Automatic insertion detection and re-inspection method and system

Abstract

The present invention provides an automatic insertion detection and re-inspection method, comprising the following steps: sequentially placing products under test at first and second insertion stations of a loading module; a first camera photographing the product at the first insertion station and sending an image to a control module; the control module receiving the image to generate a driving instruction, so that an insertion module grabs and moves a member to be inserted and inserts said member into the product at the first insertion station; the first camera re-inspecting the quality of the product completing insertion, and a second camera simultaneously photographing the product at the second insertion station and sending an image to the control module; the control module receiving the image to generate an instruction, so that the insertion module grabs and moves a member to be inserted and inserts said member into the product at the second insertion station; the second camera re-inspecting the quality of the product completing insertion, and the first camera simultaneously positioning and photographing a next product under test; and cyclically executing the operations. The method enables parallel processing of positioning and re-inspection operations at a plurality of stations, significantly improving production efficiency, and shortening the waiting and switching time.

Description

An automatic insertion detection re-inspection method and system TECHNICAL FIELD

[0001] The present application belongs to the technical field of display panels, and particularly relates to an automatic insertion detection re-inspection method and system. BACKGROUND

[0002] In the liquid crystal display panel detection industry, before product lighting, an automatic pressure connection or automatic insertion method is usually used to ensure that the electrical signal is connected with the product, so as to realize the lighting function. This scheme is widely used in the process of automatic insertion of U-FPC and FFC, including taking materials, accurate positioning of photographing, insertion, and re-inspection after insertion. However, the current operation process has several challenges, mainly that the multi-step action leads to the extension of the site time, which cannot meet the high requirements of customers on production efficiency.

[0003] The prior art requires accurate positioning of photographing and re-inspection after insertion for each layer of the platform, and the accumulation of these steps increases the time cost of processing each product. In addition, most of the actions waste time in waiting, and fail to fully utilize the potential of the double-layer space, and cannot realize the advantage of processing multiple products at the same time. Therefore, it is crucial to seek a more efficient operation process and device optimization scheme to improve production efficiency and meet market demand. SUMMARY

[0004] In order to solve all or part of the problems of the above prior art, the present application provides an automatic insertion detection re-inspection method and system, which changes the arrangement direction of the photographing camera, realizes positioning and photographing and re-inspection at the same time on the upper and lower layers, and improves the efficiency of the device.

[0005] To achieve the above purpose, the present application provides the following technical scheme:

[0006] An automatic insertion detection re-inspection method, comprising the following steps: S1. sequentially placing products to be tested on a first insertion station and a second insertion station of a feeding module, using a first camera in a camera module to take a picture of the insertion point of the product to be tested in the first insertion station for positioning, and sending the picture to a control module; S2. The control module receives the image information taken by the first camera, generates a driving instruction according to the image information, drives the insertion module to grab and move the insertion part, and inserts the obtained insertion part into the insertion point of the product to be tested in the first insertion station; S3. After the insertion is completed, the first camera re-inspects the product to be tested in the first insertion station that has completed the insertion, and confirms the insertion quality; at the same time, a second camera in the camera module takes a picture of the insertion point of the product to be tested in the second insertion station for positioning, and sends the picture to the control module; S4. The control module receives the image information taken by the second camera, generates a driving instruction according to the image information, drives the insertion module to grab and move the insertion part, and inserts the obtained insertion part into the insertion point of the product to be tested in the second insertion station; S5. After the insertion is completed, the second camera re-inspects the product to be tested in the second insertion station that has completed the insertion, and confirms the insertion quality; at the same time, the first camera takes a picture of the insertion point of the next product to be tested in the first insertion station for positioning, and the above operations are repeated.

[0007] The method can take pictures for positioning and re-inspection at different stations simultaneously through the first camera and the second camera, and can process multiple insertion operations within the same time period. This parallel processing significantly shortens the processing time of each product, thereby improving the overall efficiency of the production line. Compared with the single camera taking pictures and checking one station at a time, this simultaneous method saves a lot of waiting and switching time.

[0008] The camera module includes at least one set of slidable camera components, and the first camera and the second camera are arranged in a staggered manner on the camera components. The staggered arrangement allows the cameras to capture images from different angles within the same time period, with the first camera re-inspecting the insertion point of the first layer of products to be tested, and the second camera positioning and taking pictures of the second layer of products to be tested, thereby shortening the operation time and improving the production efficiency.

