A detection device
By using an automated inspection device to capture and analyze multi-angle images of the welding quality of coils and terminals, the inconsistency and misjudgment problems in welding quality inspection in existing technologies are solved, and efficient and accurate welding quality control is achieved.
Patent Information
- Application Number
- CN202522061482.8
- Authority / Receiving Office
- CN · China
- Patent Type
- Utility models(China)
- Current Assignee / Owner
- Filing Date
- 2025-09-25
- Publication Date
- 2026-08-25
- Estimated Expiration
- 2035-09-25
AI Technical Summary
In existing technologies, welding quality inspection relies on manual visual inspection, which suffers from inconsistent inspection standards and subjectivity, making it difficult to effectively control missed or misjudged welding defects, especially problems such as incomplete welds that are difficult to quantify.
An automated inspection device is adopted, including a material handling mechanism, a material carrying mechanism, and a vision inspection mechanism. Through multi-angle shooting and lighting, the welding quality of the coil and terminal is automatically inspected from all angles. The camera and light source of the vision inspection mechanism are used to shoot and analyze the solder joint images from multiple angles, and the processor makes an automated judgment.
It has enabled automated full inspection of welding quality, ensuring the consistency and effectiveness of inspection standards, reducing the input of manpower and material resources, significantly reducing the omission and misjudgment of welding defects, and improving the efficiency and accuracy of inspection.
Smart Images
Figure CN224674076U_ABST
Abstract
Description
Technical Field
[0001] This application relates to the field of magnetic device testing, and specifically to a testing device. Background Technology
[0002] With the rapid development of technology, especially the emergence of multifunctional devices, the demand for passive components is increasing, and magnetic components, as one of the passive elements, have been widely used. Magnetic components, including integrally molded inductors, mainly consist of a magnet, a coil (also known as a "winding"), and terminals (also known as "external terminals" or "external electrodes"). The magnet is integrally die-cast from magnetic powder using a pre-defined process. The coil is welded to the terminals, and after welding, the coil is die-cast into the magnet. The welding process between the coil and the terminals is an extremely critical and low-tolerance core step in the production process, directly determining the electrical performance, long-term reliability, and final yield of the product. Poor welding generally manifests in various forms such as incomplete solder joints, detached solder joints, empty solder joints, and long solder joints. Poor welding directly affects the core advantages of magnetic components, namely ultra-low DC resistance and the critical factor for long-term product reliability, such as resistance to mechanical stress and thermal fatigue.
[0003] Currently, most manufacturers monitor weld quality by using high-magnification microscopes in conjunction with visual sampling inspections by inspectors. This method not only introduces the inspectors' experience and subjectivity, but also makes it difficult to guarantee the consistency and effectiveness of the inspectors' judgment methods (i.e., inspection standards) for weld defects such as cold welds, which are difficult to quantify and define clearly. Moreover, even with a large investment of manpower and resources, the subjective nature of inspectors and the fatigue inherent in visual inspections can still lead to unstable control over missed and misjudged weld defects. Utility Model Content
[0004] In view of this, this application provides a testing device that can automatically inspect all the welding quality of coils and terminals, which not only ensures the consistency and effectiveness of the inspection standards, but also reduces manpower and material resources while providing relatively stable control over the omission and misjudgment of welding defects.
[0005] This application provides a testing device for testing semi-finished components, the semi-finished components including terminals and coils soldered to the terminals, the testing device comprising: A material handling mechanism, including material handling devices, for obtaining at least half of the finished product device to be inspected; A material-carrying motion mechanism is disposed to the side of the material-picking mechanism. The material-carrying motion mechanism includes a material-carrying platform, which is used to carry the semi-finished device. A visual inspection mechanism includes a camera, a light source, and a processor. The camera and the light source are positioned above the material carrier platform. The camera is distributed at multiple angles. The light source is used to illuminate the semi-finished device from the multiple angles. The camera is connected to the processor and is used to capture images of the semi-finished device from the multiple angles and send them to the processor. The processor is used to inspect the semi-finished device based on the images.
[0006] Optionally, the material handling mechanism further includes a fixed bracket and a first guide rail and a second guide rail mounted on the fixed bracket. The material handling device is mounted on the second guide rail, and the second guide rail is mounted on the first guide rail. The second guide rail is used to allow the material handling device to move back and forth in the vertical direction, and the first guide rail is used to allow the material handling device and the second guide rail to move back and forth in the first horizontal direction.
[0007] Optionally, the material handling device is equipped with a suction nozzle, which is used to suction the semi-finished device to be tested under negative pressure.
