A line scan camera module adjustment device

Abstract

The utility model provides a kind of line scanning camera module adjusting device: including camera module, light source module, control module, camera module, light source module are accessed control module by DP communication, camera module, light source module are located above or below strip, corresponding strip upper surface detection and lower surface detection, the camera module includes camera support seat, camera assembly and the inclination angle adjusting assembly for adjusting the inclination angle of camera assembly are movably connected on the camera support seat, the lower part of the camera support seat is provided with the pitch angle adjusting assembly for adjusting the pitch angle of camera support seat.The utility model design is reasonable, to solve the problem that line scanning camera needs to be stopped manually adjusted in the existing aluminum plate strip surface defect detection, deviation after dynamic operation is easy and needs to be adjusted repeatedly, realize machine column dynamic online adjustment, without stopping, and the adjustment precision is high, can reduce pseudo defect, improve detection efficiency and stability.

Description

Technical Field

[0001] This utility model relates to an adjustment device for a line scan camera module. Background Technology

[0002] In the finishing and straightening process of aluminum strip, the strip runs at high speed (usually requiring a high-speed machine train), and a line scanning camera is needed to detect surface defects (such as scratches, indentations, oxide spots, etc.) in real time. However, the existing line scan camera inspection system has the following technical problems: (1) The system integration is complex and the fault tolerance is low: The line scan camera needs to be highly coordinated with the machine train motion control system, and the detection range is small. If there is a slight positional deviation of the camera or light source during the operation of the aluminum strip, it is easy to cause the detection system to fail or misidentify a large number of "false defects", affecting the production judgment; (2) The adjustment is difficult after the replacement of the inspection roller: The inspection roller is a key component that supports the strip and cooperates with the inspection. After the inspection roller is replaced, due to the difference between the old and new roller diameters, the position of the light strip illuminating the surface of the strip will shift. At this time, the position, angle, aperture, focal length and other parameters of the inspection camera need to be adjusted; (3) The adjustment efficiency is low and the accuracy is poor when the machine is stopped: The existing adjustment method requires manual operation when the machine train is stopped. When the machine is stopped, the strip and the inspection roller are in a static state. After the machine train is running dynamically, factors such as the strip tension and roller vibration will cause the actual working state of the camera and the light source to be different from the stop adjustment state. It is often necessary to repeat the stop-adjust-start- The testing cycle not only wastes a lot of production time, but also makes it difficult to guarantee adjustment accuracy, seriously affecting production efficiency and the reliability of product quality testing.

[0003] To address the aforementioned issues, there is an urgent need to design a device that enables line scan camera adjustment during the dynamic operation of the machine train, thereby resolving the pain points of adjustment during downtime and repeated adjustments, and improving the stability and accuracy of the detection system. Utility Model Content

[0004] In view of this, the purpose of this utility model is to overcome the shortcomings of the prior art and provide a line scan camera module adjustment device.

[0005] This utility model is implemented using the following solution: a line scan camera module adjustment device, comprising a camera module, a light source module, and a control module, wherein the camera module and the light source module are connected to the control module via DP communication, and the camera module and the light source module are located above or below the strip.

[0006] Furthermore, the camera module includes a camera support base, on which a camera component and a tilt adjustment component for adjusting the tilt angle of the camera component are movably connected. A tilt adjustment component for adjusting the pitch angle of the camera support base is provided at the lower part of the camera support base, and the tilt adjustment component is mounted above or below the strip.

[0007] Furthermore, the light source module includes a light source support base, on which a light source assembly is rotatably connected, and a light source sway motor for driving the light source assembly to sway is installed on the side of the light source support base.

[0008] Furthermore, the control module includes an ET200S substation, a stepper module, and a counting module. The control module includes an ET200S substation with a stepper module and a counting module. The stepper module is connected to the camera assembly and the tilt adjustment assembly. An encoder is installed on the motor shaft of the light source swing motor. The counting module is electrically connected to the encoder. A frequency converter for adjusting the light source swing motor is connected to the light source assembly.