[0009] The first insertion station or the second insertion station has three insertion points on each side of the product to be tested, and the camera components take pictures of each insertion point in sequence when taking pictures for positioning or re-inspection. After the camera components complete the picture taking, they slide to the initial position. The camera components operate in sequence according to the preset program, ensuring the consistency and accuracy of the operation.

[0010] Three first cameras and three second cameras are arranged on the camera assembly, and the camera assembly captures three insertion points at a time when positioning and photographing or reexamination photographing is performed. Each time of photographing can cover multiple insertion points, thereby saving a large amount of positioning and photographing time compared with sequentially photographing a single insertion point.

[0011] The control module receives image information captured by the first camera, verifies whether the to-be-tested product is correctly inserted at the first insertion station, removes the to-be-tested product if the insertion is correct, and places a new to-be-tested product. If the insertion is incorrect, the control module generates driving information and sends the driving information to the insertion module to drive the insertion module to remove the to-be-inserted part that fails to be inserted and reinsert the to-be-inserted part. Through real-time verification and automatic error correction, the control module helps to ensure the insertion quality of each product.

[0012] The application further provides an automatic insertion detection and reexamination system, comprising:

[0013] The loading module comprises a first insertion station and a second insertion station arranged in a staggered manner, and the first insertion station and the second insertion station are sequentially arranged with to-be-tested products. The insertion module is responsible for grabbing and moving a to-be-inserted part for insertion with the to-be-tested product, and inserting the to-be-inserted part into the corresponding insertion point of the to-be-tested product. The camera module is used for capturing a position image of the insertion point of the to-be-tested product and sending the captured image to the control module. The control module receives image information captured by the camera module, generates driving instructions according to the image information, and drives the insertion module to grab, move and insert the to-be-inserted part. The system comprises a loading module, an insertion module, a camera module and a control module, and through accurate image analysis and real-time feedback, each to-be-inserted part is accurately and efficiently inserted into a specified position, thereby effectively reducing human errors and improving the reliability of the production line.

[0014] The insertion module comprises a loading mechanism and a mechanical arm. The loading mechanism is used for placing the to-be-inserted part. The mechanical arm is used for grabbing the to-be-inserted part from the loading mechanism according to the driving instructions of the control module, and inserting the to-be-inserted part into the insertion point of the to-be-tested product at the first insertion station or the second insertion station. The cooperative operation of the loading mechanism and the mechanical arm ensures rapid and continuous insertion operation, thereby greatly reducing the time and cost of manual intervention.

[0015] The camera module comprises at least one set of slidable camera assembly. Each set of camera assembly comprises a first camera and a second camera arranged in a staggered manner. The first camera and the second camera correspond to the to-be-tested products at the first insertion station and the second insertion station, respectively. The first camera and the second camera can work at the same time without waiting, thereby improving the processing efficiency and response speed of the system.

[0016] The fixed focal lengths of the first camera and the second camera correspond to the positions of the products to be tested on the first insertion station and the second insertion station respectively. Because the focal lengths are fixed and aligned with specific positions, the shooting errors caused by focal length changes or position shifts can be significantly reduced.

[0017] The camera module includes two groups of camera assemblies, one group of which captures the insertion points on one side of the product to be tested on the first insertion station or the second insertion station, and the other group of which captures the insertion points on the other side of the product to be tested. The grouping design of the camera module allows the system to process data on both sides in parallel, improving the efficiency and processing capacity of the production line.

[0018] The present application has at least the following beneficial effects:

[0019] 1) The system uses multiple cameras to operate in parallel, which can simultaneously position and detect at different stations, significantly shortening the processing time of each product. Traditional single camera systems need to take pictures and check one by one, while this parallel processing method can handle multiple insertion operations in the same time period, effectively improving the overall efficiency of the production line. By operating multiple cameras simultaneously, the system can quickly acquire and process the data of the insertion points, greatly shortening the positioning and shooting time, and achieving a significant improvement in production efficiency.

