A polyurethane composite board deformation and filling monitoring device based on machine vision

Abstract

The utility model discloses a kind of polyurethane composite board deformation and filling monitoring devices based on machine vision, including installation crossbeam, sliding assembly, support, sensing device and visual component. Through the integration of high-precision industrial camera, servo motor and industrial light source, automatic image capture and analysis to plate cutting section are realized. The device adopts dynamic snapshot mode, combines size numerical value judgment method and graphic similarity comparison technology, accurately detects plate deformation and filling defects. Servo motor drives sliding assembly to adjust shooting width, two groups of symmetrical components detect left and right tongue in an all-round way, diffuse reflection laser sensor triggers dynamic snapshot, and industrial surface light source optimizes imaging effect. The device realizes automated, efficient, accurate quality monitoring, significantly improves detection efficiency and consistency, reduces labor cost and labor intensity, and is suitable for real-time quality control of polyurethane composite board production line.

Description

Technical Field

[0001] This utility model belongs to the field of machine vision equipment, and in particular relates to a machine vision-based device for monitoring the deformation and filling of polyurethane composite panels. Background Technology

[0002] Polyurethane / rock wool composite panels are widely used in building insulation, and their quality directly affects the insulation effect and construction quality of buildings. Currently, the quality inspection of polyurethane / rock wool composite panels mainly relies on manual visual inspection. This method is not only inefficient but also difficult to achieve full inspection, prone to omissions, and cannot guarantee the consistency and accuracy of the inspection. In addition, manual inspection also suffers from strong subjectivity, high labor intensity, and high cost.

[0003] While some companies have attempted to use surveillance cameras for real-time monitoring, current technologies still require manual intervention for assessment and lack automated dimensional measurement and image comparison capabilities. This semi-automated inspection method cannot meet the demands of modern industrial production for efficient and accurate testing. In particular, existing technologies are insufficient for detecting tongue-and-groove deformation and filling tightness in panel materials. Deformation of the tongue-and-groove dimensions can lead to misalignment during on-site installation, resulting in uneven walls or poor sealing; while poor filling coverage, hollow areas, or unevenness directly affect the wall's insulation performance.

[0004] The technical solution of this patent proposes an automated inspection method that aims to achieve automated monitoring of deformation and filling of polyurethane composite panels through machine vision technology. This greatly improves inspection efficiency and accuracy, reduces manual intervention, lowers production costs, and provides reliable technical support for the quality control of polyurethane / rock wool composite panels, thereby improving production efficiency and product quality. Utility Model Content

[0005] In view of this, the present invention aims to address the aforementioned problems by proposing a machine vision-based deformation and filling monitoring device for polyurethane composite panels. This device integrates a high-precision industrial camera, sensors, a servo motor, and an industrial light source to achieve automatic image capture and analysis of the panel's cut cross-section. The sliding component and servo motor in the device automatically adjust the shooting position according to the width of the panel, ensuring comprehensive and accurate detection. The sensors can detect the panel's forward movement in real time, triggering the industrial camera to dynamically capture images, thereby achieving real-time monitoring of continuously produced panels on the production line.

[0006] To achieve the above objectives, the technical solution of this utility model is implemented as follows: A machine vision-based polyurethane composite board deformation and filling monitoring device includes a mounting beam, a sliding assembly, a bracket, a sensing device, and a vision component. The mounting beam spans an external device, the main body of the sliding assembly is mounted on the mounting beam, the sensing device is mounted on the mounting beam, one end of the bracket is fixed to the sliding part of the sliding assembly, and the other end of the bracket is connected to the vision component. The sensing device is connected to the vision component and an electronic control system circuit. The external device is a band saw cutting frame, and the device is positioned after band saw cutting to facilitate image capture of the cut cross-section of the board. The mounting beam spans the band saw cutting frame, the main body of the sliding assembly is on the mounting beam, one end of the bracket moves with the sliding part of the sliding assembly, and the other end is connected to the vision component. When the sensing device detects the arrival of the board, it controls the industrial camera in the vision component to start capturing images.

[0007] The deformation of the polyurethane composite panel in the captured image is judged using a "dimensional value" method. Specifically, three key dimensional values ​​are extracted from the panel's contour curve. If these values ​​exceed the preset deviation values, the system will determine that the panel deformation is unqualified and issue an alarm.