[0009] Furthermore, the pitch angle adjustment assembly includes a pitch angle adjustment motor, which is electrically connected to a servo controller and a rotary transformer. The motor shaft of the pitch angle adjustment motor is mounted under the camera support. The pitch angle adjustment motor is mounted above or below the strip. The servo controller is connected to the control module via DP communication.

[0010] Furthermore, the tilt adjustment assembly includes a tilt adjustment plate and a tilt adjustment motor. A swing base is provided under the tilt adjustment plate. The lower part of the swing base is hinged to the camera support base. The tilt adjustment motor is mounted on the camera support base. The motor shaft end of the tilt adjustment motor is mounted on the rotation center of the lower end of the swing base. The tilt adjustment motor is electrically connected to the stepper module. The step angle of the tilt adjustment motor is 1.8°.

[0011] Furthermore, the camera assembly includes a camera body, which is mounted on a tilt adjustment plate. On the left and right sides of the camera body, on the tilt adjustment plate, are respectively a focal length adjustment component for adjusting the focal length of the camera body and an aperture adjustment component for adjusting the aperture of the camera body.

[0012] Furthermore, a focal length gear is fitted around the focusing ring of the camera body, and the focal length adjustment assembly includes a focal length adjustment motor. The focal length adjustment motor is mounted on the tilt adjustment plate, and a focal length adjustment gear is mounted on the motor rotation shaft of the focal length adjustment motor. The focal length adjustment gear meshes with the focal length gear, and the focal length adjustment motor is electrically connected to the stepper module. The step angle of the focal length adjustment motor is 1.8°.

[0013] Furthermore, the aperture ring of the camera body is fitted with an aperture gear, the aperture adjustment assembly includes an aperture adjustment motor, the aperture adjustment motor is mounted on the tilt adjustment plate, the aperture adjustment gear is mounted on the motor rotation shaft of the aperture adjustment motor, the aperture adjustment gear meshes with the aperture gear, the aperture adjustment motor is electrically connected to the stepper module, and the step angle of the aperture adjustment motor is 1.8°.

[0014] Furthermore, the light source assembly includes a light source body, a hinge seat is provided on the rear of the light source body, the hinge seat is hinged to the light source support seat, the motor shaft of the light source swing motor is mounted on the hinge center of the hinge seat, an encoder is installed at the connection between the motor shaft of the light source swing motor and the hinge center, and the light source swing motor is a synchronous motor.

[0015] Compared with the prior art, the present invention has the following advantages: it is reasonably designed to solve the problems of the existing aluminum plate and strip surface defect detection line scanning camera requiring manual adjustment after shutdown, and easy deviation after dynamic operation requiring repeated adjustment. It realizes automatic pre-adjustment of camera and light source after roller diameter change, reduces manual intervention, and improves the adaptability and stability of detection system. Attached Figure Description

[0016] Figure 1 This is a schematic diagram of the light source path of the present invention; Figure 2 This is a schematic diagram of the camera module structure of the present invention; Figure 3 This is a top view of the camera module structure of the present invention; Figure 4 This is a side view of the camera module structure of the present invention; Figure 5 This is a schematic diagram of the structure of the light source module of the present invention.

[0017] In the diagram: 1-Inspection roller; 2-Camera module; 3-Light source module; 4-Control module; 6-Strip; 7-Camera support; 8-Camera assembly; 9-Tilt adjustment assembly; 10-Pitch adjustment assembly; 11-Light source support; 12-Light source assembly; 13-Light source swing motor; 14-Frequency converter; 15-Pitch adjustment motor; 16-Servo controller; 17-Tilt adjustment plate; 18-Tilt adjustment motor; 19-Swing seat; 20-Camera body; 21-Focal length adjustment assembly; 22-Aperture adjustment assembly; 23-Focal length gear; 24-Aperture gear; 25-Focal length adjustment motor; 26-Focal length adjustment gear; 27-Aperture adjustment motor; 28-Aperture adjustment gear; 29-Light source body; 30-Hinge seat. Detailed Implementation

[0018] The present invention will be further described below with reference to the accompanying drawings and embodiments.

