Integrated multi-station automatic detection device

Abstract

The utility model relates to a kind of integrated multi-station automatic detection device, involve automated visual inspection equipment technical field, including the feeding machine, cleaning machine, cleaning machine, AOI detection machine and unloader that are sequentially arranged;Feeding machine realizes automatic feeding and empty tray recycling;Cleaning machine is cleaned to product front and back by VPV module and turnover module;Cleaning machine adopts five-axis movement module to cooperate with cleaning module to clean product outer contour;AOI detection machine detects product multi-angle by five-axis detection module and vision system;Unloader realizes the automatic sorting of good and bad products and unloading.The utility model realizes the full automation of detection process, greatly improves production efficiency;Through effective cleaning and flexible detection, significantly reduce the misjudgment rate, improve detection accuracy and reliability;Its modular and flexible design also enables the equipment to quickly adapt to the production needs of different products, reduces the equipment investment cost of enterprise.

Description

Technical Field

[0001] This utility model relates to the field of automated visual inspection equipment technology, and in particular to an integrated multi-station automatic inspection device for product appearance inspection. Background Technology

[0002] Product appearance inspection is a crucial step in ensuring product quality, especially in industrial production, particularly in consumer electronics and precision components. Currently, most automated appearance inspection equipment widely used in the market is a single-machine, single-function dedicated machine. The structure and operating mode of this type of equipment are as follows:

[0003] 1. Structure and Composition: This type of equipment typically consists of a fixed base, one or more fixedly mounted vision cameras (such as area scan cameras or line scan cameras), a simple conveying mechanism or fixture for transporting products, and a matching light source and control system. Its overall structure is designed around a single, specific detection function.

[0004] 2. Working Mode and Connection Relationship: During operation, products are intermittently conveyed to a fixed inspection station below the camera via a conveyor mechanism, or picked up by a robotic arm and placed in a fixed position. Subsequently, the camera acquires and analyzes images of specific surface features (such as dimensions, scratches, and stains) of the product at a preset, fixed angle and position. The entire inspection process is completed independently within the equipment, with each functional unit (such as loading, positioning, inspection, and unloading) tightly integrated within the same machine frame, forming a "rigid" closed system.

[0005] Therefore, although the above structure is efficient for large-volume, standardized single-product testing, its inherent single-machine, single-function mode leads to the following problems:

[0006] 1. Limited functionality and poor versatility: Each device can typically only perform one or a few preset testing tasks. When the product model changes or new testing requirements are added (such as changing from testing the front to also testing the side), large-scale and costly mechanical and program modifications to the entire machine are often required, and even the purchase of new specialized equipment is necessary, making it impossible to achieve rapid compatibility and flexible production.

[0007] 2. Lack of cleaning process, high false detection rate: Existing equipment generally lacks an integrated pre-treatment cleaning unit. Before inspection, the surface of the product may be covered with dust, fingerprints, and other dirt. These interfering substances are easily misjudged as product defects by the vision system, resulting in a low inspection yield and requiring a large amount of manual re-inspection, which reduces overall efficiency.

[0008] 3. Fixed detection angle with blind spots: Since cameras and product fixtures are usually fixed or have only limited degrees of freedom, it is impossible to image the complex contours, concave surfaces, or sides of the product from multiple angles and in all directions. This results in unavoidable blind spots, affecting the comprehensiveness and accuracy of the detection.

[0009] 4. Fragmented Automated Processes: Loading, unloading, cleaning, inspection, and sorting processes are typically completed by multiple independent, unconnected devices. Transfer between processes relies on manual labor or additional handling robots, resulting in lengthy production lines, large floor space requirements, low overall coordination efficiency, and difficulty in achieving full-process data traceability. Utility Model Content

[0010] The technical problem to be solved by this utility model is to provide an integrated multi-station automatic detection device to realize the fully automated operation of products from loading, cleaning, washing, detection to sorting and unloading.