[0008] Optionally, the material-carrying motion mechanism further includes a third guide rail, on which the material-carrying platform is mounted and can move along the third guide rail to the target position below the camera and the light source.
[0009] Optionally, the third guide rail extends along the second horizontal direction.
[0010] Optionally, the second horizontal direction is perpendicular to the first horizontal direction.
[0011] Optionally, the material carrier platform is provided with at least one air hole for negative pressure adsorption and positioning of the semi-finished device; and / or, the material carrier platform is provided with multiple protrusions for limiting the semi-finished device.
[0012] Optionally, slots are provided on opposite sides of the material loading platform to expose the corresponding sides of the semi-finished device.
[0013] Optionally, the camera includes a first camera, a second camera, a third camera, a fourth camera, and a fifth camera. The optical axes of the first camera, the second camera, and the third camera are all parallel to the vertical direction. The fourth camera and the fifth camera are disposed on both sides of the first camera, and the angle between the optical axis of the fourth camera and the vertical direction is an acute angle. The light source includes a first light source for illuminating the shooting field of the first camera, a second light source for illuminating the shooting field of the second camera, a third light source for illuminating the shooting field of the third camera, a fourth light source for illuminating the shooting field of the fourth camera, and a fifth light source for illuminating the shooting field of the fifth camera. The visual inspection mechanism further includes two prisms, one of which is positioned directly below the second camera and on the side of the second light source facing away from the material carrier platform, for establishing an optical path between the semi-finished device and the second camera via one of the slots; the other prism is positioned directly below the third camera and on the side of the third light source facing away from the material carrier platform, for establishing an optical path between the semi-finished device and the second camera via the other slot.
[0014] Optionally, the first light source is a coaxial light source, and the second, third, fourth and fifth light sources are all ring light sources.
[0015] Optionally, the included angle is 15°±5°.
[0016] Optionally, the detection device further includes a labeling mechanism, located downstream of the visual inspection mechanism, for labeling the semi-finished device after it has been inspected by the visual inspection mechanism.
[0017] As described above, in the testing device of this application, the semi-finished device to be tested is obtained by the picking device of the picking mechanism, the loading platform of the loading motion mechanism carries the semi-finished device, and the vision inspection mechanism captures an image of the semi-finished device to be tested and performs inspection based on the image. This achieves automatic full inspection of the welding quality of coils and terminals. This automated inspection method not only ensures the consistency and effectiveness of inspection standards, but also reduces manpower and material resources while providing relatively stable control over missed or false judgments of welding defects. In addition, the cameras of the vision inspection mechanism are distributed at multiple angles, and the light source is used to illuminate the semi-finished device from multiple angles, so that the captured images can clearly show the condition of the solder joints from all directions, further avoiding missed or false judgments of welding defects. Attached Figure Description
[0018] Figure 1 This is a schematic diagram of the structure of a detection device provided in an embodiment of this application; Figure 2 This is a schematic diagram of the structure of a semi-finished device provided in an embodiment of this application; Figure 3 This is a structural schematic diagram of multiple semi-finished devices obtained in one step according to this application; Figure 4 yes Figure 1A schematic diagram of the material handling mechanism of the detection device shown. Figure 5 yes Figure 1 A schematic diagram of the material loading mechanism of the detection device shown. Figure 6 yes Figure 5 The schematic diagram of the material loading platform of the material loading mechanism shown is as follows. Figure 7 yes Figure 1 A schematic diagram of the visual inspection mechanism of the detection device shown. Figure 8 yes Figure 7 A schematic diagram of the first camera of the visual inspection mechanism taking pictures of the semi-finished device. Figure 9 yes Figure 7 A schematic diagram of the fourth and fifth cameras of the visual inspection mechanism taking pictures of the semi-finished components. Figure 10 yes Figure 7 A schematic diagram of the second camera of the visual inspection mechanism taking pictures of the semi-finished components; Figure 11 yes Figure 7 A schematic diagram of the third camera of the visual inspection mechanism taking pictures of the semi-finished components. Figure 12 yes Figure 1 A schematic diagram of the labeling mechanism of the detection device shown.
