An online visual intelligent detection system special for carrier tape paper

Abstract

The application discloses a special online visual intelligent detection system for carrier tape paper, which comprises a detection equipment main body, a feeding stabilizing support is arranged on the top of the detection equipment main body, the feeding stabilizing support is arranged below a paper tape transmission path and used for supporting the paper tape, a bottom light source is arranged below the feeding stabilizing support, a camera is arranged above the feeding stabilizing support and used for shooting the paper tape in transmission, a round hole detection sensor is arranged near the camera and used for triggering the camera to shoot, paper tape transmission mechanisms are arranged on the two sides of the feeding stabilizing support and used for the transmission of the paper tape, a winding machine is arranged behind the outlet side of the detection equipment main body, and the paper tape is output through the paper tape transmission mechanism and then enters the winding machine to complete winding; the detection system further comprises a main control computer which is connected with the camera, the bottom light source and the round hole detection sensor through lines. The system has the following advantages: full-automatic online detection, accurate and rapid detection of the quality of the paper tape.

Description

Technical Field

[0001] This utility model relates to an online visual intelligent inspection system for carrier paper, specifically in the field of online visual intelligent inspection of carrier paper. Background Technology

[0002] The existing paper tape quality inspection method involves a professional quality inspection department using a two-dimensional image analyzer to sample 40cm from the beginning and end of each roll of paper tape and run a pre-written fixed inspection program for quality inspection. The average inspection time for each sample of paper tape is about 10 minutes, which is time-consuming. Moreover, if the first inspection fails, the paper tape needs to be re-sampled and sent for inspection, which will result in multiple inspections, which will take even longer and delay the start-up of the punching machine, thus affecting production efficiency.

[0003] Furthermore, this traditional method of paper tape quality inspection has several significant limitations. First, it relies on manual sampling, which not only increases labor costs but also may lead to deviations in test results due to human factors (such as inaccurate sampling location or operational errors). Second, sampling only 40cm from the beginning and end of each roll of paper tape may not fully reflect the quality of the entire roll, especially if quality problems are scattered in different parts of the paper tape; this localized inspection method is prone to missed detections.

[0004] If the initial inspection fails and paper needs to be re-drawn and sampled, it not only increases the additional testing time and cost, but more importantly, it leads to a longer standby time for subsequent production equipment such as punching machines, which seriously affects the continuity of the production line and the overall production efficiency. Summary of the Invention

[0005] The technical problem this invention aims to solve is the deficiency in the existing technology. It provides a dedicated online visual intelligent inspection system for carrier paper, which is fully automatic online inspection without downtime, has high inspection efficiency, and can support high-speed production lines. It can accurately and quickly complete the inspection of paper tape quality, greatly improving inspection efficiency and accuracy. It can also effectively reduce human intervention, reduce the risk of missed and false inspections, and further optimize the production process, prevent the occurrence of quality problems in advance, thereby comprehensively improving the overall quality and efficiency of paper tape production.

[0006] To solve the above technical problems, the present invention adopts the following technical solution: An online visual intelligent inspection system for carrier paper includes an inspection device body. A feeding stabilizing bracket is provided on the top of the inspection device body. The feeding stabilizing bracket is located below the paper tape conveying path to support the paper tape. A bottom light source is installed below the feeding stabilizing bracket. A camera is provided above the feeding stabilizing bracket to capture images of the paper tape during transmission. A circular hole detection sensor is installed near the camera to trigger the camera to capture images. Paper tape conveying mechanisms are provided on both sides of the feeding stabilizing bracket for conveying the paper tape. A winding machine is provided at the rear of the outlet side of the inspection device body. The paper tape is output from the paper tape conveying mechanism and then enters the winding machine to complete the winding. The detection system also includes a main control computer, which is connected to a camera, a bottom light source, and a circular hole detection sensor via wiring.

[0007] Furthermore, the feeding stabilizing bracket uses a flexible material to support the paper tape.

[0008] Furthermore, the bottom light source employs a high-brightness LED array, which is vertically projected onto the paper tape plane.

[0009] Furthermore, the camera is positioned above the paper tape transport path, directly opposite the paper tape area supported by the feeding stabilizing bracket. The height of the camera can be adjusted using an adjustment knob to ensure that the image covers the entire width of the paper tape.

