supply. Attached Figure Description

[0019] To more clearly illustrate the technical solutions in the embodiments of this utility model or the prior art, the drawings used in the description of the embodiments or the prior art will be briefly introduced below. Obviously, the drawings described below are some embodiments of this utility model. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0020] Figure 1 A schematic diagram of a visual rapid detection device for recognizing the shape features of prefabricated composite slabs according to an embodiment of the present invention is shown. Figure 2 A schematic diagram of a multi-row industrial vision sensor array and a multi-row laser ranging sensor array structure is shown in a visual rapid detection device for recognizing the shape features of prefabricated composite slabs. Figure 3 A schematic diagram of the workflow of a visual rapid detection device for recognizing the shape features of prefabricated composite slabs is shown. Figure 1Name of the winning designation: 101—Multi-row laser ranging sensor array unit; 102—Overall support structure unit of the device; 103—Prefabricated composite plate to be tested; 104—Dual-drive linear sliding platform unit; 105—Multi-row industrial vision sensor array unit; 106—High-brightness uniform matrix illumination unit; 107—Double transverse reinforced crossbeam integrated support structure unit. Detailed Implementation

[0021] To enable those skilled in the art to better understand the present invention, the technical solutions of the present invention 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 invention, and not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort should fall within the protection scope of the present invention.

[0022] Figure 1 A schematic diagram of a rapid visual detection device for recognizing the shape features of prefabricated composite slabs according to an embodiment of the present invention is shown.

[0023] Figure 2 The diagram shows a multi-row industrial vision sensor array and a multi-row laser ranging sensor array for a rapid visual inspection device for recognizing the shape features of prefabricated composite slabs.

[0024] Figure 3 A schematic diagram of the workflow of a visual rapid detection device for recognizing the shape features of prefabricated composite slabs is shown.

[0025] Example 1:

[0026] like Figure 1 As shown, the visual rapid detection device for recognizing the shape features of precast composite slabs of this utility model includes: The multi-row laser ranging sensor array unit 101 is fixed on the double transverse reinforcing beam integrated bracket structure unit 108, and is composed of several rows of laser ranging sensors. The specific distribution of the sensors is determined by the size of the prefabricated composite plate to be tested and the testing requirements. The overall support structure unit 102 of the device includes several support components such as diagonal reinforcing ribs for enhancing structural strength, and a track wheel assembly is provided at the bottom. The track wheel can be driven under the control of the control system to realize the flexible movement and positioning of the device body. The prefabricated composite slab 103 to be tested serves as the detection target for industrial vision sensors to collect image data. The dual-drive linear sliding platform unit 104 is connected to the dual transverse reinforcing beam integrated support structure unit 108, and is composed of a dual-drive synchronous belt module, which drives the data acquisition module to move as a whole. The multi-row industrial vision sensor array unit 105 is fixed on the double transverse reinforcing beam integrated bracket structure unit 108 and consists of several industrial vision sensors. The number of sensors is determined by the specifications and sampling range of the prefabricated composite plate to be tested. The high-brightness uniform matrix illumination unit 106 is composed of several rows of highly uniform strip light sources. It is arranged in a matrix according to the sampling field of view to form a planar light field to optimize the imaging effect and ensure the image acquisition quality. The double transverse reinforced crossbeam integrated support structure unit 107 consists of two long crossbars and several crossbeams.

[0027] Example 2:

[0028] like Figure 1 , Figure 2 , Figure 3 As shown, specifically, this embodiment provides a visual rapid detection device for recognizing the shape features of prefabricated composite slabs. It proposes using an industrial vision sensor array, a laser rangefinder sensor array, and a matrix illumination unit to rapidly identify and detect the shape features of prefabricated composite slabs of different specifications. The main steps include: Step 1: System initialization. The control system sends control commands to drive the detection system to move to the preset detection position, while the dual-drive linear sliding platform unit 104 is reset to the detection starting point.

