CCD on-line defect detection system with adaptive light source control

Abstract

The utility model relates to defect detection technical field, concretely for adaptive light source regulation and control's CCD online defect detection system, including conveyer table, controller and test board, be equipped with conveyer belt on the conveyer table, be equipped with support assembly between the top of conveyer table with test board, the bottom of test board is equipped with annular seat and CCD camera, the CCD camera is located the center position of test board, and bottom is equipped with lens, be equipped with irradiation lamp on the annular seat, the irradiation lamp is equipped with a plurality of and annular array setting, the top of test board is equipped with lifting device and drive motor, the output of lifting device and the output of drive motor all extend to the bottom of test board, the utility model does not need artificial to put right work piece and manual replacement filter, realizes full process automation detection, adapts multiple varieties work piece, promotes detection efficiency and accuracy, compact structure, strong practicality.

Description

Technical Field

[0001] This utility model relates to the field of defect detection technology, specifically to an online CCD defect detection system with adaptive light source control. Background Technology

[0002] As is well known, CCD imaging inspection technology is widely used in the field of industrial product defect detection due to its high accuracy and fast response. However, existing inspection equipment still faces the following technical challenges in actual production: The contradiction between workpiece positioning and light source adaptation: Workpieces (such as hardware, plastic parts, and electronic components) in production lines often exhibit inconsistent placement angles due to conveyor belt vibration and feeding deviations. Existing equipment requires manual workpiece alignment or the addition of a robotic positioning mechanism, which not only increases labor costs and equipment complexity but also reduces production line efficiency due to positioning time. Simultaneously, light sources are mostly designed with fixed angles and brightness, making it impossible to flexibly adjust the illumination direction according to the actual placement angle of the workpiece. This can easily lead to localized overexposure or shadowing of the workpiece, affecting the clarity of defect imaging.

[0003] Inefficiency and errors in filter replacement: Workpieces of different materials and colors have significantly different spectral requirements for light (e.g., metals need to have specular reflections filtered out, while transparent parts need to highlight internal impurities), requiring the matching of different types of filters. Existing equipment mostly uses manual filter replacement, which requires stopping the machine during the replacement process, resulting in extremely low efficiency when switching between multiple product varieties; moreover, manual installation is prone to misalignment between the filter and the lens coaxiality, leading to image distortion and affecting detection accuracy.

[0004] Insufficient system integration and automation: Existing testing equipment has modules such as light source control, filter switching, and workpiece conveying that are mostly controlled independently, lacking a unified collaborative control mechanism. This makes it difficult to achieve full-process automation of "workpiece positioning - light source adaptation - filter switching - imaging detection", and fails to meet the continuous and efficient testing needs of modern industrial production lines.

[0005] Therefore, there is an urgent need for a highly integrated online CCD defect detection system that can achieve adaptive light source control, automatic filter replacement, and high integration. Utility Model Content

[0006] (a) Technical problems to be solved In view of the technical defects of existing CCD defect detection equipment for industrial products, such as low workpiece positioning efficiency, poor light source adaptability, cumbersome filter replacement, and insufficient system automation, this utility model provides an adaptive light source control CCD online defect detection system.

[0007] (II) Technical Solution To achieve the above objectives, this utility model provides the following technical solution: an adaptive light source-controlled CCD online defect detection system, comprising a conveyor, a controller, and a test board. The conveyor is equipped with a conveyor belt, and a support assembly is provided between the top of the conveyor and the test board. A ring-shaped seat and a CCD camera are located at the bottom of the test board, with the CCD camera positioned at the center of the test board and having a lens at its bottom. Multiple illumination lamps are provided on the ring-shaped seat and arranged in a ring array. A lifting device and a drive motor are provided at the top of the test board. The output ends of the lifting device and the drive motor both extend through the test board to its bottom. A conical disk is provided at the output end of the lifting device, and an adjusting column is provided at the output end of the drive motor. An adjusting plate is provided below the test board, and a splicing mechanism is provided between the adjusting plate and the adjusting column. A threaded hole is provided on the adjusting plate, and a conical groove is provided at the top of the threaded hole. A filter is threaded into the threaded hole, and multiple threaded holes are arranged in a ring array.