[0008] To determine the tightness and uniformity of the filling, an image similarity comparison method is used. An image of a qualified board material is used as the target image sample. Each real-time image captured is compared with this target image for similarity. If the similarity exceeds a predetermined threshold, the board material is considered to have a filling problem and is thus a substandard product.

[0009] This device employs a dynamic capture method, perfectly suited for the continuous production of sheet metal on a production line. The industrial camera is mounted on the outside of the sheet metal on the production line, and under normal operating conditions, it can acquire images of the sheet metal without requiring lateral movement.

[0010] In a structure that optimizes the aforementioned solution, the sliding assembly, bracket, and vision assembly are arranged in two sets, with the two sets of sliding assemblies positioned opposite each other on the left and right sides of the mounting beam. These two sets of sliding assemblies, positioned opposite each other on the left and right sides of the mounting beam, can drive the connected bracket and vision assembly to detect the left and right tongue-and-groove joints of the sheet material. This structure can simultaneously detect the left and right tongue-and-groove joints of the sheet material, providing a more comprehensive monitoring of the sheet material's deformation and filling condition.

[0011] In a structure that optimizes the aforementioned solution, a servo motor is further included, which is connected to the sliding assembly. The servo motor is connected to the electronic control system circuitry and is used to drive the sliding part on the sliding assembly to move along the track of the sliding assembly, thereby adjusting the image capture width. This structure can adjust the image capture width to adapt to the detection needs of different sized sheet materials, improving the versatility of the device.

[0012] Preferably, the stroke of the sliding component is 500mm.

[0013] In a structure that optimizes the aforementioned solution, the vision component includes an industrial camera and a camera mounting plate. The camera mounting plate is disposed at one end of a bracket, and the industrial camera is fixed to the camera mounting plate. This structure provides a stable mounting structure for the industrial camera, ensuring the accuracy of the shooting position.

[0014] In a structure that optimizes the aforementioned solution, an oblong hole is provided at the rear of the camera mounting plate for adjusting the shooting angle of the industrial camera. This structure allows for flexible adjustment of the industrial camera's shooting angle to obtain more suitable images of the material, thereby improving monitoring effectiveness.

[0015] In a structure that optimizes the aforementioned solution, the vision component further includes a protective housing disposed outside the industrial camera. The protective housing protects the industrial camera from external environmental factors (such as dust and moisture), extending its lifespan and ensuring image quality.

[0016] In a structure that optimizes the aforementioned solution, an industrial light source is further included. This industrial light source is mounted on a bracket via a light source mounting base, aligning with the vision component. The center of the industrial light source is 250mm away from the vision component. The industrial light source is a surface light source, illuminating the product directly above it. This surface light source, illuminating from directly above, provides uniform and sufficient illumination to the material, resulting in clearer images captured by the industrial camera, which is beneficial for subsequent judgment of image distortion and fill conditions.

[0017] Preferably, the industrial light source is 280mm away from the bottom surface of the equipment, the industrial camera is 125mm away from the bottom surface of the equipment, and the bottom surface of the equipment is the surface on which the board is placed.

[0018] In a structure that optimizes the aforementioned solution, one of the mounting holes of the light source mounting base is oblong, allowing adjustment of the industrial light source's tilt angle. This structure can adjust the illumination angle of the light source according to actual needs, further optimizing the lighting effect to meet the testing requirements of different sheet materials.

[0019] In a structure that optimizes the aforementioned solution, the sensing device is a diffuse reflection laser sensor. The sensing device is used for end detection during the material's forward movement. When the material is detected to have arrived, it controls the industrial camera to start capturing images. This enables dynamic image capture, accurately controlling the industrial camera to capture images when the material reaches the appropriate position, ensuring timely and effective capture, while avoiding meaningless camera shots and saving resources.

[0020] In a structure that optimizes the aforementioned solution, the bracket is an L-shaped bracket. The L-shaped bracket facilitates the connection between the sliding component and the vision component, providing a reasonable structural layout for the device and making it easy to install and fix the various components.