[0011] The technical solution adopted by this utility model to solve its technical problem is: an integrated multi-station automatic detection device, including a feeder, a cleaning machine, a washing machine, an AOI detection machine and a unloading machine arranged sequentially along the product processing flow;

[0012] The feeding machine, cleaning machine, washing machine, AOI inspection machine and unloading machine are connected by at least one conveying component for transferring products between adjacent machines;

[0013] The feeding machine includes a feeding and lifting assembly for lifting the carrier tray, a material handling assembly for taking and transferring material from the carrier tray, a positioning assembly for accurately positioning the product, and an empty tray stacking assembly for collecting empty carrier trays.

[0014] The cleaning machine includes a first VPV cleaning module, a flipping module, a second VPV cleaning module, and a transfer module. The first VPV cleaning module and the second VPV cleaning module are located on the upstream and downstream sides of the flipping module, respectively, so that the product is first cleaned by the first VPV cleaning module, then flipped 180° by the flipping module, and then the reverse side is cleaned by the second VPV cleaning module.

[0015] The cleaning machine includes a multi-axis motion module and a cleaning module mounted thereon. The multi-axis motion module drives the cleaning module to perform multi-degree-of-freedom cleaning on the outer contour surface of the product.

[0016] The AOI inspection machine includes a multi-axis inspection module and a vision inspection system. The multi-axis inspection module is used to clamp and drive the product to move, enabling the vision inspection system to acquire images of the product from multiple angles and positions.

[0017] The unloading machine includes a dual unloading bin assembly for distinguishing between good and defective products, a product lifting assembly for receiving and lifting products, and a material handling assembly for transporting products from the product lifting assembly to the corresponding unloading bin.

[0018] Furthermore, the base of the cleaning machine and / or the AOI inspection machine described in this utility model is made of marble.

[0019] Furthermore, the cleaning module of the cleaning machine of this utility model includes a cleaning cloth roll, a take-up shaft, a cleaning fixture, and a pressing cylinder. The pressing cylinder drives the cleaning fixture to press the cleaning cloth onto the product surface, and the multi-axis motion module drives the product and the cleaning fixture to move relative to each other to achieve multi-angle cleaning.

[0020] Furthermore, the visual inspection system of the AOI inspection machine of this utility model includes at least one line scan camera and at least one area scan camera.

[0021] Furthermore, the VPV cleaning module of the cleaning machine described in this utility model is driven by a linear module and can reciprocate relative to the product surface to generate an ion flow for cleaning.

[0022] Furthermore, the flipping module of this utility model includes a fixture for clamping the product, a flipping shaft for driving the fixture to flip 180°, and a lifting shaft for driving the fixture to move up and down.

[0023] Furthermore, the multi-axis detection module of the AOI inspection machine of this utility model is a five-axis motion module, including an X-axis, a Y-axis, a Z-axis, a U-axis and an R-axis, and the end of the R-axis is provided with a product fixture for adsorbing and fixing the product.

[0024] Furthermore, the overall workflow of the platform described in this utility model is coordinated and controlled by a central control system. The detection result signal of the AOI inspection machine is fed back to the unloading machine to control it to sort good and bad products.

[0025] The beneficial effect of this utility model is that it solves the defects existing in the background technology.

[0026] 1. This utility model integrates feeding, cleaning, washing, detection, and unloading into one system, realizing full-process automation and improving production efficiency;

[0027] 2. Employing a multi-axis motion system and a self-developed cleaning / washing module, it effectively removes dirt from the product surface, reducing the false detection rate;

[0028] 3. Through a multi-axis vision inspection system, multi-angle and multi-position inspection can be achieved, reducing blind spots;

[0029] 4. The equipment has a standardized structure, strong versatility, and is easy to adapt to different product types;

[0030] 5. The use of marble base plates enhances the rigidity and stability of the equipment and improves testing accuracy. Attached Figure Description

[0031] Figure 1 This is a schematic diagram of the overall structure of this utility model;

[0032] Figure 2 This is a schematic diagram of the feeding machine structure of this utility model;

[0033] Figure 3 This is a schematic diagram of the cleaning machine structure of this utility model;

[0034] Figure 4 This is a schematic diagram of the cleaning machine structure of this utility model;