[0008] Furthermore, the splicing mechanism includes a splicing groove and a splicing column. The splicing groove is formed at the bottom end of the adjusting column, and the splicing column is installed at the top center of the adjusting plate. A fastening hole is formed on one side of the splicing groove, and a through hole is formed through the adjusting column on the other side of the splicing groove. A positioning hole is formed on the splicing column, and a lead screw is provided in the through hole. The lead screw passes through the positioning hole and is threaded to the fastening hole.

[0009] Furthermore, the bottom end of the adjusting column and the test plate is provided with a bearing seat.

[0010] Furthermore, the conical groove is adapted to the size of the conical disk.

[0011] Furthermore, the lifting device is an electric push rod.

[0012] Furthermore, the drive motor is a servo motor.

[0013] Furthermore, one end of the lead screw is provided with a screw block, and the outer surface of the screw block is provided with anti-slip texture.

[0014] (III) Beneficial Effects Compared with the prior art, this utility model provides an adaptive light source control CCD online defect detection system, which has the following beneficial effects: This adaptive light source-controlled CCD online defect detection system, through a controller linking multiple ring array illumination lamps on a ring mount, can precisely control the switching and brightness of the illumination lamps corresponding to the workpiece's orientation based on the workpiece's placement angle captured in real time by the CCD camera. Without the need for manual or robotic workpiece alignment, the system eliminates shadows or overexposure caused by workpiece tilt through flexible adaptation of light source angle and brightness, ensuring clear imaging of defective areas. This simplifies the equipment structure and improves the continuous operation efficiency of the production line.

[0015] With the coordinated operation of the drive motor, adjustment column, adjustment disk and lifting device, the controller can drive the adjustment disk to rotate according to the workpiece material, color or preset requirements to realize the automatic switching of different types of filters (polarizing, narrowband, monochromatic, etc.); at the same time, through the cooperation of the conical disk and the conical groove, the filter and lens are precisely centered and locked, with a coaxiality error ≤0.1mm.

[0016] The combination of multiple filters and adaptive light sources can cover the inspection needs of workpieces made of different materials such as metal, plastic, glass, and printed materials. It can highlight scratches on metal surfaces and air bubbles inside plastics, as well as identify defects such as misregistration in printed materials. It is suitable for defect inspection in multiple industries such as electronics, automobiles, and packaging, and has strong technical versatility. Attached Figure Description

[0017] Figure 1 This is a schematic diagram of the overall structure of this utility model; Figure 2 This is a schematic diagram of the overall structure of this utility model from another angle; Figure 3 This utility model Figure 1 Enlarged half-section view of the test board structure; Figure 4 This utility model Figure 1 A top-view half-section view of the enlarged structure of the test board.

[0018] In the diagram: 1. Conveyor table; 2. Test board; 3. Conveyor belt; 4. Support assembly; 5. Circular seat; 6. CCD camera; 7. Lens; 8. Illumination lamp; 9. Lifting device; 10. Drive motor; 11. Conical disc; 12. Adjusting column; 13. Adjusting plate; 14. Conical groove; 15. Filter; 16. Splicing column; 17. Lead screw; 18. Fastening hole; 19. Bearing seat. Detailed Implementation

[0019] 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.