[0029] Step 2: Upon reaching the detection position, the control system sends a start detection signal. The dual-drive linear sliding platform unit 104 moves to detection position #1. The industrial vision sensor array unit 105, the laser rangefinder array unit 101, and the high-brightness uniform matrix illumination unit 106 move together with the double transverse reinforced crossbeam integrated support structure unit 107. After moving to the designated position, the industrial camera group begins to acquire images and uploads them to the host computer via gigabit network. During the movement, the laser rangefinder array acquires point cloud data at regular intervals. After the acquisition is completed, the system moves to detection position #2 and repeats the above data acquisition process.

[0030] Step 3: Fuse multiple sets of image data and combine them with point cloud data analysis to obtain complete images and surface condition data of precast slab components; use machine vision technology and deep learning algorithms to measure the size and recognize features of the images to achieve rapid detection of component shape features; Step 4: Using the precast composite slab standard model database, compare the test results to determine whether the target under test meets the quality standards, generate a test report, and archive the test data.

[0031] Step 5: After completing the detection of the precast composite slab to be tested at the current position, the control system sends a command to drive the detection system to move to the next detection position, while the dual-drive linear sliding platform unit 104 returns to the detection origin.

[0032] The technical solution of this utility model has been described in detail above with reference to the accompanying drawings. This patent proposes a visual rapid detection device that combines machine vision technology and laser detection technology to identify the shape features of precast composite slabs. This device realizes automated detection of precast slab components, which can effectively improve the accuracy of detection, reduce production costs, and improve product quality.

[0033] Regarding the limitation on the scope of protection of this utility model, those skilled in the art should understand that various modifications or variations that can be made by those skilled in the art without creative effort based on the technical solution of this utility model are still within the scope of protection of this utility model.

Claims

1. A rapid visual detection device for recognizing the shape features of precast composite slabs, characterized in that: It features an image data acquisition unit arranged in a multi-row array, which works in collaboration with multiple rows of industrial vision sensors to achieve higher coverage and resolution; A scanning array unit consisting of multiple rows of laser rangefinders arranged in a longitudinal and transverse pattern is provided to acquire surface contour information of the component. An illumination array consisting of multiple high-brightness, uniformly emitting linear illumination elements is used to form a planar light field to optimize the imaging effect; Each unit is integrated and installed on an integrated support structure composed of double transverse reinforcing beams, together forming a data acquisition module; The data acquisition module is supported by a set of dual-drive linear moving platforms. The drive units on both sides adopt a linkage structure and maintain motion consistency through end fixed connection components.

2. The visual rapid detection device for recognizing the shape features of prefabricated composite slabs according to claim 1, characterized in that: The multi-row industrial vision sensor array is arranged according to the size range of the component under test and the imaging field of view, and is installed on an integrated bracket structure composed of double transverse reinforcing beams.

3. The visual rapid detection device for recognizing the shape features of prefabricated composite slabs according to claim 1, characterized in that: The entire testing device is equipped with a movable bottom wheel assembly, which can move smoothly along a predetermined track between different testing stations.

4. The visual rapid detection device for recognizing the shape features of prefabricated composite slabs according to claim 1, characterized in that: The multi-row laser ranging sensors are arrayed according to the size of the component detection area and the accuracy requirements of point cloud acquisition, and are fixed along the side of the integrated support structure.

5. The visual rapid detection device for recognizing the shape features of prefabricated composite slabs according to claim 1, characterized in that: Multiple high-brightness, uniform linear lighting devices are arranged in a matrix according to the image acquisition area and are fixed to the horizontal support parts of the integrated bracket structure and the frame beams respectively.

6. The visual rapid detection device for recognizing the shape features of prefabricated composite slabs according to claim 1, characterized in that: The integrated support structure is mounted on a dual-drive linear sliding platform, which is driven synchronously to move the data acquisition module smoothly along the acquisition path.

7. The visual rapid detection device for recognizing the shape features of prefabricated composite slabs according to claim 1, characterized in that: The entire testing device is powered by either a battery storage module or an external power source.

Images