[0035] Figure 5 This is a schematic diagram of the AOI inspection machine of this utility model;

[0036] Figure 6 This is a schematic diagram of the feeding machine structure of this utility model;

[0037] In the diagram: 1. Feeding machine; 2. Cleaning machine; 3. Washing machine; 4. AOI inspection machine; 5. Unloading machine;

[0038] 11. Feeding and lifting assembly; 12. Material handling assembly; 13. Positioning assembly; 14. Transfer assembly; 15. Transfer assembly; 21. First VPV cleaning module; 22. Tilting module; 23. Second VPV cleaning module; 24. Handling assembly; 31. Five-axis motion module; 32. Cleaning module; 41. Five-axis detection module; 42. Vision inspection system; 51. Unloading bin assembly; 52. Product lifting assembly; 53. Material handling assembly; 54. Cargo pallet lifting assembly. Detailed Implementation

[0039] The present invention will now be described in further detail with reference to the accompanying drawings and preferred embodiments. These drawings are simplified schematic diagrams, illustrating only the basic structure of the present invention, and therefore only show the components relevant to the present invention.

[0040] like Figure 1The integrated multi-station automatic inspection device shown connects five originally independent functional modules—loading machine, cleaning machine, washing machine, AOI inspection machine, and unloading machine—into a continuous automated production line through an integrated material handling system. These machines are arranged sequentially along a straight line or according to the site layout, and precise product transfer between adjacent workstations is achieved through material handling components (such as multi-axis gantry cranes or robotic arms). The platform is uniformly coordinated and controlled by a central control system (not shown in the figure, such as a PLC or industrial PC), realizing a complete closed-loop operation from empty tray loading, product cleaning, precision washing, and all-around inspection to automatic sorting and unloading of good / defective products.

[0041] like Figure 2 As shown, the feeder is the starting point of the production line, mainly responsible for the automatic supply of products and the recovery of empty pallets. It includes:

[0042] Material loading and lifting assembly: This assembly includes a platform driven by a Z-axis lifting module and a tray guide column to guide the trays up and down. The operator manually places the tray containing multiple layers of products onto the platform, and the lifting module then raises the top tray level by level to a fixed picking height.

[0043] Material handling assembly: This assembly is typically a three-axis right-angle assembly with multiple vacuum cylinder-driven suction cups as its end effectors. Once the carrier tray is in position, the assembly moves above the tray, and the suction cups descend to pick up the product.

[0044] Positioning Component: The material handling component places the product on the positioning platform. The positioning platform is equipped with positioning blocks (or ejector pins) driven by cylinders, which clamp or lift the product from both sides or the bottom to achieve precise positioning and eliminate positional errors caused during the material handling process.

[0045] Empty pallet stacking assembly: After all products on a pallet have been removed, the loading and lifting assembly continues to lift the empty pallet to the empty pallet stacking station. The empty pallet stacking assembly takes over the empty pallet and stacks it temporarily using its cylinder-driven push rod or fork arm. Once all products have been processed, the equipment prompts the operator to remove the entire stack of empty pallets.

[0046] like Figure 3 As shown, the cleaning machine is responsible for removing dust, static electricity, and minor deposits from the product surface, preparing it for subsequent precision testing.

[0047] First cleaning station: Products transferred from the loading machine are transported by the cleaning machine's handling components (usually a fixture driven by a linear module) to the top of the first VPV cleaning module and paused. Driven by the linear module, the VPV cleaning module reciprocates close to the product surface, and the resulting ionized airflow effectively blows away dust from the front of the product and eliminates static electricity.

[0048] Flipping Station: After front-side cleaning, the product is transported to the flipping module. The fixture of the flipping module first picks up the product, then its lifting shaft raises the product to avoid surrounding mechanisms. Next, the flipping shaft drives the fixture to rotate 180°, so that the reverse side of the product faces upward.

[0049] Second cleaning station: The flipped product is lowered and transferred to the transfer module. After one or more transfers, it is sent to the top of the second VPV cleaning module for reverse cleaning in the same way.

