A visual detection device for the internal wiring state of a junction box
By using multi-dimensional visual inspection equipment and AI algorithms, the problems of low efficiency and easy omissions in traditional inspection methods have been solved, achieving high-precision and reliable junction box inspection, which is adaptable to complex structures and multiple models of junction boxes.
Patent Information
- Application Number
- CN202521231115.1
- Authority / Receiving Office
- CN · China
- Patent Type
- Utility models(China)
- Current Assignee / Owner
- Filing Date
- 2025-06-16
- Publication Date
- 2026-08-25
- Estimated Expiration
- 2035-06-16
AI Technical Summary
Traditional testing methods are inefficient, prone to missing detections, difficult to handle complex junction boxes, and have poor light adaptability, failing to meet the high reliability testing requirements of new energy vehicles and smart home appliances.
Employing multi-dimensional visual inspection equipment, including high-definition cameras, structured light 3D cameras, and ring light source components, combined with positioning mechanisms and AI algorithm modules, it achieves multi-angle inspection and adaptive lighting, supporting high-precision inspection of multiple types of junction boxes.
It significantly improves detection efficiency and accuracy, reduces the false negative rate, enhances detection reliability, adapts to different junction box structures, and enables real-time quality control.
Smart Images
Figure CN224682113U_ABST
Abstract
Description
Technical Field
[0001] This utility model relates to the field of detection equipment technology, specifically a visual inspection device for the wiring status inside a junction box. Background Technology
[0002] Traditional inspection methods primarily rely on manual visual inspection or single two-dimensional vision systems. Manual inspection is inefficient and prone to missed detections due to subjective judgment. Traditional vision inspection equipment generally uses fixed-angle light sources and monocular cameras, which are insufficient for inspecting complex junction boxes with deep cavities or multi-curved surfaces, resulting in blind spots. Furthermore, the positioning mechanisms are mostly mechanical clamping types, susceptible to vibration causing junction box displacement and image distortion. In addition, existing equipment lacks adaptive lighting systems, exhibiting poor adaptability to different junction box models, with significantly reduced inspection performance in low-light areas, making it difficult to meet the automated inspection requirements for high-reliability junction boxes in fields such as new energy vehicles and smart home appliances. Utility Model Content
[0003] In order to overcome the shortcomings of existing technical solutions, this utility model provides a visual inspection device for the wiring status inside a junction box, which can effectively solve the problems mentioned in the background art.
[0004] The technical solution adopted by this utility model to solve its technical problem is:
[0005] A visual inspection device for the wiring status inside a junction box includes a frame, a conveying device for conveying the junction box to be inspected, a visual inspection device, and a control system for controlling the inspection process and processing the inspection data. The conveying device is installed at the bottom of the frame, and the visual inspection device is located at the top of the frame.
[0006] The visual inspection device includes at least three high-definition cameras, a structured light 3D camera, and a ring light source assembly. The high-definition cameras are evenly distributed around the structured light 3D camera at 120° angles and all face the inspection area of the conveying device. The ring light source assembly is installed below the high-definition cameras and the structured light 3D camera. The ring light source assembly includes an inner ring LED light source, an outer ring adjustable angle light source, and an angle adjustment component connecting the outer ring adjustable angle light source. The control system is electrically connected to the conveying device, the high-definition cameras, and the structured light 3D camera, respectively.
[0007] As a further description of the above technical solution, the inner ring LED light source illuminates vertically downwards, and the outer ring adjustable angle light source can adjust the illumination angle within the range of 0-90° through an angle adjustment component.
[0008] As a further description of the above technical solution, the angle adjustment component includes a servo motor and a gear and rack transmission mechanism. The servo motor drives the outer ring adjustable angle light source to rotate circumferentially around the frame through the gear and rack transmission mechanism.
[0009] As a further description of the above technical solution, the conveying device includes a conveyor belt and a positioning mechanism. The positioning mechanism includes a buffer positioning slope block and a cylinder. The buffer positioning slope block is connected to the frame through the cylinder. The top surface of the buffer positioning slope block is provided with a rising slope, a positioning groove and a falling slope. The positioning groove matches the shape of the junction box to be tested.
[0010] As a further description of the above technical solution, the positioning mechanism also includes a position sensor, which is installed below the buffer positioning slope block and electrically connected to the control system, for detecting the position of the buffer positioning slope block and feeding it back to the control system.