[0019] First direction x, second direction y, third direction z, first view direction z1, second view direction z2; 200 semi-finished components, 300 coils, 400 terminals, 310 lead ends, and 500 connectors; The system includes: a detection device 100, a material handling mechanism 1, a material handling device 11, a suction nozzle 111, a fixed bracket 12, a first guide rail 131, and a second guide rail 132; a material carrying mechanism 2, a material carrying platform 21, an air hole 211, a protrusion 212, an air suction hole 213, a raised strip 214, a slot 215, an empty area 216, a third guide rail 22, and a fixed bracket 23; a vision inspection mechanism 3, a first camera 311, a second camera 312, a third camera 313, a fourth camera 314, a fifth camera 315, a first light source 321, a second light source 322, a third light source 323, a fourth light source 324, and a fifth light source 325, a column 301, a crossbeam 302, a prism / first prism 331, and a prism / second prism 332; a marking mechanism 4, a mounting column 40, a laser generating unit 41, and a laser emitting head 42. Detailed Implementation
[0020] To address the aforementioned technical problems in the prior art, the testing device of this application obtains the semi-finished device to be tested through the material handling mechanism, the material handling platform of the material carrying mechanism carries the semi-finished device, and the vision inspection mechanism captures an image of the semi-finished device to be tested and performs inspection based on the image. This achieves automatic full inspection of the welding quality of coils and terminals. This automated testing method not only ensures the consistency and effectiveness of inspection standards, but also reduces manpower and material resources while providing relatively stable control over missed or false judgments of welding defects.
[0021] In this detection device, the specific form of the shape, quantity, size, and other parameters of any of the material handling mechanism, material handling device, material carrying motion mechanism, material carrying platform, and vision inspection mechanism can be determined according to the adaptability required by the actual scenario, and this application does not limit it.
[0022] To make the objectives, technical solutions, and advantages of this application clearer, the technical solutions of this application will be clearly described below in conjunction with specific embodiments and corresponding drawings. Obviously, the embodiments described below are only a part of the embodiments of this application, and not all of them. Unless otherwise specified, the following embodiments and their technical features can be combined with each other, and also belong to the technical solutions of this application.
[0023] Figure 1 This is a schematic diagram of a testing device provided in an embodiment of this application. The testing device 100 is used to test semi-finished devices, also known as "semi-finished magnetic devices". Figure 2 A schematic diagram of the structure of a single semi-finished device 200 is shown. Figure 3 This illustrates a test sample consisting of multiple semi-finished components 200 connected by two connectors 500. Figure 1 The detection device 100 shown can obtain in one go Figure 3 The 200 semi-finished components shown were tested. (Together) Figure 2 and Figure 3 As shown, the semi-finished device 200 includes terminals 400 and coils 300 welded to the terminals 400, but does not include the magnet of the magnetic device. The coil 300 is a wound structure, and the specific number of turns can be determined according to the actual scenario. Its overall shape after winding is cylindrical, and the orthographic projection of the wound cylindrical area can be circular or elliptical. The coil 300 can be wound from a single wire (e.g., enameled wire), thus having two lead ends 310. One lead end 310 extends from the top of the coil 300, and the other lead end 310 extends from the bottom of the coil 300, and is welded to the corresponding terminal 400 to achieve electrical connection. Figure 2In the view shown, the lead end 310 on the left extends from above the coil 300 and is soldered to a terminal 400 on the left, while the lead end 310 on the right extends from below the coil 300 and is soldered to a terminal 400 on the right. Figure 3 In the example, the terminals 400 on the left side of multiple semi-finished devices 200 are connected by a connector 500, and the terminals 400 on the right side are connected by another connector 500. Of course, in other examples, these two connectors 500 may not be set, and each semi-finished device 200 may be set separately. Figure 3 The number of semi-finished components 200 shown is merely illustrative and does not constitute a limitation on the scope of protection of this application. The so-called inspection in this application can be regarded as the inspection of the welding quality of the lead end 310 and the terminal 400, specifically the inspection of the solder joint or the quality of the solder joint.
[0024] It should be understood that Figure 2 and Figure 3 The coil 300 and terminal 400 shown are merely illustrative examples and do not constitute a limitation on the scope of protection of this application. For example, in other embodiments, the coil 300 may be formed by winding a long strip (or a long strip-shaped sheet) of flat wire. The flat wire has a low DC resistance (DCR), resulting in a low impedance of the coil 300. The flat wire includes a body and an insulating outer layer covering the outer surface of the body. The body is a conductive element, and the insulating outer layer ensures electrical insulation between the turns of the flat wire after winding. As another example, the terminal 400 shown in the figure represents the straight state before die-casting the magnet. After die-casting the magnet, the portion of the terminal 400 extending beyond the magnet can be bent and fitted to the corresponding surface of the magnet.
[0025] Please refer to the following: Figure 1 , Figures 4 to 12 As shown, a detection device 100 according to an embodiment of this application includes a material handling mechanism 1, a material carrying and moving mechanism 2, and a vision inspection mechanism 3.