[0050] Discharge: After double-sided cleaning, the product is transferred to the cleaning machine by the handling component.

[0051] like Figure 4 As shown, the cleaning machine is used to perform a more thorough physical cleaning of the outer contour surface of the product, removing stubborn stains such as fingerprints and oil.

[0052] Loading and securing: Products from the cleaning machine are placed on the R-axis product fixture of the five-axis motion module of the cleaning machine. This fixture secures the products by vacuum adsorption. The five-axis motion module typically includes three linear axes (X, Y, and Z), as well as a U-axis (oscillating axis) and an R-axis (rotational axis).

[0053] Cleaning Operation: The five-axis motion module carries the product to a position below the cleaning module. The cleaning module descends along its Z-axis, bringing the cleaning fixture close to the product surface. Then, the pressing cylinder actuates, firmly pressing the cleaning cloth (from the unloading reel) onto the area of ​​the product to be cleaned. Simultaneously, the cleaning module's motor drives the take-up shaft, slowly winding up the cleaning cloth, continuously providing a clean cloth surface. The five-axis motion module works in tandem, causing the product to undergo complex rotations and deflections under the cleaning fixture, ensuring its entire outer contour surface is thoroughly wiped. Throughout the process, the cleaning cloth can be sprayed with cleaning media.

[0054] Discharge: After cleaning, the five-axis motion module moves the product to the bottom of the transfer module, where the transfer module picks it up and transfers it to the AOI inspection machine.

[0055] like Figure 5 As shown, the AOI inspection machine is the core of this platform, responsible for conducting comprehensive appearance defect inspection on the cleaned products.

[0056] Loading and Positioning: The product is placed and fixed onto the R-axis product fixture of the AOI inspection machine's five-axis inspection module by the transfer module. This five-axis inspection module has a structure similar to that of a cleaning machine, and is mounted on a marble base plate to ensure extremely high motion stability and positioning accuracy.

[0057] Image Acquisition: The five-axis inspection module carries the product into the inspection station. Under program control, the vision inspection system (including line scan cameras and area scan cameras positioned at different angles), in conjunction with the five-axis module, sequentially moves each area of ​​the product to be inspected to the optimal field of view and focal length of the camera, performing multi-angle, multi-position image acquisition. This moving imaging method greatly eliminates blind spots in the inspection process.

[0058] Data processing and unloading: The acquired image data is transmitted to the image processing system for analysis and judgment. After completion, the five-axis module moves the product to the unloading position, where the transfer module picks it up and transfers it to the unloading machine. At the same time, the detection result (good / defective product) signal is sent to the control system of the unloading machine.

[0059] like Figure 6 As shown, the feeding machine automatically sorts and collects products based on the detection results.

[0060] Empty pallet supply: A stack of empty pallets is manually placed into the empty pallet hopper. The Z-axis lifting module of the pallet lifting assembly operates, pushing out the bottom empty pallet, which is then received by its platform and lowered to the unloading position.

[0061] Product receiving and sorting: Products from the AOI inspection machine are first placed on the fixture of the product lifting assembly, which lifts the products to the transport height via a linear module.

[0062] Handling and palletizing: The picking and handling assembly (XYZ three-axis) picks up products from the product lifting assembly and, based on the received detection result signals, accurately places them into the corresponding good or defective product trays in the unloading assembly.

[0063] Full tray recovery: When a tray is full of products, the tray lifting assembly lifts the full tray and stores it temporarily, while the next empty tray is ejected from the empty tray hopper, and the cycle repeats. The equipment will alarm when all empty trays are used up or the hopper is full, prompting manual intervention.

[0064] The overall operation steps of this platform are as follows:

[0065] Loading Machine: ① Manually place multiple stacks of pallets loaded with products onto the platform of the loading and lifting assembly; ② The loading and lifting assembly lifts the pallets to the transport position; ③ The picking and transporting module removes the products from the pallets and transports them to the positioning assembly; ④ After the products are positioned on the positioning assembly by cylinders, the transfer assembly picks up and fixes the products onto the fixture, and then transports them to the cleaning machine; ⑤ When all the products in a pallet are removed, the loading and lifting assembly lifts the pallet to the empty pallet stacking assembly station, where the empty pallet is fixed in position after being positioned by cylinders; then the loading and lifting assembly descends to the transport position for the next picking and transporting operation; ⑥ After all pallets have been loaded, the equipment prompts the operator to remove the empty pallets.