[0011] As a further description of the above technical solution, the control system includes an image processing module for receiving and processing image data, an AI algorithm module with a built-in deep learning model, and an alarm module. The image processing module is connected to a high-definition camera and a structured light 3D camera, respectively. The AI algorithm module is connected to the image processing module, and the alarm module is connected to the AI algorithm module. The alarm module includes an audible and visual alarm and a wireless communication module.
[0012] Compared with the prior art, the beneficial effects of this utility model are:
[0013] The present invention provides a visual inspection device for the wiring status inside a junction box, which has at least one of the following beneficial effects during use:
[0014] Multi-dimensional technological innovation significantly improves junction box inspection performance: The positioning mechanism adopts a buffer positioning slope block and position sensor closed-loop control, reducing the positioning time of a single junction box to 0.3 seconds, minimizing positioning error, and achieving a high positioning success rate under high-speed transport, ensuring image acquisition accuracy; The fusion of a three-lens high-definition camera and a structured light 3D camera, combined with a 0-90° adjustable angle light source, enables collaborative detection of 2D images and 3D point cloud data, identifying 3D defects such as wire height deviations of 0.1mm and terminal tilt angles within 1°, significantly reducing the missed detection rate; The AI algorithm module incorporates a deep learning model, supporting high-speed detection, automatically distinguishing defects such as cold solder joints and incorrect connections, and outputting confidence levels, combined with audible and visual alarms and wireless communication modules to achieve real-time quality control; The equipment is compatible with multiple junction box models, and the adaptive adjustment of the light source angle improves the detection effect in low-light areas, significantly improving detection efficiency and reducing quality loss costs compared to traditional solutions, significantly enhancing the reliability and intelligence level of industrial inspection. Attached Figure Description
[0015] Figure 1 This is a schematic diagram of the overall structure of a visual inspection device for the wiring status inside a junction box according to the present invention.
[0016] Figure 2 This is a first perspective structural diagram of a visual inspection device for the wiring status inside a junction box according to the present invention.
[0017] Figure 3 This is a second perspective structural diagram of a visual inspection device for the wiring status inside a junction box according to the present invention.
[0018] Numbering on the map:
[0019] 1. Frame; 101. Control system; 2. Conveying device; 201. Conveyor belt; 3. Vision inspection device; 301. Ring light source assembly; 302. Outer ring adjustable angle light source; 303. Inner ring LED light source; 304. Structured light 3D camera; 305. High-definition camera; 306. Angle adjustment component; 4. Positioning mechanism; 401. Buffer positioning slope block; 402. Positioning groove; 403. Position sensor. Detailed Implementation
[0020] The technical solutions of the present utility model will be clearly and completely described below with reference to the accompanying drawings of the embodiments. Obviously, the described embodiments are only some embodiments of the present utility model, and not all embodiments. Based on the embodiments of the present utility model, all other embodiments obtained by those of ordinary skill in the art without creative effort are within the protection scope of the present utility model.
[0021] like Figure 1-3 As shown, this utility model provides a visual inspection device for the wiring status inside a junction box, including a frame 1, a conveying device 2 for conveying the junction box to be inspected, a visual inspection device 3, and a control system 101 for controlling the inspection process and processing the inspection data. The conveying device 2 is installed at the bottom of the frame 1, and the visual inspection device 3 is located at the top of the frame 1.
[0022] In this embodiment, the conveyor belt 201 of the conveyor device 2 operates at a constant speed, transporting the junction box to be tested from the feed end to the testing area in the middle of the frame 1. The conveyor belt 201 is made of anti-slip material to ensure that the junction box does not slip or deviate during transport. When the junction box moves with the conveyor belt 201 to the positioning mechanism 4 area, the control system 101 sends a command to the cylinder, the cylinder piston rod extends, and pushes the buffer positioning slope block 401 upward. The rising slope on its top surface guides the junction box to slide along the slope until it falls into the positioning groove 402 that matches the shape of the junction box, achieving precise alignment. The descending slope design allows the buffer block to descend after the test is completed by the cylinder retracting, so that the junction box can smoothly slide onto the conveyor belt 201 for continued transport. The position sensor 403 installed below the buffer positioning slope block 401 detects its height position in real time and feeds back to the control system 101 through an electrical signal to ensure that the buffer block is at the same height each time it is positioned, avoiding positioning deviations caused by mechanical errors.