[0019] It should be noted that the following detailed descriptions are exemplary and intended to provide further explanation of this application. Unless otherwise specified, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this application pertains.

[0020] It should be noted that the terminology used herein is for the purpose of describing particular embodiments only and is not intended to limit the exemplary embodiments according to this application. As used herein, the singular form is intended to include the plural form as well, unless the context clearly indicates otherwise. Furthermore, it should be understood that when the terms "comprising" and / or "including" are used in this specification, they indicate the presence of features, steps, operations, devices, components, and / or combinations thereof.

[0021] like Figure 1-5 As shown, a line scan camera module adjustment device includes a camera module 2, a light source module 3, and a control module 4. The camera module and the light source module are connected to the control module via DP communication. The camera module and the light source module are located above or below the strip, corresponding to the detection of the upper surface and the lower surface of the strip 6. The camera module includes a camera support 7, on which a camera component 8 and a tilt adjustment component 9 for adjusting the tilt angle of the camera component are movably connected. A tilt adjustment component 10 for adjusting the tilt angle of the camera support 8 is provided at the lower part of the camera support 7. The tilt adjustment component is mounted above or below the strip. The light source module includes a light source support 11, on which a light source component 12 is rotatably connected. A light source sway motor 13 for driving the sway of the light source component is installed on the side of the light source support 7.

[0022] In this embodiment, the control module includes an ET200S substation with a stepper module and a counting module. The ET200S substation acts as a distributed I / O station, exchanging data with the main control system via the PROFIBUS-DP protocol. The stepper module and the counting module serve as extended functional modules of the ET200S substation, respectively used to output stepper motor control pulses and receive encoder feedback signals. The stepper module drives the camera assembly and tilt adjustment assembly to move. An encoder is mounted on the motor shaft of the light source swing motor, and the counting module is electrically connected to the encoder. The counting module is used to receive position signals fed back from the encoder. A frequency converter 14 for adjusting the light source swing motor is connected to the light source assembly. The tilt adjustment assembly and the frequency converter are connected to the main control system via DP communication to realize the transmission of command and status data with the main control system.

[0023] In this embodiment, the pitch angle adjustment assembly includes a pitch angle adjustment motor 15, which is electrically connected to a servo controller 16 and a rotary transformer. The motor shaft of the pitch angle adjustment motor is mounted under the camera support. The rotation of the motor shaft of the pitch angle adjustment motor drives the camera support to rotate around the axis. The pitch angle adjustment motor is mounted above or below the strip. The tilt angle adjustment assembly includes a tilt angle adjustment plate 17 and a tilt angle adjustment motor 18. A swing seat 19 is provided under the tilt angle adjustment plate. The lower part of the swing seat is hinged to the camera support. The tilt angle adjustment motor is mounted on the camera support. The end of the motor shaft of the tilt angle adjustment motor is mounted on the rotation center of the lower end of the swing seat. That is, the end of the motor shaft of the tilt angle adjustment motor is fixed to the swing seat. The rotation of the swing seat is achieved by the rotation of the motor shaft of the tilt angle adjustment motor. The servo controller is connected to the control module via DP communication. The tilt angle adjustment motor is electrically connected to the stepper module.

[0024] In this embodiment, the camera assembly includes a camera body 20, which is mounted on a tilt adjustment plate. On the left and right sides of the camera body, on the tilt adjustment plate, a focal length adjustment component 21 for adjusting the focal length of the camera body and an aperture adjustment component 22 for adjusting the aperture of the camera body are respectively mounted.