[0026] To facilitate the description and understanding of the present application, the height direction (i.e., the gravity direction g) of the detection device 100 is referred to as the second direction y, and a three-dimensional rectangular coordinate system is established with the second direction y as one of the coordinate axes. The positive directions of the other two coordinate axes of this three-dimensional rectangular coordinate system are referred to as the first direction x and the third direction z, respectively, and the first direction x, the second direction y, and the third direction z are all perpendicular to each other. It should be understood that the term "perpendicular" throughout the present application does not require that the angle between the two directions must be 90°, but allows for deviations of, for example, ±10°. That is, "perpendicular" can be understood as the angle between any two directions being 80° to 100°. Similarly, the term "parallel" throughout the present application does not require that the angle between the two directions be 0° or 180°, but allows for deviations of, for example, ±10°. That is, "parallel" can be understood as the angle between any two directions being 0° to 10° or 170° to 190°.
[0027] In one example, following the sequence of the detection process, the material-carrying mechanism 2 is located downstream of the material-picking mechanism 1, and the vision inspection mechanism 3 is located downstream of the material-carrying mechanism 2. Corresponding to... Figure 1 In the arrangement scenario shown, along the first direction x, the material picking mechanism 1 and the vision inspection mechanism 3 are arranged opposite to each other, and the material carrying motion mechanism 2 is arranged below the core components of the material picking mechanism 1 and the vision inspection mechanism 3. The core components are key structural parts that perform their respective corresponding processes.
[0028] The material handling mechanism 1 includes a material handling device 11, used to acquire the semi-finished product device 200 to be inspected. Figure 1 and Figure 4 In the example, the material handling mechanism 1 may include two material handling devices 11 arranged opposite each other along a third direction x. Each material handling device 11 is provided with multiple suction nozzles 111. The suction nozzles 111 are used to suction at least half of the finished product device 200 to be tested under negative pressure. The number of suction nozzles 111 can be determined according to the number of semi-finished products 200 to be obtained each time. For example, if the number of semi-finished products 200 to be obtained each time is 6, and the suction nozzles 111 are used to suction the terminals 400 of the semi-finished products 200 under negative pressure, then there are 12 suction nozzles 111. The suction nozzles 111 can be flexible components. By suctioning under negative pressure, the material handling efficiency can be improved, and the problems of damage to the semi-finished products 200 and deformation of the terminals 400 can be effectively prevented during the material handling process.
[0029] In addition, the material handling mechanism 1 also includes a fixed bracket 12 and a first guide rail 131 and a second guide rail 132 mounted on the fixed bracket 12. There can be two fixed brackets 12. Each fixed bracket 12 is a square column extending along the second direction y, such as a channel steel part or an aluminum alloy part. The two fixed brackets 12 are arranged opposite each other along the third direction z, and their bottom ends can be mounted on the ground, etc., so as to fix the material handling mechanism 1 to the corresponding installation position. The first guide rail 131 extends along the third direction z and is mounted on the top of the two fixed brackets 12. The material handling device 11 is mounted on the second guide rail 132. The second guide rail 132 extends along the second direction y and is mounted on the first guide rail 131. The second guide rail 132 is used to allow the material handling device 11 to move back and forth in the vertical direction or in the second direction y. The first guide rail 131 is used to allow the material handling device 11 and the second guide rail 132 to move back and forth in the first horizontal direction (i.e., parallel to the third direction z).
[0030] The material loading mechanism 2 is located to the side of the material handling mechanism 1, for example... Figure 1 As shown on the right, the material-carrying motion mechanism 2 includes a material-carrying platform 21, which is used to carry the semi-finished device 200. Figure 1 , Figure 5 and Figure 6 In the example, the material carrier platform 21 is provided with at least one air hole 211 and multiple protrusions 212. The multiple protrusions 212 are used to limit the semi-finished device 200 so that the semi-finished device 200 is carried in the corresponding position. The air hole 211 is used for negative pressure adsorption and positioning of the semi-finished device 200. With the dual protection of the physical limitation of the protrusions 212 and the negative pressure fastening of the air hole 211, the material carrier platform 21 can not only improve the stability of the subsequent visual inspection mechanism 3 during inspection, but also reduce the phenomenon of material dropping and movement causing the coil 300 to tilt during the inspection process. The number and position of the pores 211 and protrusions 212 can be adapted to actual needs. For example, the material carrier platform 21 can be provided with four protrusions 212 and six pores 211 on its surface. The four protrusions 212 are located at the four vertices of a rectangular area to limit the semi-finished device 200. Suction holes 213 can be provided on the side of the material carrier platform 21, which communicate with the six pores 211 to achieve the negative pressure adsorption positioning effect. The six pores 211 are arranged in two rows, with three pores 211 in each row. The three pores 211 in each row are arranged opposite each other with equal distances between them, thus providing a relatively uniform negative pressure adsorption force to the semi-finished device 200. In other examples, the material carrier platform 21 may also be provided with only one pore 211 or only multiple protrusions 212.