[0023] The visual inspection device 3 includes at least three high-definition cameras 305, a structured light 3D camera 304, and a ring light source assembly 301. The high-definition cameras 305 are evenly distributed around the structured light 3D camera 304 at 120° angles and all face the inspection area of the conveying device 2. The ring light source assembly 301 is installed below the high-definition cameras 305 and the structured light 3D camera 304. The ring light source assembly 301 includes an inner ring LED light source 303, an outer ring adjustable angle light source 302, and an angle adjustment component 306 connecting the outer ring adjustable angle light source 302. The control system 101 is electrically connected to the conveying device 2, the high-definition cameras 305, and the structured light 3D camera 304, respectively.
[0024] The inner ring LED light source 303 illuminates the detection area vertically downwards, providing uniform base backlighting, highlighting the outline of the wiring inside the junction box, and reducing interference from top surface reflections. The outer ring adjustable angle light source 302, driven by a servo motor and a rack and pinion transmission mechanism, can adjust the illumination angle within the range of 0-90°. For example, when detecting wiring in a deep groove, the light source angle is adjusted to 30° oblique illumination, using diffuse reflection to illuminate the bottom of the groove; when detecting flat wiring, the angle is adjusted to 90° vertical supplementary lighting to avoid shadows. The angle adjustment process is automatically controlled by the control system 101 according to a preset detection scheme, achieving adaptive lighting.
[0025] Three high-definition cameras 305 are evenly distributed at 120° around the structured light 3D camera 304, simultaneously capturing images of the top and sides of the junction box from the left, right, and directly above, covering the blind spots of traditional monocular vision and acquiring two-dimensional details such as terminals and wire routing. A structured light pattern (such as Gray code stripes) is projected onto the surface of the junction box, and the camera captures the deformed stripe images. Using triangulation principles, three-dimensional coordinate data such as the height of the terminals and the curvature of the wires are calculated to construct a three-dimensional model of the junction box's interior.
[0026] Furthermore, the inner ring LED light source 303 illuminates vertically downwards, while the outer ring adjustable angle light source 302 can adjust its illumination angle within the range of 0-90° via the angle adjustment component 306. Compared to single two-dimensional visual inspection, this device combines 2D image stitching from three angles with 3D point cloud data to detect three-dimensional defects that are difficult to quantify using traditional methods, such as wire height deviation (accuracy up to 0.1mm) and terminal tilt angle (error ≤1°), thus solving the blind spot problem in the inspection of the internal three-dimensional structure of junction boxes. For example, for hidden solder joint defects, the 3D point cloud can accurately identify them through height abrupt change features, reducing the false negative rate from 8% of traditional methods to below 0.5%.
[0027] Furthermore, the angle adjustment component 306 includes a servo motor and a rack and pinion transmission mechanism. The servo motor drives the outer ring adjustable angle light source 302 to rotate circumferentially around the frame 1 via the rack and pinion transmission mechanism. The 0-90° dynamic adjustment function of the outer ring light source effectively addresses the structural differences of different types of junction boxes (such as deep cavity type and flat type). Taking a certain type of deep slot junction box as an example, when the light source angle is adjusted to 45°, the image contrast of the wiring in the slot is improved by 60%, and the edge clarity is improved by 40%, significantly improving the detection effect in low-light areas.
[0028] Furthermore, the conveying device 2 includes a conveyor belt 201 and a positioning mechanism 4. The positioning mechanism 4 includes a buffer positioning slope block 401 and a cylinder. The buffer positioning slope block 401 is connected to the frame 1 through the cylinder. The top surface of the buffer positioning slope block 401 is provided with a rising slope, a positioning groove 402 and a falling slope. The positioning groove 402 matches the shape of the junction box to be tested.
[0029] The rising slope guides the junction box to automatically center, and the positioning groove 402 fits the outer contour, reducing the positioning time of a single junction box to 0.3 seconds, which is 5 times more efficient than manual positioning, and the positioning error is ≤0.2mm, avoiding image acquisition deviation caused by position offset.
[0030] Furthermore, the positioning mechanism 4 also includes a position sensor 403, which is installed below the buffer positioning slope block 401 and electrically connected to the control system 101. The position sensor 403 is used to detect the position of the buffer positioning slope block 401 and feed it back to the control system 101. The image processing module preprocesses the RGB image received from the high-definition camera 305 and the point cloud data from the structured light 3D camera 304, performing image noise reduction (such as median filtering), edge detection (Canny operator), point cloud registration, and other processing to extract feature parameters such as terminal block position, wire color, and solder joint shape.