[0025] In this embodiment, a focal length gear 23 is fitted around the focusing ring of the camera body, and an aperture gear 24 is fitted around the aperture ring of the camera body. The focal length adjustment assembly includes a focal length adjustment motor 25, which is mounted on a tilt adjustment plate. A focal length adjustment gear 26 is mounted on the motor rotation shaft of the focal length adjustment motor, and the focal length adjustment gear meshes with the focal length gear. The aperture adjustment assembly includes an aperture adjustment motor 27, which is mounted on a tilt adjustment plate. An aperture adjustment gear 28 is mounted on the motor rotation shaft of the aperture adjustment motor, and the aperture adjustment gear meshes with the aperture gear. Both the focal length adjustment motor and the aperture adjustment motor are electrically connected to a stepper module. The step angle of the tilt adjustment motor, the focal length adjustment motor, and the aperture adjustment motor is 1.8°. Specifically, the tilt adjustment motor, the focal length adjustment motor, and the aperture adjustment motor are all stepper motors, and the matching stepper driver is set to 200 pulses / revolution, i.e., 1 STEP. The module controls the rotation of the stepper motor by outputting pulse signals. Every 200 pulses output, the stepper motor rotates one revolution (360°), corresponding to a precise adjustment of the step angle of 1.8°.

[0026] In this embodiment, the light source assembly includes a light source body 29, and a hinge seat 30 is provided on the rear of the light source body. The hinge seat is hinged to the light source support seat. The motor shaft of the light source swing motor is mounted on the hinge center of the hinge seat, that is, the motor shaft of the light source swing motor is fixed on the hinge seat. The rotation of the motor shaft of the light source swing motor drives the movement of the hinge seat, thereby realizing the swing of the light source body. An encoder is installed at the connection between the motor shaft of the light source swing motor and the hinge center. The encoder is electrically connected to the counting module and is used to feed back the actual rotation angle of the light source swing motor to the counting module to form a closed-loop control to ensure the accuracy of the swing angle of the light source body. The light source swing motor is a synchronous motor, which is driven by a frequency converter. The frequency converter receives instructions from the control module to control the rotation angle of the synchronous motor.

[0027] A method for adjusting a line scan camera module includes the following steps: S1: After replacing the inspection roller 1, the operator manually inputs the roller diameter value of the new inspection roller into the control system. S2: Based on the input roller diameter value, the system automatically calculates the target position of the light strip, the angle parameters of the light source module, and the angle parameters of the camera module; S3: Based on the calculation results, the system automatically pre-adjusts the camera module pitch angle and the position of the light source module; S4: Close the aluminum strip surface defect acquisition software and start the camera module debugging software; S5: Controls the operation of the aluminum sheet and strip train to establish stable tension in the strip; S6: Adjust the tilt angle of the camera module through the control system until the brightness of the entire screen displayed in the camera module debugging software is uniform. S7: By fine-tuning the tilt angle of the camera module lens, the camera module lens can make the brightest part of the direct light band, and while ensuring that the image grayscale value is between 60-120, adjust to a smaller aperture value to obtain the maximum brightness, so as to ensure the maximum depth of field of the camera module. S8: Adjust the focal length of the camera module until the image of the strip surface displayed in the camera module debugging software is clear; S9: Start the aluminum strip surface defect acquisition software to complete the dynamic online adjustment of the line scan camera module. This adjustment can be performed while the machine is running to avoid the failure of the surface inspection system adjustment due to the difference between static and dynamic conditions.

[0028] In this embodiment, the method for calculating the target position of the light strip, the angle parameters of the light source module, and the angle parameters of the camera module in step S2 is as follows: (1) The initial target position of the light strip is set to ±120° of the outer circle of the standard inspection roller. In order to reduce the mirror glare caused by the high reflectivity of the aluminum strip surface, the initial angle between the camera module and the strip surface is set to 60°, and the initial angle between the light source module and the strip surface is 30°. (2) Based on the roll diameter of the standard inspection roll, the equation of the outer circle curve of the roll diameter of the standard inspection roll is derived: ; Where R is the radius of the standard inspection roller, the axis of the standard inspection roller is the origin of the coordinate system, and x and y are the horizontal and vertical coordinates of the coordinate system. Therefore, the position coordinates of the light band at the initial position of ±120° are obtained as follows: When inspecting the upper surface: ; When inspecting the lower surface: ; Based on the target position of the light strip and the initial parameters of the light source module, the ray equation of the light source module and the scanning position equation of the camera module are established through existing geometric relationships. Light source module ray equation: When inspecting the upper surface: ; When inspecting the lower surface: ; Camera module scanning position equation: When inspecting the upper surface: ; When inspecting the lower surface: ; When the inspection roller is repaired or replaced, and the roller radius changes from R to r, the set target position of the light strip becomes: When inspecting the upper surface: ; When inspecting the lower surface: ; By combining the ray equations of the light source module, the scanning position equation of the camera module, and the target position coordinates of the light band, the slope of the ray equation of the light source module can be calculated using the point-slope formula: When inspecting the upper surface: ; When inspecting the lower surface: ; The slope of the camera module's scanning position equation: When inspecting the upper surface: ; When inspecting the lower surface: ; (3) Calculate the angle θ1 between the light source module and the surface of the aluminum plate and strip, and the angle θ2 between the camera module and the surface of the aluminum plate and strip using the arctangent function: ; (4) The system will include the angle θ 1. Convert to a light source module, adjust the angle, and adjust the included angle. θ 2. Convert to camera module pitch angle adjustment.