[0031] like Figure 6 As shown, the cross-section of the loading platform 21 can be provided with multiple protrusions 214. These protrusions 214 are arranged in two rows, and a slot 215 is formed between two adjacent protrusions 214 in each row. The slots 215 in these two rows correspond one-to-one along the third direction z. Thus, slots 215 are provided on opposite sides of the loading platform 21. Two slots 215 located in the same direction z form two positions for receiving terminals 400. Figure 3 and Figure 6 As shown, when multiple semi-finished devices 200 are supported on the surface of the loading platform 21, the two terminals 400 of each semi-finished device 200 are respectively clamped in two slots 215 located in the same direction z. The coil 300 is located in the clearance area 216 between the two slots 215, and the protrusion 212 is located between the two terminals 400 of two adjacent semi-finished devices 200. The negative pressure adsorption of the corresponding terminal 400 by each air hole 211 in the corresponding slot 215 allows the loading platform 21 to expose the corresponding two sides of the semi-finished device 200 from the slots 215, that is, to expose the solder joints of the coil 300 and the terminal 400 on both sides. From the two sides of the loading platform 21 along the third direction z, that is, from Figure 6 The first viewing direction z1 and the second viewing direction z2 indicated by the middle arrows, the two slots 215 can respectively expose the solder joints of the coil 300 and the two terminals 400, specifically the sides of the solder joints.
[0032] Furthermore, the material-carrying motion mechanism 2 may also include a third guide rail 22, which extends along a second horizontal direction (i.e., a direction parallel to the first direction x), wherein the second horizontal direction is perpendicular to the first horizontal direction; the material-carrying platform 21 is mounted on the third guide rail 22 and can move along the extension direction of the third guide rail 22. Of course, the material-carrying motion mechanism 2 may also include a fixed bracket 23, which is used to fix the material-carrying motion mechanism 2 to the corresponding work position, and the third guide rail 22 is mounted on the fixed bracket 23.
[0033] The visual inspection mechanism 3 includes multiple cameras, multiple light sources, and a processor (not shown in the figure). Figure 1 and Figure 7In the example, the visual inspection mechanism 3 may include two columns 301 and a crossbeam 302. Each column 301 is a columnar structural member extending along a second direction y. The two columns 301 are arranged on opposite sides of the material carrying mechanism 2 along a third direction z. The crossbeam 302 extends along a third direction z, and both ends of the crossbeam 302 are fixed to the tops of the two columns 301, thereby mounting the crossbeam 302 above the material carrying mechanism 2. The multiple cameras and multiple light sources are mounted on the crossbeam 302, thereby being positioned above the material carrying platform 21. The multiple cameras are distributed at multiple angles and are all connected to the processor. The multiple light sources are used to illuminate the semi-finished device 200 to be inspected from the multiple angles. The multiple cameras are used to capture images of the semi-finished device 200 from the multiple angles and send them to the processor. The processor is used to inspect the solder joints of the semi-finished device 200 based on the images.
[0034] exist Figure 1 , Figures 7 to 11 In the example, the plurality of cameras includes a first camera 311, a second camera 312, a third camera 313, a fourth camera 314, and a fifth camera 315. The optical axes of the first camera 311, the second camera 312, and the third camera 313 are all parallel to the vertical direction (i.e., the direction of gravity), meaning that the cameras of these three cameras face downwards. The fourth camera 314 and the fifth camera 315 are located on both sides of the first camera 311 along the third direction z, and the angle α between the optical axis of the fourth camera 314 and the fifth camera 315 and the vertical direction is an acute angle, for example, the angle α is 15°±5°.
[0035] The plurality of light sources includes a first light source 321, a second light source 322, a third light source 323, a fourth light source 324, and a fifth light source 325. The first light source 321 illuminates the field of view of the first camera 311, enabling the first camera 311 to capture a clear image of the front solder joint. The second light source 322 illuminates the field of view of the second camera 312, enabling the second camera 312 to... Figure 6 A clear image of the solder joint on one side is obtained by shooting from the first viewpoint z1 shown. The third light source 323 is used to illuminate the field of view of the third camera 313, so that the third camera 313 can illuminate the field of view. Figure 6The second viewing direction z2 shown in the figure obtains a clear image of the solder joint on the other side. The fourth light source 324 is used to illuminate the shooting field of the fourth camera 314 so that the fourth camera 314 can capture solder joint images other than those of the first camera 311 and the second camera 312. The fifth light source 325 is used to illuminate the shooting field of the fifth camera 315 so that the fifth camera 315 can capture solder joint images other than those of the first camera 311 and the third camera 313. In this way, the visual inspection mechanism 3 can obtain an all-round image of the solder joint.