[0010] Furthermore, the paper tape conveying mechanism includes a front guide roller and a rear guide roller, which are arranged on both sides of the feeding stabilizing bracket. The front guide roller is equipped with a front pressure roller, and the rear guide roller is equipped with a rear pressure roller.

[0011] Furthermore, the front guide roller and the front pressure roller are located at the entrance of the paper tape transport path, and the rear guide roller and the rear pressure roller are located at the exit of the paper tape transport path. The rear pressure roller cooperates with the front guide roller to eliminate paper tape vibration and ensure paper feeding stability.

[0012] Furthermore, an encoder is installed on the shaft end of the rear pressure roller. The encoder communicates with the circular hole detection sensor and simultaneously sends pulse signals to the circular hole detection sensor and the main control computer.

[0013] Furthermore, the winding machine has a built-in tension sensor for detecting the tension of the winding machine.

[0014] Furthermore, the main control computer includes a CPU unit, which is connected to an image acquisition interface unit, an encoder signal interface unit, a light source control unit, an I / O control interface unit, and a motor control unit. The image acquisition interface unit is connected to a camera via a PCIe interface and is used to control camera movements. The encoder signal interface unit is connected to an encoder, which can simultaneously send pulse signals to the CPU unit and the circular hole detection sensor. The light source control unit is connected to a bottom light source and adjusts the brightness of the bottom light source through PWM dimming. The I / O control interface unit is connected to a circular hole detection sensor and a tension sensor. The motor control unit is connected to a front guide roller drive motor and a rear pressure roller drive motor.

[0015] This utility model adopts the above technical solution and has the following technical effects compared with the prior art: fully automatic online detection without machine shutdown, detection efficiency of 40 m / min, supporting high-speed production lines; it can accurately and quickly complete the detection of paper tape quality, and complete the accurate measurement of the whole roll of paper tape, thereby realizing online full-width and real-time detection of paper tape. This not only greatly improves the detection efficiency and accuracy, but also effectively reduces human intervention, reduces the risk of missed detection and false detection, and further optimizes the production process, preventing the occurrence of quality problems in advance, thereby comprehensively improving the overall quality and efficiency of paper tape production. Attached Figure Description

[0016] To more clearly illustrate the specific embodiments of this utility model or the technical solutions in the prior art, the drawings used in the description of the specific embodiments or the prior art will be briefly introduced below. In all the drawings, similar elements or parts are generally identified by similar reference numerals. In the drawings, the elements or parts are not necessarily drawn to scale.

[0017] Figure 1 This is a schematic diagram of the structural principle of this utility model. Detailed Implementation

[0018] As shown in Figure 1, an online visual intelligent inspection system for carrier paper includes a main body 1 of the inspection equipment. A feeding stabilizing bracket 3 is provided on the top of the main body 1. The feeding stabilizing bracket 3 is located below the paper tape transmission path to support the paper tape. The feeding stabilizing bracket 3 is made of flexible material to support the paper tape, further reducing the impact of vibration on imaging.

[0019] A bottom light source 5 is installed below the feeding stabilizing bracket 3. The bottom light source 5 adopts a high-brightness LED array, which is vertically projected onto the paper tape plane to form a uniform backlight. The light intensity is adjustable from 5000 to 10000 Lux, ensuring that the apertures transmit light to form a bright solid circle.

[0020] A camera 4 is mounted above the feeding stabilizing bracket 3. The camera 4 is positioned above the paper tape transport path and directly faces the paper tape area supported by the feeding stabilizing bracket. The height of the camera 4 can be adjusted by an adjustment knob to ensure that the image covers the entire paper tape area. The camera 4 is a high-resolution industrial camera (resolution ≥ 4096 × 2160 pixels), with a frame rate ≥ 40 fps, supports encoder trigger mode, and is synchronized with the paper feed speed. The camera 4 is equipped with a telecentric lens with a working distance of 200~300 mm and a lateral resolution ≤ 0.005 mm / pixel to ensure distortion-free imaging.

[0021] The detection system also includes a circular hole detection sensor 10, which is installed near the camera 4, close to the paper tape transport path, and is used to trigger the camera 4 to take pictures.