[0029] In this embodiment, the camera module and the light source module are projected onto the horizontal plane on opposite sides of the corresponding light strip in the strip conveying direction. Therefore, the projection of the camera module on the horizontal plane is located on the light strip near the exit side in the strip conveying direction, and the projection of the light source module on the horizontal plane is located on the light strip near the entrance side in the strip conveying direction.

[0030] In this embodiment, the initial installation distance between the light source module and the surface of the aluminum plate strip is 300mm, and the initial installation distance between the camera module and the surface of the aluminum plate strip is 300mm.

[0031] In this embodiment, in step S3, the system drives the pitch angle adjustment motor through the servo controller of the pitch angle adjustment component and drives the light source swing motor through the frequency converter of the light source component according to the calculation results, thereby completing the automatic pre-adjustment of the camera pitch angle and the light source.

[0032] In this embodiment, in S7, the aperture adjustment motor is driven by the 1STEP module, and the pitch angle adjustment motor is finely adjusted by the servo controller so that the camera lens directly hits the brightest part of the light band and obtains the maximum brightness within a small aperture range, so as to ensure the maximum depth of field of the camera.

[0033] In this embodiment, in S8, the focal length adjustment motor is driven by the 1STEP module to adjust the focal length of the camera body until the image of the strip surface displayed in the camera debugging software is clear.

[0034] Unless otherwise stated, if any of the technical solutions disclosed in this utility model discloses a numerical range, then the disclosed numerical range is a preferred numerical range. Any person skilled in the art should understand that the preferred numerical range is merely one among many feasible numerical values ​​that has a more obvious or representative technical effect. Because there are many numerical values, it is impossible to list them all. Therefore, this utility model discloses only some numerical values ​​to illustrate the technical solutions of this utility model. Furthermore, the numerical values ​​listed above should not constitute a limitation on the scope of protection of this utility model.

[0035] If the terms "first" or "second" are used in this document to specify components, those skilled in the art should know that the use of "first" or "second" is merely for the purpose of distinguishing components in description, and unless otherwise stated, the above terms have no special meaning.

[0036] If this utility model discloses or relates to mutually fixedly connected parts or structural components, then unless otherwise stated, a fixed connection can be understood as: a detachable fixed connection (e.g., using bolts or screws), or a non-detachable fixed connection (e.g., riveting, welding). Of course, mutually fixed connections can also be replaced by an integral structure (e.g., manufactured by integral molding using a casting process) (except where it is obviously impossible to use an integral molding process).

[0037] Furthermore, the orientations or positional relationships indicated by terms such as "longitudinal," "lateral," "up," "down," "front," "back," "left," "right," "vertical," "horizontal," "top," "bottom," "inner," and "outer" used in any of the technical solutions disclosed in this utility model are based on the orientations or positional relationships shown in the accompanying drawings and are only for the convenience of describing this patent. They are not intended to indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation. Therefore, they should not be construed as limitations on this patent. In addition, unless otherwise stated, the terms used to indicate shape in any of the technical solutions disclosed in this utility model include shapes that are similar to, close to, or approximate with it.

[0038] Any component provided by this utility model can be assembled from multiple individual components, or it can be a single component manufactured by a one-piece molding process.