[0036] In a real-world scenario, the first light source 321 can be a frontal coaxial light source, set coaxially with the first camera 311. The second camera 312 and the third camera 313 are both side ring light sources, and the fourth camera 314 and the fifth camera 315 are both angled ring light sources. The light emitted by each light source can be distributed around the corresponding camera's field of view, thereby providing relatively uniform lighting for the corresponding field of view.
[0037] Combination Figure 10 and Figure 11 As shown, the visual inspection mechanism 3 may further include two prisms 331 and 332, referred to as the first prism 331 and the second prism 332, respectively. The first prism 331 is disposed directly below the second camera 312 and located on the side of the second light source 322 facing away from the material carrier platform 21, for establishing an optical path between the semi-finished device 200 and the second camera 312 via one of the slots 215, so that the second camera 312 can travel along the corresponding slot 215 of the material carrier platform 21. Figure 6 The first viewing angle z1 shown captures an image of the solder joints on the corresponding side of the semi-finished device 200. The second prism 332 is positioned directly below the third camera 313 and on the side of the third light source 323 facing away from the material carrier platform 21. It is used to establish an optical path between the semi-finished device 200 and the third camera 313 via another slot 215, so that the third camera 313 can travel along the corresponding slot 215 of the material carrier platform 21. Figure 6 The solder joint image of the corresponding side of the semi-finished device 200 was obtained by taking a picture from the second perspective direction z2.
[0038] In practical scenarios, each camera can be a 200-pixel color industrial camera with a focal length of 110mm. The field of view during shooting can be adjusted to 41.62mm*11.16mm, and the detection accuracy can reach 0.008939mm / pixel. Combined with... Figure 8As shown, during the inspection, the distance d1 between the first camera 311 and the semi-finished device 200 can be 110±10mm, and the distance d2 between the first light source 321 located below the first camera 311 and the semi-finished device 200 can be 65±5mm. Combined with... Figure 9 As shown, during the inspection, the distance d3 between the fourth camera 314 and the semi-finished device 200 can be 110±10mm, the distance d4 between the fourth light source 324 and the semi-finished device 200 can be 20±20mm, the fifth camera 315 is symmetrically arranged with the fourth camera 314, and the distance d5 between the fifth camera 315 and the semi-finished device 200 can be 110±10mm, the distance d6 between the fifth light source 325 and the semi-finished device 200 can be 40±20mm, and the maximum rotatable angle of the fourth light source 324 and the fifth light source 325 is 30°. Combined with... Figure 10 As shown, during the inspection, the distance d7 between the second camera 312 and the semi-finished device 200 can be 110±20mm, and the distance d8 between the first prism 331 and the semi-finished device 200 can be 30±20mm. Combined with... Figure 11 As shown, during the inspection, the distance d9 between the third camera 313 and the semi-finished device 200 can be 110±20mm, and the distance d10 between the second prism 332 and the semi-finished device 200 can be 30±20mm. The angles of the first prism 331 and the second prism 332 are adjustable, for example, the adjustable angle is 0±10°.
[0039] Combined Figures 1 to 11 As shown, the working principle and process of the detection device 100 are as follows: First, the picking device 11 of the picking mechanism 1 moves downward along the second guide rail 132 and horizontally along the first guide rail 131 to reach the station where the semi-finished device 200 is loaded. Then, the suction nozzle 111 sucks up the semi-finished device 200 to be tested by negative pressure. Since the picking mechanism 1 is equipped with two picking devices 11, the picking mechanism 1 can pick up two sets of semi-finished devices 200 at a time.