[0022] The detection system also includes a paper tape conveying mechanism, which includes a front guide roller 6 and a rear guide roller 8. The front guide roller 6 and the rear guide roller 8 are arranged on both sides of the feeding stabilizing bracket 3. A front pressure roller 7 is provided on the front guide roller 6, and a rear pressure roller 9 is provided on the rear guide roller 8. The front guide roller 6 and the front pressure roller 7 are located at the entrance of the paper tape conveying path, and the rear guide roller 8 and the rear pressure roller 9 are located at the exit of the paper tape conveying path. The rear pressure roller 9 cooperates with the front guide roller 6 to eliminate paper tape vibration and ensure paper feeding stability.

[0023] An encoder is installed on the shaft end of the rear pressure roller 9. The encoder communicates with the circular hole detection sensor 10. The encoder sends pulse signals to the circular hole detection sensor 10 and the main control computer 11, which can accurately capture the paper tape movement distance corresponding to the roller rotation. The encoder triggers once every 17.48mm movement of the carrier paper, ensuring that the shooting frequency (frame rate ≥40fps) of the dedicated camera is completely synchronized with the paper feeding speed (≤40m / min), avoiding missed shots or reshots due to speed deviation.

[0024] The detection system also includes a winding machine 2, which has a built-in tension sensor. The winding machine 2 is located behind the outlet side of the main body of the detection equipment. The paper tape is output through the rear pressure roller and then enters the winding machine 2 to complete the winding.

[0025] The detection system also includes a main control computer 11, which is connected to the camera 4, the bottom light source 5, and the circular hole detection sensor 10 via cables. It is placed next to the main body of the detection equipment for easy viewing and operation by the operator. The main control computer 11 has built-in image processing algorithms to analyze data in real time and store abnormal information.

[0026] The main control computer 11 includes a CPU unit, which is connected to an image acquisition interface unit, an encoder signal interface unit, a light source control unit, an I / O control interface unit, and a motor control unit. The image acquisition interface unit connects to the camera 4 via a PCIe interface and is used to control the movement of the camera 4. The encoder signal interface unit is connected to an encoder, which can simultaneously send pulse signals to the CPU unit and the circular hole detection sensor 10. The encoder sends one trigger pulse for every 17.48mm movement of the carrier paper, which is synchronously transmitted to the CPU unit through the encoder signal interface unit. The light source control unit is connected to a bottom light source 5 and adjusts the brightness of the bottom light source 5 through PWM dimming. When the CPU unit receives the pulses sent by the encoder, it sends a brightness adjustment command to the bottom light source to control the LED. The array is vertically projected, allowing light to pass through the holes and forming bright, solid areas. The I / O control interface unit is connected to a circular hole detection sensor 10 and a tension sensor. The encoder sends pulse signals to the circular hole detection sensor 10, which in turn sends a trigger request signal to the CPU unit. The CPU unit sends a shooting trigger signal to the camera. The tension sensor transmits the winding machine tension to the CPU unit. The CPU unit receives the winding machine tension signal and, combined with the encoder's displacement signal, calculates the paper feed speed. The motor control unit is connected to a front guide roller drive motor and a rear pressure roller drive motor. The CPU unit sends speed adjustment commands to the front guide roller drive motor and the rear pressure roller drive motor. Through pre-stabilization of the front guide roller and secondary compaction of the rear pressure roller, the roller speed is controlled to match the paper feed speed, eliminating transverse / longitudinal vibration of the paper belt.

[0027] The detection steps of the online visual intelligent inspection system for carrier paper are as follows: a. Stable transport of carrier paper: The perforated carrier paper is discharged from the tension wheel of the winding machine and passes through the front guide roller and front pressure roller, the feeding stabilizing bracket and the rear guide roller and rear pressure roller in sequence to eliminate vibration and maintain uniform speed (production line speed ≤ 40 m / min) to ensure the stability of the carrier paper and ensure the accuracy of the test data. b. When the paper tape enters the feeding stabilizing bracket, the bottom light source is automatically turned on, and the transmission hole forms a bright area. The dedicated camera takes pictures according to the encoder signal (triggered once every 17.48 mm movement), and collects 40 frames per second to ensure that adjacent images have a 3 mm field of view overlap to avoid missed detection.

[0028] The advantages of this invention are that it provides fully automated online detection without downtime, achieving a detection efficiency of 40 m / min and supporting high-speed production lines. It can accurately and quickly detect the quality of paper tape, accurately measuring the entire roll of paper tape to achieve online, full-width, real-time detection. This not only significantly improves detection efficiency and accuracy but also effectively reduces human intervention, lowering the risk of missed or false detections. Furthermore, it optimizes the production process, preventing quality problems in advance, thereby comprehensively improving the overall quality and efficiency of paper tape production.