[0066] Cleaning Machine: ① The product transported from the feeder stops moving when it passes above the first VPV cleaning module station. The VPV cleaning module starts, generating an ion airflow driven by the linear module to clean the product surface repeatedly. After cleaning for a certain period of time, the feeder's transfer module continues to move, transporting the product to the cleaning machine's flipping component; ② The fixture on the flipping component picks up and fixes the product, then the flipping shaft rotates 180°. After the rotation is complete, the lifting shaft descends, and the product is placed on the fixture of the transfer component; ③ The transfer component transports the product to below the transport component, and the transport component's Z-axis descends to pick up and fix the product on the fixture. After the pick-up is complete, the Z-axis rises, and then the product is transported above the second VPV cleaning module and stops moving; ④ The VPV cleaning module starts, generating an ion airflow driven by the linear module to clean the reverse side of the product; after cleaning is complete, the transport module continues to move, transporting the product to the cleaning machine.

[0067] Cleaning Machine: ① Products from the cleaning machine are placed on the R-axis product fixture of the five-axis motion cleaning assembly; ② After the fixture picks up and fixes the product, the Y-axis moves and moves to below the cleaning module, and then the Z-axis cleaning module descends and is positioned above the product; ③ The cylinder of the cleaning module descends, pressing the product against the cleaning fixture and cleaning cloth; ④ The motor of the cleaning module starts, the cleaning cloth is driven, and the cleaning medium is mixed to clean the product on the product fixture; ⑤ Through the five-axis motion system, the cleaning fixture cleans the product from multiple angles and positions; ⑥ After cleaning, the product is moved to below the transfer module, the Z-axis of the transfer module descends, the fixture picks up and fixes the product, then the product is lifted up and transported to the AOI inspection machine by the cylinder.

[0068] AOI Inspection Machine: ① Products transferred from the cleaning machine are placed on the R-axis product fixture of the five-axis inspection component; ② After the fixture picks up and fixes the product, the Y-axis moves and moves to below the inspection component; ③ The five-axis inspection component moves, and through the five-axis motion system, it performs multi-angle and multi-position inspection on the product; ④ After the inspection is completed, the product is moved to below the transfer module, the Z-axis of the transfer module descends, the fixture picks up and fixes the product, and then the product is lifted up and transported to the unloading machine by the action of the cylinder.

[0069] Unloading Machine: ① Manually place multiple stacks of empty pallets into the empty pallet hopper; ② The loading and lifting assembly's platform rises, retrieves an empty pallet from the empty pallet hopper, and then descends to the unloading position of the hopper; ③ Products from the AOI inspection machine are placed on the fixture of the product lifting assembly; ④ After the fixture picks up and fixes the product, the linear module of the product lifting assembly lifts and transports the product to the picking and handling position; ⑤ The picking and handling assembly moves the product from the fixture of the product lifting assembly to the pallet of the unloading hopper assembly; during the handling operation, products are divided into good and defective products, and then moved to the corresponding hopper pallets; ⑥ After the pallets of the unloading hopper assembly are full of products, the pallet lifting assembly rises, retrieves an empty pallet from the empty pallet hopper, and after retrieving all empty pallets, the pallet lifting assembly descends, then continues to wait for the picking and handling assembly to move products; ⑦ After all empty pallets are full of products, the equipment prompts the operator to operate.

[0070] As can be seen from the detailed embodiments described above, the key point of this utility model lies in the seamless integration of five specialized machines into a highly efficient joint inspection platform through modular layout and central collaborative control. The transport components between the machines are not only physical connections but also guarantees the synchronization of data and material flows. In particular, the tandem design of the cleaning machine and the washing machine constitutes a unique two-stage cleaning system, removing dust first and then contaminants, laying a solid foundation for high-precision visual inspection; while the application of the five-axis motion system in the cleaning and inspection stations enables comprehensive processing and observation of complex three-dimensional products without blind spots.