[0040] Then, the material handling mechanism 1 moves the semi-finished device 200 to the material carrying mechanism 2 via the second guide rail 132 and the first guide rail 131. The material carrying mechanism 2 moves the material carrying platform 21 to below one of the material handling devices 11 via the third guide rail 22. The material handling device 11 stops the negative pressure to place the semi-finished device 200 on the material carrying platform 21. The material carrying platform 21 limits and positions the semi-finished device 200 through the protrusions 212 and the air holes 211 respectively, so as to avoid shaking the semi-finished device 200 when the material carrying platform 21 moves. The material carrying mechanism 2 moves the material carrying platform 21 and the semi-finished device 200 supported on it to below the visual inspection mechanism 3 via the third guide rail 22, specifically to the target position below the multiple cameras and multiple light sources. In one example, the semi-finished device 200 can first be moved to the shooting positions corresponding to the first camera 311, the second camera 312, and the fifth camera 315, where these three cameras simultaneously capture images. Then, it can be moved to the shooting positions corresponding to the third camera 313 and the fourth camera 314, where these two cameras simultaneously capture images. The loading platform 21 can carry six semi-finished devices 200 at a time; therefore, the loading platform 21 needs to be moved 11 times to complete the shooting of all six semi-finished devices 200. The background or the surface of the loading platform 21 can be white during shooting to create a clearer contrast with the semi-finished devices 200, making the solder joint features in the images more distinct.
[0041] After capturing images of six semi-finished components 200, the processor obtains the images and performs preset feature processing on them using visual inspection software. This includes at least one of binarization, noise reduction, and edge enhancement processing to ensure the processed images have relatively clear imaging quality. The processor then determines whether any solder joint defects exist based on a corresponding preset threshold comparison. In one example, the solder joint defects may include one or more of the following 14 items: poor coil winding, open solder joint, cold solder joint, solder joint overlap, solder joint offset (upward or downward), solder joint length, solder joint tilting, solder joint tilting, outer coil scratch, detachment, poor winding, severe coil tilting, and coil misalignment. A semi-finished component 200 without any of these solder joint defects is considered a qualified product; conversely, a semi-finished component 200 with any of these defects is considered a non-qualified product.
[0042] Continue reading Figure 1 and Figure 12As shown, the detection device 100 may further include a marking mechanism 4, which is located downstream of the visual inspection mechanism 3. The marking mechanism 4 is used to mark the semi-finished products 200 after they have been inspected by the visual inspection mechanism 3. For example, the marking mechanism 4 is a laser marking mechanism, which includes a mounting post 40, a laser generating unit 41 and a laser emitting head 42. The mounting post 40 is used to install the marking mechanism 4 at the corresponding work station. The laser generating unit 41 is mounted on the mounting post 40 and is used to generate laser. The laser emitting head 42 is mounted on the laser generating unit 41 and is used to emit laser downwards to mark the unqualified semi-finished products 200 with laser.
[0043] After the solder joint defect inspection is completed, the semi-finished components 200 are moved sequentially from the material platform 21 to below the marking mechanism 4. When passing through the marking mechanism 4, qualified products do not trigger the marking mechanism 4 to emit laser light, i.e., qualified products are not laser-marked. Unqualified products will trigger the marking mechanism 4 to emit laser light, i.e., unqualified products are laser-marked, for example, on their terminals 400. Products passing through the marking mechanism 4, including qualified and unqualified products, are placed on the material fork by the material pick-up nozzle. Unqualified products with laser markings will be discharged in the subsequent appearance inspection process, thus retaining only qualified products. The subsequent magnetic powder die-casting process is only performed on qualified products.
[0044] As described above, in the detection device 100 of this application, the semi-finished device 200 to be inspected is obtained by the picking device 11 of the picking mechanism 1, the loading platform 21 of the loading motion mechanism 2 carries the semi-finished device 200, and the vision inspection mechanism 3 captures an image of the semi-finished device 200 to be inspected and performs inspection based on the image. Thus, this application realizes automatic full inspection of the welding quality of the coil 300 and the terminal 400. This automated inspection method can not only ensure the consistency and effectiveness of the inspection standards, but also reduce manpower and material resources while providing relatively stable control over the omission and misjudgment of welding defects. In addition, the multiple cameras of the vision inspection mechanism 3 are distributed at multiple angles, and multiple light sources are used to illuminate the semi-finished device 200 from multiple angles, so that the captured image can clearly show the condition of the solder joint from all directions, further avoiding the omission and misjudgment of welding defects.
[0045] In practical scenarios, the production efficiency of the detection device 100 can reach 2000pcs / h, the processing speed of the visual inspection mechanism 3 can reach 192ms / pcs, the detection display resolution is 0.001mm, and the overall detection efficiency can be improved by more than 10 times compared with the existing manual full inspection. At the same time, the average yield can reach more than 97%, the detection effectiveness can reach 98%, the false judgment rate is 0.93%, and the false negative rate is 0.21%.
[0046] It should be understood that the detection device 100 provided in this application embodiment is a complete device and also has the structure of known detection devices. This document only describes the necessary components required for detection in the detection device 100. Other components can be referred to the figures and will not be described in detail here.