[0029] The description of this invention is given for illustrative and descriptive purposes only and is not intended to be exhaustive or to limit the invention to the forms disclosed. Many modifications and variations will be apparent to those skilled in the art. The embodiments were chosen and described in order to better illustrate the principles and practical application of the invention and to enable those skilled in the art to understand the invention and design various embodiments with various modifications suitable for a particular purpose.

Claims

1. A dedicated online visual intelligent inspection system for carrier paper, characterized in that: The device includes a detection equipment body (1), a feeding stabilizing bracket (3) on the top of the detection equipment body (1), the feeding stabilizing bracket (3) is located below the paper tape transmission path to support the paper tape, a bottom light source (5) is installed below the feeding stabilizing bracket (3), a camera (4) is installed above the feeding stabilizing bracket (3), the camera (4) is used to photograph the paper tape in transmission, a round hole detection sensor (10) is installed near the camera (4) to trigger the camera (4) to take pictures, paper tape transmission mechanisms are provided on both sides of the feeding stabilizing bracket (3), the paper tape transmission mechanisms are used for the transmission of the paper tape, a winding machine (2) is provided behind the outlet side of the detection equipment body (1), the paper tape is output through the paper tape transmission mechanism and enters the winding machine (2) to complete the winding; The detection system also includes a main control computer (11), which is connected to a camera (4), a bottom light source (5), and a circular hole detection sensor (10) via a line.

2. The online visual intelligent inspection system for carrier paper as described in claim 1, characterized in that: The feeding stabilizing bracket (3) uses a flexible material to support the paper tape.

3. The online visual intelligent inspection system for carrier paper as described in claim 1, characterized in that: The bottom light source (5) uses a high-brightness LED array, which is projected vertically onto the paper tape plane.

4. The online visual intelligent inspection system for carrier paper as described in claim 1, characterized in that: The camera (4) is located above the paper tape transport path and directly opposite the paper tape area supported by the feeding stabilizing bracket. The height of the camera (4) can be adjusted by adjusting the knob to ensure that the shooting covers the entire width of the paper tape.

5. The online visual intelligent inspection system for carrier paper as described in claim 1, characterized in that: The paper tape conveying mechanism includes a front guide roller (6) and a rear guide roller (8). The front guide roller (6) and the rear guide roller (8) are arranged on both sides of the feeding stabilizing bracket (3). The front guide roller (6) is provided with a front pressure roller (7), and the rear guide roller (8) is provided with a rear pressure roller (9).

6. The online visual intelligent inspection system for carrier paper as described in claim 5, characterized in that: The front guide roller (6) and the front pressure roller (7) are set at the entrance of the paper tape transport path, and the rear guide roller (8) and the rear pressure roller (9) are set at the exit of the paper tape transport path. The paper tape vibration is eliminated by the cooperation of the rear pressure roller (9) and the front guide roller (6), thus ensuring the stability of paper feeding.

7. The online visual intelligent inspection system for carrier paper as described in claim 5, characterized in that: An encoder is installed on the shaft end of the rear pressure roller (9). The encoder communicates with the circular hole detection sensor (10) and simultaneously sends pulse signals to the circular hole detection sensor (10) and the main control computer (11).

8. The online visual intelligent inspection system for carrier paper as described in claim 5, characterized in that: The winding machine (2) is equipped with a tension sensor for detecting the tension of the winding machine (2).

9. The online visual intelligent inspection system for carrier paper as described in claim 8, characterized in that: The main control computer (11) includes a CPU unit, which is connected to an image acquisition interface unit, an encoder signal interface unit, a light source control unit, an I / O control interface unit, and a motor control unit. The image acquisition interface unit is connected to a camera (4) via a PCIe interface and is used to control the movement of the camera (4). The encoder signal interface unit is connected to an encoder, which can simultaneously send pulse signals to the CPU unit and the circular hole detection sensor (10). The light source control unit is connected to a bottom light source (5) and adjusts the brightness of the bottom light source (5) through PWM dimming. The I / O control interface unit is connected to a circular hole detection sensor (10) and a tension sensor. The motor control unit is connected to a front guide roller drive motor and a rear pressure roller drive motor.

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