[0021] Compared with existing technologies, the machine vision-based polyurethane composite board deformation and filling monitoring device of this utility model has the following advantages: Compared to existing technologies, this solution integrates machine vision and automated control to replace manual visual inspection, enabling real-time monitoring of continuous sheet materials. This significantly improves inspection efficiency and consistency while reducing labor costs and intensity. Machine vision is used to accurately detect deformation and filling conditions, eliminating subjective errors. A servo motor-driven sliding component allows for adjustable shooting width, and two symmetrical components can comprehensively inspect the left and right tongue-and-groove joints of different sheet material specifications. A diffuse reflection laser sensor triggers a dynamic capture by an industrial camera, matching the continuous production rhythm and avoiding invalid shots. An industrial surface light source, combined with a waist-shaped aperture, adjusts the lighting and shooting angle, while a protective casing ensures stable equipment operation. The L-shaped bracket and modular design facilitate installation and maintenance. The overall device reduces quality risks, improves yield, and achieves an intelligent, efficient, precise, and universal upgrade for polyurethane composite board quality inspection. Attached Figure Description

[0022] The accompanying drawings, which form part of this utility model, are used to provide a further understanding of the utility model. The illustrative embodiments of the utility model and their descriptions are used to explain the utility model and do not constitute an undue limitation of the utility model. In the drawings: Figure 1 This is a schematic diagram of the deformation and filling monitoring device for polyurethane composite panels based on machine vision described in this utility model. Figure 2 Right view of the machine vision-based polyurethane composite board deformation and filling monitoring device of this utility model.

[0023] Explanation of reference numerals in the attached figures: 101. Mounting beam; 102. Sliding assembly; 103. Servo motor; 104. Bracket; 105. Light source mounting base; 106. Industrial light source; 107. Protective housing; 108. Industrial camera; 109. Camera mounting plate; 200. Sensing device; 301. Polyurethane composite board; 302. Tongue and groove joint of polyurethane composite board; 303. Internal filling of polyurethane composite board. Detailed Implementation

[0024] It should be noted that, unless otherwise specified, the embodiments and features described in these embodiments can be combined with each other.

[0025] In the description of this utility model, it should be understood that the terms "center," "longitudinal," "lateral," "upper," "lower," "front," "rear," "left," "right," "vertical," "horizontal," "top," "bottom," "inner," and "outer," etc., indicating orientation or positional relationships based on the orientation or positional relationships shown in the accompanying drawings, are only for the convenience of describing this utility model and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation, and therefore should not be construed as a limitation of this utility model. Furthermore, the terms "first," "second," etc., are used for descriptive purposes only and should not be construed as indicating or implying relative importance or implicitly specifying the number of indicated technical features. Thus, features defined with "first," "second," etc., may explicitly or implicitly include one or more of that feature. In the description of this utility model, unless otherwise stated, "a plurality of" means two or more.

[0026] In the description of this utility model, it should be noted that, unless otherwise explicitly specified and limited, the terms "installation," "connection," and "joining" should be interpreted broadly. For example, they can refer to a fixed connection, a detachable connection, or an integral connection; they can refer to a mechanical connection or an electrical connection; they can refer to a direct connection or an indirect connection through an intermediate medium; and they can refer to the internal connection of two components. Those skilled in the art can understand the specific meaning of the above terms in this utility model based on the specific circumstances.

[0027] The present invention will now be described in detail with reference to the accompanying drawings and embodiments.

[0028] The structural assembly process of a machine vision-based polyurethane composite panel deformation and filling monitoring device is as follows: A mounting beam 101 is horizontally and securely fixed to the band saw cutting frame, ensuring it is level and stable. The main body of the sliding assembly 102 is mounted on the mounting beam 101 and connected to the servo motor 103, ensuring the sliding part can move smoothly along the track. One end of the L-shaped bracket 104 is fixed to the sliding part of the sliding assembly 102, and the other end is connected to the vision assembly. The vision assembly includes an industrial camera 108, a camera mounting plate 109, and a protective housing 107. The industrial camera 108 is fixed to the bracket 104 via the camera mounting plate 109, and the protective housing 107 covers the industrial camera 108 to protect it from environmental influences. An industrial light source 106 is fixed to the bracket 104 via a light source mounting base 105, and the tilt angle of the light source is adjusted to uniformly illuminate the surface of the sheet material from directly above. A diffuse reflection laser sensor 200 is mounted on the mounting beam 101, ensuring it can accurately detect the forward movement of the sheet material. The sensing device 200, servo motor 103, industrial camera 108, and industrial light source 106 are connected to the electrical control system to ensure that all components work together.