[0047] The above description is only a part of the embodiments of this application and does not limit the patent scope of this application. For those skilled in the art, any equivalent structural transformations made using the content of this specification and drawings are similarly included within the patent protection scope of this application.
[0048] In the description of the embodiments of this application, the terms "center", "longitudinal", "lateral", "length", "width", "thickness", "upper", "lower", "front", "rear", "left", "right", "vertical", "horizontal", "top", "bottom", "inner", "outer", "clockwise", "counterclockwise", etc., indicate the orientation or positional relationship based on the orientation or positional relationship shown in the accompanying drawings. They are only for the convenience of describing the technical solutions of the corresponding embodiments, and are not intended to indicate or imply that the device or element must have a specific orientation, or be constructed and operated in a specific orientation. They should not be construed as limitations on this application.
[0049] Although this document uses terms such as "first," "second," etc., to describe various types of information, this information should not be limited to these terms. These terms are only used to distinguish information of the same type from one another. Furthermore, the singular forms "a," "an," and "the" are intended to also include the plural forms. The terms "or" and "and / or" are interpreted as inclusive, or meaning either one or any combination thereof. Exceptions to this definition only arise when combinations of elements, functions, steps, or operations are inherently mutually exclusive in some way.
Claims
1. A testing device for testing semi-finished components, the semi-finished components comprising terminals and coils soldered to the terminals, characterized in that, The detection device includes: A material handling mechanism, including material handling devices, for obtaining at least half of the finished product device to be inspected; A material-carrying motion mechanism is disposed to the side of the material-picking mechanism. The material-carrying motion mechanism includes a material-carrying platform, which is used to carry the semi-finished device. A visual inspection mechanism includes a camera, a light source, and a processor. The camera and the light source are positioned above the material carrier platform. The camera is distributed at multiple angles. The light source is used to illuminate the semi-finished device from the multiple angles. The camera is connected to the processor and is used to capture images of the semi-finished device from the multiple angles and send them to the processor. The processor is used to inspect the semi-finished device based on the images.
2. The detection device according to claim 1, characterized in that, The material handling mechanism further includes a fixed bracket and a first guide rail and a second guide rail mounted on the fixed bracket. The material handling device is mounted on the second guide rail, and the second guide rail is mounted on the first guide rail. The second guide rail is used to allow the material handling device to move back and forth in the vertical direction, and the first guide rail is used to allow the material handling device and the second guide rail to move back and forth in the first horizontal direction.
3. The detection device according to claim 1, characterized in that, The material handling device is equipped with a suction nozzle, which is used to suck up the semi-finished device to be tested under negative pressure.
4. The detection device according to claim 2, characterized in that, The material-carrying motion mechanism also includes a third guide rail, on which the material-carrying platform is mounted and can move along the third guide rail to the target position below the camera and the light source.
5. The detection device according to claim 4, characterized in that, The third guide rail extends along a second horizontal direction, which is perpendicular to the first horizontal direction.
6. The detection device according to claim 1, characterized in that, The material carrier platform is provided with at least one air hole for negative pressure adsorption and positioning of the semi-finished device; and / or, the material carrier platform is provided with multiple protrusions for limiting the semi-finished device.
7. The detection device according to claim 6, characterized in that, The material loading platform has slots on its opposite sides to expose the corresponding sides of the semi-finished device.
8. The detection device according to claim 7, characterized in that, The camera includes a first camera, a second camera, a third camera, a fourth camera, and a fifth camera. The optical axes of the first camera, the second camera, and the third camera are all parallel to the vertical direction. The fourth camera and the fifth camera are located on both sides of the first camera, and the angles between the optical axes of the fourth camera and the vertical direction are both acute angles. The light source includes a first light source for illuminating the shooting field of the first camera, a second light source for illuminating the shooting field of the second camera, a third light source for illuminating the shooting field of the third camera, a fourth light source for illuminating the shooting field of the fourth camera, and a fifth light source for illuminating the shooting field of the fifth camera. The visual inspection mechanism further includes two prisms, one of which is positioned directly below the second camera and on the side of the second light source facing away from the material carrier platform, for establishing an optical path between the semi-finished device and the second camera via one of the slots; the other prism is positioned directly below the third camera and on the side of the third light source facing away from the material carrier platform, for establishing an optical path between the semi-finished device and the second camera via the other slot.
9. The detection device according to claim 8, characterized in that, The included angle is 15°±5°.
10. The detection device according to claim 1, characterized in that, The detection device also includes a labeling mechanism, which is located downstream of the visual inspection mechanism and is used to label the semi-finished device after it has been inspected by the visual inspection mechanism.