[0071] Ultimately, the beneficial effects of this invention are significant: it achieves full automation of the testing process, greatly improving production efficiency; through effective cleaning and flexible testing, it significantly reduces the false judgment rate and improves testing accuracy and reliability; its modular and flexible design also enables the equipment to quickly adapt to the production needs of different products, reducing the equipment investment costs for enterprises.

[0072] The above description is only a specific embodiment of the present utility model. Various examples and illustrations do not constitute a limitation on the substantive content of the present utility model. Those skilled in the art can make modifications or variations to the above-described specific embodiments after reading the description without departing from the essence and scope of the utility model.

Claims

1. An integrated multi-station automatic inspection device, characterized in that: This includes a feeding machine, a cleaning machine, a washing machine, an AOI inspection machine, and a unloading machine arranged sequentially along the product processing flow. The feeding machine, cleaning machine, washing machine, AOI inspection machine and unloading machine are connected by at least one conveying component for transferring products between adjacent machines; The feeding machine includes a feeding and lifting assembly for lifting the carrier tray, a material handling assembly for taking and transferring material from the carrier tray, a positioning assembly for accurately positioning the product, and an empty tray stacking assembly for collecting empty carrier trays. The cleaning machine includes a first VPV cleaning module, a flipping module, a second VPV cleaning module, and a transfer module. The first VPV cleaning module and the second VPV cleaning module are located on the upstream and downstream sides of the flipping module, respectively, so that the product is first cleaned by the first VPV cleaning module, then flipped 180° by the flipping module, and then the reverse side is cleaned by the second VPV cleaning module. The cleaning machine includes a multi-axis motion module and a cleaning module mounted thereon. The multi-axis motion module drives the cleaning module to perform multi-degree-of-freedom cleaning on the outer contour surface of the product. The AOI inspection machine includes a multi-axis inspection module and a vision inspection system. The multi-axis inspection module is used to clamp and drive the product to move, enabling the vision inspection system to acquire images of the product from multiple angles and positions. The unloading machine includes a dual unloading bin assembly for distinguishing between good and defective products, a product lifting assembly for receiving and lifting products, and a material handling assembly for transporting products from the product lifting assembly to the corresponding unloading bin.

2. The integrated multi-station automatic detection device as described in claim 1, characterized in that: The base of the cleaning machine and / or the AOI inspection machine is made of marble.

3. The integrated multi-station automatic detection device as described in claim 1, characterized in that: The cleaning module of the cleaning machine includes a cleaning cloth roll, a take-up shaft, a cleaning fixture, and a pressing cylinder. The pressing cylinder drives the cleaning fixture to press the cleaning cloth onto the product surface. The multi-axis motion module drives the product and the cleaning fixture to move relative to each other to achieve multi-angle cleaning.

4. The integrated multi-station automatic detection device as described in claim 1, characterized in that, The visual inspection system of the AOI inspection machine includes at least one line scan camera and at least one area scan camera.

5. The integrated multi-station automatic detection device as described in claim 1, characterized in that, The VPV cleaning module of the cleaning machine is driven by a linear module and can reciprocate relative to the product surface to generate an ion flow for cleaning.

6. The integrated multi-station automatic detection device as described in claim 1, characterized in that, The flipping module includes a fixture for holding the product, a flipping shaft for driving the fixture to flip 180°, and a lifting shaft for driving the fixture to move up and down.

7. The integrated multi-station automatic detection device as described in claim 1, characterized in that, The multi-axis detection module of the AOI inspection machine is a five-axis motion module, including X-axis, Y-axis, Z-axis, U-axis and R-axis. The end of the R-axis is provided with a product fixture for adsorbing and fixing the product.

8. The integrated multi-station automatic detection device as described in claim 1, characterized in that, The overall workflow of the platform is coordinated and controlled by the central control system. The detection result signal of the AOI inspection machine is fed back to the unloading machine to control it to sort good and bad products.

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