[0020] 2) The automatic insertion and re-inspection process effectively reduces human intervention, thereby reducing errors and variables that may be introduced during the operation. Each product is operated in sequence according to the set program, ensuring the consistency and accuracy of the insertion. The multiple camera components provided by the system can capture images from different angles and perspectives, which helps to accurately position and detect, further ensuring a high level of insertion quality for each product. The real-time control module verifies the insertion quality and automatically corrects it when necessary, ensuring that each product meets the preset quality standards, thereby improving the overall product quality and production efficiency. BRIEF DESCRIPTION OF DRAWINGS

[0021] In order to more clearly illustrate the technical solutions in the specific embodiments of the present application, the following will briefly introduce the drawings needed to be used in the embodiment description. Obviously, the drawings described below are only some embodiments of the present application, and other drawings can also be obtained by those skilled in the art without creative labor on the basis of these drawings.

[0022] Figure 1 is a first perspective view of an automatic insertion detection and re-inspection system according to an embodiment of the present application.

[0023] Figure 2 is a second perspective view of an automatic insertion detection and re-inspection system according to an embodiment of the present application.

[0024] Fig. 3 is a schematic diagram of the structure of a camera module in an automatic insertion detection and re-inspection system according to an embodiment of the present application.

[0025] Reference signs: 1 - feeding module; 101 - first insertion station; 102 - second insertion station; 2 - camera module; 201 - camera assembly; 2011 - first camera; 2012 - second camera; 202 - gantry; 203 - linear module; 204 - sliding plate; 3 - insertion module; 301 - feeding mechanism; 302 - mechanical arm; 4 - product to be tested; 401 - insertion point. DETAILED DESCRIPTION

[0026] The technical solutions in the specific embodiments of the present application will be described clearly and completely below. Obviously, the described embodiments are only a part of the embodiments of the present application, rather than all the embodiments. Based on the embodiments in the present application, all other embodiments obtained by those of ordinary skill in the art without creative work fall within the scope of protection of the present application.

[0027] In the embodiments of the present application, in combination with reference to Figs. 1-3, an automatic insertion detection and re-inspection system includes the following: a feeding module 1, an insertion module 3, a camera module 2, and a control module. The feeding module 1 is designed with two insertion stations: a first insertion station 101 and a second insertion station 102, which are arranged in an up-down staggered manner and sequentially place the products to be tested, preparing for the subsequent insertion operation. The insertion module 3 is responsible for grabbing and moving the insertion piece to be inserted into the product to be tested, and inserting the obtained insertion piece to be inserted into the corresponding insertion point of the product to be tested. The camera module 2 is used to shoot the position image of the insertion point of the product to be tested, and send the shot image to the control module. The control module receives the image information transmitted by the camera module 2, generates driving instructions according to the image information, to drive the insertion module 3 to accurately grab, move and insert the insertion piece. This system operation process can effectively improve the precision and efficiency of the insertion operation, through the real-time monitoring of the camera module 2 and the intelligent driving of the control module, the accuracy of the insertion operation and the overall efficiency of the production line can be significantly improved, and human errors and resource waste can be reduced.

[0028] The plug-in module 3 includes a feeding mechanism 301 and a mechanical arm 302, which is designed to efficiently and accurately complete the plug-in task between the plug-in component and the product to be tested. The feeding mechanism 301 is used to place and position the plug-in component, and is also equipped with a camera module for capturing images of the plug-in component. These image data are transmitted to the control module for processing to generate driving instructions to ensure that the mechanical arm 302 can accurately grasp and move the plug-in component. The control module receives and analyzes the image information from the camera module, and dynamically generates driving instructions suitable for the current plug-in task in combination with the image data of the product to be tested. These instructions guide the mechanical arm 302 to accurately insert the plug-in component into the specified position of the target product at the system preset plug-in station.

[0029] The camera module 2 includes at least one set of slidable camera assemblies 201, each set of camera assemblies 201 including a first camera 2011 and a second camera 2012 distributed in an up-down staggered manner, for respectively shooting the products to be tested on the first plug-in station 101 and the second plug-in station 102. The cameras can be freely adjusted in position as needed to optimize the shooting angle and field of view. The fixed focal lengths of the first camera 2011 and the second camera 2012 respectively correspond to the positions of the products to be tested on the first plug-in station 101 and the second plug-in station 102, ensuring that the plug-in components on different stations can be accurately captured and recognized. In this embodiment, the camera module 2 includes two sets of camera assemblies 201, each set for shooting multiple plug-in points on the side of the product to be tested. One set of camera assemblies 201 is responsible for shooting three plug-in points on one side of the product to be tested, while the second set is specifically designed to shoot three plug-in points on the other side. In addition, the camera module 2 also includes a gantry 202 structure, one side of which is provided with a linear module 203, and the module is provided with a track for supporting the sliding of the camera assemblies 201. The camera assemblies 201 are installed on a sliding plate 204, which slides in the track of the gantry 202, thereby achieving precise control and adjustment of the camera position.