[0029] Device operation process: 1. Preparation for board inspection: Start the device, and the servo motor 103 drives the sliding component 102 to adjust the position of the industrial camera 108 and the industrial light source 106 to adapt to the width of the board to be inspected.

[0030] 2. Board arrival inspection: When the board enters the inspection area after being cut by the band saw, the diffuse reflection laser sensor 200 detects the end of the board and triggers the industrial camera 108 to start dynamic capture.

[0031] 3. Image Acquisition and Analysis: The industrial camera 108 captures images of the cut cross-section of the sheet metal, and the industrial light source 106 provides uniform illumination to ensure image clarity. The captured images are transmitted to the electronic control system, which extracts three key dimensional values ​​of the sheet metal contour curve to determine whether they exceed preset deviation values. Simultaneously, the real-time image is compared with the target image to determine the compactness and uniformity of the filling.

[0032] 4. Result Judgment and Alarm: If the dimensional value exceeds the deviation or the image similarity is lower than the threshold, the system determines that the board is unqualified and issues an alarm; if the inspection is qualified, the board continues to the next process.

[0033] 5. Continuous monitoring: The device repeats the above process to achieve real-time monitoring of the continuously produced boards on the production line, ensuring that the quality of each board meets the requirements.

[0034] Through the above assembly and operation process, this device realizes automated and efficient monitoring of the deformation and filling of polyurethane composite panels, significantly improving detection accuracy and production efficiency.

[0035] The above description is only a preferred embodiment of the present utility model and is not intended to limit the present utility model. Any modifications, equivalent substitutions, improvements, etc., made within the spirit and principles of the present utility model should be included within the protection scope of the present utility model.

Claims

1. A machine vision-based device for monitoring the deformation and filling of polyurethane composite panels, characterized in that: The device includes a mounting beam (101), a sliding assembly (102), a bracket (104), a sensing device (200), and a vision component. The mounting beam (101) is mounted across an external device. The main body of the sliding assembly (102) is mounted on the mounting beam (101). The sensing device (200) is mounted on the mounting beam (101). One end of the bracket (104) is fixed to the sliding part of the sliding assembly (102), and the other end of the bracket (104) is connected to the vision component.

2. The machine vision-based polyurethane composite board deformation and filling monitoring device according to claim 1, characterized in that: The sliding component (102), bracket (104), and vision component are in two sets, with the two sets of sliding components (102) arranged opposite each other on the left and right sides of the mounting beam (101).

3. The machine vision-based polyurethane composite board deformation and filling monitoring device according to claim 2, characterized in that: It also includes a servo motor (103) connected to the sliding assembly (102).

4. The machine vision-based polyurethane composite board deformation and filling monitoring device according to claim 1, characterized in that: The vision component includes an industrial camera (108) and a camera mounting plate (109). The camera mounting plate (109) is set at one end of the bracket (104), and the industrial camera (108) is fixed on the camera mounting plate (109).

5. The machine vision-based polyurethane composite board deformation and filling monitoring device according to claim 4, characterized in that: The camera mounting plate (109) has a waist-shaped hole at the rear for adjusting the shooting angle of the industrial camera (108).

6. The machine vision-based polyurethane composite board deformation and filling monitoring device according to claim 4, characterized in that: The vision component also includes a protective housing (107) disposed outside the industrial camera (108).

7. The machine vision-based polyurethane composite board deformation and filling monitoring device according to claim 1, characterized in that: It also includes an industrial light source (106), which is mounted on a bracket (104) via a light source mounting base (105) and is positioned in conjunction with the vision component.

8. The machine vision-based polyurethane composite board deformation and filling monitoring device according to claim 7, characterized in that: One of the mounting holes of the light source mounting base (105) is waist-shaped, which can adjust the tilt angle of the industrial light source (106).

9. The machine vision-based polyurethane composite panel deformation and filling monitoring device according to claim 1, characterized in that: The sensing device (200) is a diffuse reflection laser sensor.

10. The machine vision-based polyurethane composite panel deformation and filling monitoring device according to claim 1, characterized in that: The bracket (104) is an L-shaped bracket.

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