[0039] Finally, it should be noted that the above embodiments are only used to illustrate the technical solution of this utility model and not to limit it; although the utility model has been described in detail with reference to preferred embodiments, those skilled in the art should understand that modifications can still be made to the specific implementation of this utility model or equivalent substitutions can be made to some technical features without departing from the spirit of the technical solution of this utility model, and all such modifications and substitutions should be covered within the scope of the technical solution claimed by this utility model.

Claims

1. A line scan camera module adjustment device, characterized in that: It includes a camera module, a light source module, and a control module. The camera module and the light source module are connected to the control module via DP communication. The camera module and the light source module are located above or below the strip.

2. The line scan camera module adjustment device of claim 1, wherein: The camera module includes a camera support base, on which a camera component and a tilt adjustment component for adjusting the tilt angle of the camera component are movably connected. A tilt adjustment component for adjusting the pitch angle of the camera support base is provided at the lower part of the camera support base, and the tilt adjustment component is mounted above or below the strip.

3. The line scan camera module adjustment device of claim 2, wherein: The light source module includes a light source support base, on which a light source component is rotatably connected, and a light source swing motor that drives the light source component to swing is installed on the side of the light source support base.

4. The line scan camera module adjustment device of claim 3, wherein: The control module includes an ET200S substation with a stepper module and a counting module. The stepper module is connected to the camera assembly and the tilt adjustment assembly. An encoder is mounted on the motor shaft of the light source swing motor. The counting module is electrically connected to the encoder. A frequency converter for adjusting the light source swing motor is connected to the light source assembly.

5. The line scan camera module adjustment device of claim 4, wherein: The pitch angle adjustment assembly includes a pitch angle adjustment motor, which is electrically connected to a servo controller and a rotary transformer. The motor shaft of the pitch angle adjustment motor is mounted under the camera support. The pitch angle adjustment motor is mounted above or below the strip. The servo controller is connected to the control module via DP communication.

6. The line scan camera module adjustment device of claim 5, wherein: The tilt adjustment assembly includes a tilt adjustment plate and a tilt adjustment motor. A swing base is provided under the tilt adjustment plate. The lower part of the swing base is hinged to the camera support base. The tilt adjustment motor is mounted on the camera support base. The end of the motor shaft of the tilt adjustment motor is mounted on the rotation center of the lower end of the swing base. The tilt adjustment motor is electrically connected to the stepper module. The step angle of the tilt adjustment motor is 1.8°.

7. The line scan camera module adjustment device of claim 4, wherein: The camera assembly includes a camera body, which is mounted on a tilt adjustment plate. On the left and right sides of the camera body, on the tilt adjustment plate, are respectively a focal length adjustment component for adjusting the focal length of the camera body and an aperture adjustment component for adjusting the aperture of the camera body.

8. The line scan camera module adjustment device of claim 7, wherein: The camera body has a focal length gear fitted around its focusing ring. The focal length adjustment assembly includes a focal length adjustment motor, which is mounted on a tilt adjustment plate. A focal length adjustment gear is mounted on the motor rotation shaft of the focal length adjustment motor. The focal length adjustment gear meshes with the focal length gear. The focal length adjustment motor is electrically connected to a stepper module. The step angle of the focal length adjustment motor is 1.8°.

9. The line scan camera module adjustment device of claim 7, wherein: An aperture gear is fitted around the aperture ring of the camera body. The aperture adjustment assembly includes an aperture adjustment motor, which is mounted on a tilt adjustment plate. An aperture adjustment gear is mounted on the motor rotation shaft of the aperture adjustment motor. The aperture adjustment gear meshes with the aperture gear. The aperture adjustment motor is electrically connected to a stepper module. The step angle of the aperture adjustment motor is 1.8°.

10. The line scan camera module adjustment device of claim 3, wherein: The light source assembly includes a light source body, a hinge seat is provided on the rear of the light source body, the hinge seat is hinged to the light source support seat, the motor shaft of the light source swing motor is mounted on the hinge center of the hinge seat, an encoder is installed at the connection between the motor shaft of the light source swing motor and the hinge center, and the light source swing motor is a synchronous motor.

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