[0031] The position sensor 403 uses closed-loop control to provide real-time feedback on the position of the buffer block. Combined with the PID algorithm of the control system 101, it enables dynamic calibration of the positioning mechanism 4. Even in high-speed conveying (1.5m / s) scenarios, the positioning success rate remains above 99.9%.
[0032] Furthermore, the control system 101 includes an image processing module for receiving and processing image data, an AI algorithm module with a built-in deep learning model, and an alarm module. The image processing module is connected to the high-definition camera 305 and the structured light 3D camera 304, respectively. The AI algorithm module is connected to the image processing module, and the alarm module is connected to the AI algorithm module. The alarm module includes an audible and visual alarm and a wireless communication module.
[0033] The AI algorithm module uses its built-in deep learning models (such as the YOLOv8 object detection model combined with a 3D point cloud segmentation network) to analyze preprocessed data. Two-dimensional detection identifies planar defects such as loose terminals, misaligned wires, and damaged insulation. Three-dimensional detection calculates the height difference of the wiring through point cloud data to determine if the terminal crimping is in place; it also analyzes the three-dimensional direction of the wires to detect entanglement or interference. Defect classification is based on a training dataset (containing tens of thousands of wiring defect samples). The model can automatically distinguish common defect types (such as cold solder joints, incorrect connections, and missing connections) and output a confidence score. When a defective product is detected, the AI algorithm module sends a command to the alarm module.
[0034] It will be apparent to those skilled in the art that this invention is not limited to the details of the exemplary embodiments described above, and that it can be implemented in other specific forms without departing from the spirit or essential characteristics of this invention. Therefore, the embodiments should be considered illustrative and non-limiting in all respects, and the scope of this invention is defined by the appended claims rather than the foregoing description. Thus, it is intended that all variations falling within the meaning and scope of equivalents of the claims be included within this invention. No reference numerals in the claims should be construed as limiting the scope of the claims.
Claims
1. A visual inspection device for the wiring status inside a junction box, characterized in that: It includes a frame, a conveying device for conveying junction boxes to be inspected, a vision inspection device, and a control system for controlling the inspection process and processing inspection data. The conveying device is installed at the bottom of the frame, and the vision inspection device is located at the top of the frame. The visual inspection device includes at least three high-definition cameras, a structured light 3D camera, and a ring light source assembly. The high-definition cameras are evenly distributed around the structured light 3D camera at 120° angles and all face the inspection area of the conveying device. The ring light source assembly is installed below the high-definition cameras and the structured light 3D camera. The ring light source assembly includes an inner ring LED light source, an outer ring adjustable angle light source, and an angle adjustment component connecting the outer ring adjustable angle light source. The control system is electrically connected to the conveying device, the high-definition cameras, and the structured light 3D camera, respectively.
2. The visual inspection device for the wiring status inside a junction box according to claim 1, characterized in that: The inner ring LED light source illuminates vertically downwards, and the outer ring adjustable angle light source can adjust the illumination angle within the range of 0-90° via an angle adjustment component.
3. The visual inspection device for the wiring status inside a junction box according to claim 1, characterized in that: The angle adjustment component includes a servo motor and a gear and rack transmission mechanism. The servo motor drives the outer ring adjustable angle light source to rotate circumferentially around the frame through the gear and rack transmission mechanism.
4. The visual inspection device for the wiring status inside a junction box according to claim 1, characterized in that: The conveying device includes a conveyor belt and a positioning mechanism. The positioning mechanism includes a buffer positioning slope block and a cylinder. The buffer positioning slope block is connected to the frame through the cylinder. The top surface of the buffer positioning slope block is provided with a rising slope, a positioning groove and a falling slope. The positioning groove matches the shape of the junction box to be tested.
5. The visual inspection device for the wiring status inside a junction box according to claim 4, characterized in that: The positioning mechanism also includes a position sensor, which is installed below the buffer positioning slope block and electrically connected to the control system. The position sensor is used to detect the position of the buffer positioning slope block and feed it back to the control system.
6. The visual inspection device for the wiring status inside a junction box according to claim 1, characterized in that: The control system includes an image processing module for receiving and processing image data, an AI algorithm module with a built-in deep learning model, and an alarm module. The image processing module is connected to a high-definition camera and a structured light 3D camera, respectively. The AI algorithm module is connected to the image processing module, and the alarm module is connected to the AI algorithm module. The alarm module includes an audible and visual alarm and a wireless communication module.