[0030] The application also provides an automatic insertion detection and re-inspection method, comprising the following steps: S1. placing the products to be tested on the first insertion station 101 and the second insertion station 102 of the feeding module 1 in turn, using the first camera 2011 in the camera module 2 to take a photo of the insertion point of the product to be tested in the first insertion station 101 for positioning, and sending the photographed image to the control module; S2. the control module receives the image information photographed by the first camera 2011, generates a driving instruction according to the image information, drives the insertion module 3 to grab and move the insertion part to be inserted, and inserts the obtained insertion part to be inserted into the insertion point of the product to be tested in the first insertion station 101; S3. after the insertion is completed, the first camera 2011 takes a re-inspection photo of the product to be tested in the first insertion station 101 which has completed the insertion, and confirms the insertion quality; at the same time, the second camera 2012 in the camera module 2 takes a photo of the insertion point of the product to be tested in the second insertion station 102 for positioning, and sends the photographed image to the control module; S4. the control module receives the image information photographed by the second camera 2012, generates a driving instruction according to the image information, drives the insertion module 3 to grab and move the insertion part to be inserted, and inserts the obtained insertion part to be inserted into the insertion point of the product to be tested in the second insertion station 102; S5. after the insertion is completed, the second camera 2012 takes a re-inspection photo of the product to be tested in the second insertion station 102 which has completed the insertion, and confirms the insertion quality; at the same time, the first camera 2011 takes a photo of the insertion point of the next product to be tested in the first insertion station 101 for positioning, and the above operation is repeated.

[0031] In step S3, the control module verifies the insertion condition of the product to be tested on the first insertion station 101 by receiving the image information photographed by the first camera 2011. If it is judged that the insertion is correct, the control module will instruct the first insertion station 101 to perform the discharging operation and place a new product to be tested to continue the production process. However, if the control module detects an insertion error, it will generate corresponding driving information and send it to the insertion module 3. At this time, the insertion module 3 will remove the insertion part to be inserted which fails to insert, and re-performs the insertion operation to ensure the assembly quality and accuracy of the product.

[0032] In the present embodiment, the camera module 2 is designed with two sets of slidable camera assemblies 201, each set of assembly is installed with a first camera 2011 and a second camera 2012, which are arranged in staggered manner on the camera assembly 201. In addition, in some specific embodiments, each camera assembly 201 can even be configured with three first cameras 2011 and three second cameras 2012. This configuration enables the camera assembly 201 to simultaneously capture multiple insertion points on each insertion station, greatly improving the efficiency of detection and re-inspection. When performing positioning photography or re-inspection photography, the camera assembly 201 will sequentially capture each insertion point, and after the camera assembly 201 completes the photography, it will slide to the initial position, preparing for the next round of positioning photography or re-inspection photography operation.

[0033] The present application realizes efficient and accurate automatic insertion detection and re-inspection operation through the cooperative work of multiple modules. The staggered arrangement of the two insertion stations and the coordinated work of the multiple camera assemblies 201 enable efficient insertion and detection process, reducing the waiting time. The automatic re-inspection function and error correction mechanism ensure the assembly quality of the final product and reduce the error risk brought by manual intervention.

[0034] It should be noted that for those skilled in the art, without departing from the principles of the present application, the present application can be improved and modified in several ways, and these improvements and modifications also fall within the scope of protection of the claims of the present application.

[0035] Enter the best mode description of the invention here.