[0020] Please see Figures 1-4This utility model is an adaptive light source-controlled CCD online defect detection system, including a conveyor platform 1, a controller, and a test plate 2. The conveyor platform 1 is equipped with a conveyor belt 3. A support assembly 4 is provided between the top of the conveyor platform 1 and the test plate 2. A ring seat 5 and a CCD camera 6 are provided at the bottom of the test plate 2. The CCD camera 6 is located at the center of the test plate 2 and has a lens 7 at its bottom. Multiple illumination lamps 8 are provided on the ring seat 5 in a ring array. A lifting device 9 and a drive motor 10 are provided at the top of the test plate 2. The output ends of the lifting device 9 and the drive motor 10 extend through the test plate 2 to its bottom. A conical disk 11 is provided at the output end of the lifting device 9, and an adjusting column 12 is provided at the output end of the drive motor 10. An adjusting disk 13 is provided below the test plate 2. A splicing mechanism is provided between the adjusting disk 13 and the adjusting column 12. A threaded hole is provided on the adjusting disk 13, and a conical groove 14 is provided at the top of the threaded hole. A filter 15 is threaded into the threaded hole. Multiple threaded holes are arranged in a circular array. In this embodiment, the support component 4 is used to support the test plate 2, such as a pillar or bracket, which is existing technology and therefore will not be described in detail in this specification. The workpiece is transported to the detection area directly below the CCD camera 6 via the conveyor belt 3 on the conveyor table 1. The controller can achieve precise positioning of the product through the drive component of the conveyor belt 3. The drive component of the conveyor belt 3 is existing mature technology (such as a motor and reducer). The controller is a conventional control device, including a control housing, microprocessor, power module, signal input interface and signal output interface, and therefore will not be described in detail in this specification. Multiple illumination lamps 8 on the annular seat 5 are turned on to provide illumination for detection. According to the workpiece placement angle on the conveyor belt 3 captured by the CCD camera 6, the controller controls the switching and brightness of the illumination lamps 8 with corresponding angle orientations on the annular seat 5. The illumination angle of the light source can be flexibly and adaptively adjusted for the workpiece placed on the conveyor belt 3. The defect detection operation and adaptive light source control of the workpiece can be realized without the need for manual alignment of the workpiece or alignment by a robotic arm. According to the material, color or preset testing requirements of the product being tested, the controller starts the drive motor 10: the drive motor 10 drives the adjustment column 12 to rotate, which in turn drives the adjustment disk 13 connected to the adjustment column 12 through the splicing mechanism to rotate synchronously; the multiple threaded holes in the annular array on the adjustment disk 13 are pre-installed with different types of filters 15, such as polarizing filters 15, narrowband filters 15, and monochromatic filters 15. Through the precise control of the drive motor 10, the threaded hole where the target filter 15 is located is rotated to be directly below the lens 7 of the CCD camera 6.Once the target filter 15 is aligned with the lens 7, the controller activates the lifting device 9. The output of the lifting device 9 drives the conical disk 11 downward, causing it to embed into the conical groove 14 at the top of the corresponding threaded hole. The conical surface engagement achieves centering and locking of the adjusting disk 13, ensuring the coaxiality of the filter 15 and the lens 7 and preventing the filter 15 from shifting during inspection. After the filter 15 is fixed, the controller adjusts the brightness and on / off state of the illumination lamp on the annular seat according to the workpiece characteristics. The CCD camera 6 images the workpiece through the lens 7 and the target filter 15, and the image data is transmitted to the controller for defect analysis. After a single inspection is completed, the lifting device 9 drives the conical disk 11 to rise and disengage from the conical groove 14. The drive motor 10 can then rotate the adjusting disk 13 again to switch the filter 15 according to the needs of the next product, achieving continuous online inspection. Multiple filters 15 can be matched with the spectral characteristics of different products to enhance the contrast between defects and background and improve detection accuracy; the overall structure is compact, integrating filter 15 switching with imaging and illumination, and adapting to the continuous needs of online inspection.

[0021] To facilitate the assembly or disassembly of the adjustment plate 13, in this design, the splicing mechanism includes a splicing groove and a splicing column 16. The splicing groove is located at the bottom end of the adjustment column 12, and the splicing column 16 is installed at the center of the top of the adjustment plate 13. A fastening hole 18 is provided on one side of the splicing groove, and a through hole is provided through the adjustment column 12 on the other side of the splicing groove. A positioning hole is provided on the splicing column 16, and a lead screw 17 is provided in the through hole. The lead screw 17 passes through the positioning hole and is threaded to the fastening hole 18. After the splicing groove at the bottom of the adjustment column 12 and the splicing column 16 at the top of the adjustment plate 13 are fitted together, the lead screw 17 passes through the through hole of the adjustment column 12 and the positioning hole of the splicing column 16, and is finally threaded to the fastening hole 18 of the splicing groove. The two are rigidly fixed by tightening the lead screw 17. This allows for quick assembly and disassembly of the adjustment disc 13 and the adjustment column 12, facilitating the replacement of the adjustment disc 13 with different pre-installed filters 15 according to testing requirements, thereby improving the system's flexibility.

[0022] To improve the rotational stability of the adjusting column 12, in this design, the bottom end of the adjusting column 12 and the test plate 2 is provided with a bearing seat 19. The inner ring of the bearing seat 19 is interference-fitted with the adjusting column 12, and the outer ring is fixed to the test plate 2, which greatly reduces the frictional resistance when the adjusting column 12 rotates, reduces the load on the drive motor 10, and extends the service life of the motor.