Claims

1. An automatic plug-in detection review method, characterized by, The method comprises the following steps: S1. sequentially placing products to be tested on a first plug-in station (101) and a second plug-in station (102) of a feeding module (1), using a first camera (2011) in a camera module (2) to take a picture of a plug-in point of the product to be tested in the first plug-in station (101) for positioning, and sending the picture to a control module; S2. the control module receives the picture information taken by the first camera (2011), generates a driving instruction according to the picture information, drives a plug-in module (3) to grab and move a plug-in piece, and plugs the obtained plug-in piece into the plug-in point of the product to be tested in the first plug-in station (101); S3. after the plugging is completed, the first camera (2011) takes a recheck picture of the product to be tested in the first plug-in station (101) which has completed plugging, to confirm the plugging quality; at the same time, a second camera (2012) in the camera module (2) takes a picture of the plug-in point of the product to be tested in the second plug-in station (102) for positioning, and sends the picture to the control module; S4. the control module receives the picture information taken by the second camera (2012), generates a driving instruction according to the picture information, drives the plug-in module (3) to grab and move a plug-in piece, and plugs the obtained plug-in piece into the plug-in point of the product to be tested in the second plug-in station (102); S5. after the plugging is completed, the second camera (2012) takes a recheck picture of the product to be tested in the second plug-in station (102) which has completed plugging, to confirm the plugging quality; at the same time, the first camera (2011) takes a picture of the plug-in point of the next product to be tested in the first plug-in station (101) for positioning, and the above operation is repeated.

2. The method of claim 1, wherein, The camera module (2) comprises at least one set of slidable camera assembly (201), and the first camera (2011) and the second camera (2012) are arranged in an up-down staggered manner on the camera assembly (201).

3. The method of claim 2, wherein, The two sides of the product to be tested on the first plug-in station (101) or the second plug-in station (102) have three plug-in points respectively, and when taking a picture for positioning or rechecking, the camera assembly (201) takes a picture of each plug-in point in turn, and after the picture taking is completed, the camera assembly (201) slides to the initial position.

4. The method of claim 2, wherein, The camera assembly (201) is provided with three first cameras (2011) and three second cameras (2012), and when taking a picture for positioning or rechecking, the camera assembly (201) takes a picture of three plug-in points at a time.

5. The method of claim 1, wherein, In step S3, the control module receives image information captured by the first camera (2011), verifies whether the to-be-tested product is correctly plugged in the first plugging station (101); if the plugging is correct, the to-be-tested product is removed and a new to-be-tested product is placed; if the plugging is incorrect, the control module generates driving information and sends it to the plugging module (3) to drive the plugging module (3) to remove the to-be-plugged part that fails to be plugged and re-plug it.

6. An automated plug-in detection review system, comprising: Comprise: The feeding module (1) comprises a first plugging station (101) and a second plugging station (102) arranged in a staggered manner, and the first plugging station (101) and the second plugging station (102) are sequentially placed with to-be-tested products; The plugging module (3) is responsible for grabbing and moving the to-be-plugged part to be plugged with the to-be-tested product, and inserting the obtained to-be-plugged part into the corresponding plugging point of the to-be-tested product; The camera module (2) is used for capturing the position image of the plugging point of the to-be-tested product and sending the captured image to the control module; The control module receives the image information captured by the camera module (2), generates driving instructions according to the image information, and drives the plugging module (3) to grab, move and plug the to-be-plugged part.

7. The system of claim 6, wherein, The plugging module (3) comprises a feeding mechanism (301) and a mechanical arm (302), the feeding mechanism (301) is used for placing the to-be-plugged part; the mechanical arm (302) is used for obtaining the to-be-plugged part from the feeding mechanism (301) according to the driving instructions of the control module, and inserting it into the plugging point of the to-be-tested product in the first plugging station (101) or the second plugging station (102).

8. The system of claim 6, wherein, The camera module (2) comprises at least one set of slidable camera assembly (201), each set of camera assembly (201) comprises a first camera (2011) and a second camera (2012) arranged in a staggered manner, and the first camera (2011) and the second camera (2012) correspond to the first plugging station (101) and the second plugging station (102) respectively.

9. The system of claim 8, wherein, The fixed focal length of the first camera (2011) and the second camera (2012) corresponds to the position of the to-be-tested product on the first plugging station (101) and the second plugging station (102) respectively.

10. The system of claim 8, wherein, The camera module (2) comprises two sets of camera assemblies (201), one set of which captures the plugging point on one side of the to-be-tested product in the first plugging station (101) or the second plugging station (102), and the other set captures the plugging point on the other side of the to-be-tested product.

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