[0023] In this design, the conical groove 14 is adapted to the size of the conical disk 11. The guiding effect of the conical surface can automatically correct the slight offset of the adjustment disk 13, so that the center of the filter 15 is precisely aligned with the center of the CCD lens 7. At the same time, the positive pressure generated by the contact of the conical surface can form friction force to achieve axial locking of the adjustment disk 13.

[0024] To improve the control accuracy of the lifting device 9, in this scheme, the lifting device 9 is an electric push rod. The electric push rod drives the lead screw to rotate through the motor, converting the rotational motion into the linear reciprocating motion of the push rod, thereby driving the conical disk 11 to move up and down. The electric push rod has high linear drive accuracy and smooth operation. The stroke can be accurately controlled by the controller to ensure that the matching force between the conical disk 11 and the conical groove 14 is consistent.

[0025] In this scheme, the drive motor 10 is a servo motor with its own encoder, which can feed back signals such as rotation angle and speed to the controller in real time to form closed-loop control; the controller precisely controls the rotation angle of the servo motor through pulse signals, thereby driving the adjustment disk 13 to rotate to the position of the target filter 15.

[0026] In this design, a screw block is provided at one end of the lead screw 17. The outer surface of the screw block is provided with anti-slip texture. The screw block at one end of the lead screw 17 increases the force-bearing area for manual operation. Combined with the anti-slip texture on the outer surface, such as a grid pattern or stripes, the difficulty of manually turning the lead screw 17 can be reduced by increasing friction.

[0027] Although embodiments of the present invention have been shown and described, it will be understood by those skilled in the art that various changes, modifications, substitutions and alterations can be made to these embodiments without departing from the principles and spirit of the present invention, the scope of which is defined by the appended claims and their equivalents.

Claims

1. An adaptive light source-controlled CCD online defect detection system, comprising a conveyor (1), a controller, and a test board (2), characterized in that, The conveyor platform (1) is provided with a conveyor belt (3). A support assembly (4) is provided between the top of the conveyor platform (1) and the test plate (2). The bottom of the test plate (2) is provided with a ring seat (5) and a CCD camera (6). The CCD camera (6) is located at the center of the test plate (2) and has a lens (7) at the bottom. The ring seat (5) is provided with an illumination lamp (8). Multiple illumination lamps (8) are provided and arranged in a ring array. The top of the test plate (2) is provided with a lifting device (9) and a drive motor (10). The output end of the lifting device (9) The output end of the drive motor (10) extends through the test plate (2) to its bottom. The output end of the lifting device (9) is provided with a conical disk (11). The output end of the drive motor (10) is provided with an adjustment column (12). An adjustment disk (13) is provided below the test plate (2). A splicing mechanism is provided between the adjustment disk (13) and the adjustment column (12). A threaded hole is provided on the adjustment disk (13). A conical groove (14) is provided at the top of the threaded hole. A filter (15) is threaded into the threaded hole. Multiple threaded holes are provided and arranged in a ring array.

2. The adaptive light source control CCD online defect detection system according to claim 1, characterized in that, The splicing mechanism includes a splicing groove and a splicing column (16). The splicing groove is opened at the bottom end of the adjusting column (12). The splicing column (16) is installed at the top center of the adjusting plate (13). A fastening hole (18) is opened on one side of the splicing groove. A through hole is opened through the adjusting column (12) on the other side of the splicing groove. A positioning hole is opened on the splicing column (16). A lead screw (17) is provided in the through hole. The lead screw (17) passes through the positioning hole and is threaded to the fastening hole (18).

3. The adaptive light source control CCD online defect detection system according to claim 1, characterized in that, The bottom end of the adjusting column (12) and the test plate (2) is provided with a bearing seat (19).

4. The adaptive light source control CCD online defect detection system according to claim 1, characterized in that, The conical groove (14) is adapted to the size of the conical disk (11).

5. The adaptive light source control CCD online defect detection system according to claim 1, characterized in that, The lifting device (9) is an electric push rod.

6. The adaptive light source control CCD online defect detection system according to claim 1, characterized in that, The drive motor (10) is a servo motor.

7. The adaptive light source control CCD online defect detection system according to claim 2, characterized in that, One end of the lead screw (17) is provided with a screw block, and the outer surface of the screw block is provided with anti-slip texture.

Images