CN102980536B - Brake block steel back flatness detection system and method - Google Patents
Brake block steel back flatness detection system and method Download PDFInfo
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Abstract
A kind of brake block steel back flatness detection system and method, this system comprises: image collecting device, some pressure detection are popped one's head in, upper computer module and power supply, image collecting device is connected with upper computer module, is sent to upper computer module in order to the brake block image on Real-time Collection streamline; Pressure detection probe is connected with upper computer module, pressure field information in order to gather brake block is sent to upper computer module, upper computer module, in order to analyze the image collected and pressure field information, analyzes the defect of brake block, obtains flatness situation and qualification rate; Power supply is popped one's head in image collecting device, pressure detection respectively and upper computer module is connected, with thinking that image collecting device, pressure detection probe and upper computer module provide electric power.The present invention has without the need to Human disturbance, counting accurately, and precision is high, production efficiency is high, the advantage that reduction labour intensity, real-time are high, practical.
Description
Technical Field
The invention relates to the field of brake pad detection, in particular to a brake pad steel backing flatness detection system and method.
Background
The automobile brake pad is a key part for ensuring the running safety of an automobile, and the flatness of a steel backing product is an important form and position error factor related to the quality of the brake pad. However, the flatness of the steel back of the brake pad is generally detected by adopting a manual surface-beating method at present, the method takes the difference between the maximum reading and the minimum reading of each point on the surface of the detected steel back as the measurement result of the flatness error value, the evaluation of the flatness by the method does not meet the minimum condition, the accuracy is low, the skill requirement on workers is high, the workers are easy to fatigue after working for a long time, the labor intensity is high, the efficiency is low, and the measuring precision is easily influenced by misoperation caused by fatigue. Therefore, the technical problems of low measurement precision, low accuracy, high labor intensity and low efficiency exist in the manual surface-beating method for detecting the flatness of the steel backing product.
Disclosure of Invention
The invention aims to provide a brake pad steel backing flatness detection system, which solves the technical problems of low measurement precision, low accuracy, high labor intensity and low efficiency in the prior art of detecting the brake pad steel backing flatness by a manual meter-making method.
The invention further aims to provide a brake pad steel backing flatness detection method to solve the technical problems of low measurement precision, low accuracy, high labor intensity and low efficiency in the prior art of detecting the brake pad steel backing flatness by a manual meter-making method.
In order to achieve the above object, the present invention provides a brake pad steel backing flatness detecting system, which comprises: the device comprises an image acquisition device, a plurality of pressure detection probes, an upper computer module and a power supply, wherein the image acquisition device is connected with the upper computer module and used for acquiring brake pad images on a production line in real time and sending the brake pad images to the upper computer module; the pressure detection probe is connected with the upper computer module and used for collecting pressure field information of the brake pad and sending the pressure field information to the upper computer module, and the upper computer module is used for analyzing the collected image and the pressure field information, analyzing the defects of the brake pad and obtaining the flatness condition and the qualified rate; the power supply is respectively connected with the image acquisition device, the pressure detection probe and the upper computer module and is used for providing electric power for the image acquisition device, the pressure detection probe and the upper computer module; wherein, the host computer module further includes:
a human-computer interaction processing unit: the device is used for receiving the operation of a user, realizing initialization work and parameter setting, and displaying detection information and a detection result in real time;
an image acquisition unit: the image acquisition device is respectively connected with the human-computer interaction processing unit and the image acquisition device and used for driving the image acquisition device to acquire the brake pad image on the assembly line in real time according to the user operation received by the human-computer interaction processing unit and sending the acquired image to the image processing unit;
pressure field information acquisition unit: the pressure detection probe is respectively connected with the human-computer interaction processing unit and the pressure detection probe and is used for driving the pressure detection probe to collect pressure field information according to user operation received by the human-computer interaction processing unit and sending the collected pressure field information to the pressure field information processing unit;
an image processing unit: the image acquisition unit is connected with the brake pad, and is used for analyzing and processing the received brake pad image, analyzing the defects of the brake pad and obtaining qualified and unqualified products;
pressure field information processing unit: the pressure field information acquisition unit is connected with the pressure field information acquisition unit, the pressure field distribution condition of the brake pad is calculated, and the flatness of the brake pad is calculated;
a statistical processing unit: the system is connected with the image processing unit and the pressure field information processing unit, is used for counting the flatness and the qualification rate of a batch of brake pad products according to the processing results of the image processing unit and the pressure field information processing unit, and sends the flatness and the qualification rate to the man-machine interaction processing unit and the database; and the number of the first and second groups,
a database: the method is used for storing the flatness and the qualification rate information of one batch of brake pad products.
According to the flatness detecting system for the steel backing of the brake pad in the preferred embodiment of the invention, the image collecting device adopts a CMOS color camera.
According to the brake pad steel backing flatness detection system of the preferred embodiment of the invention, the statistical processing unit generates a report of the flatness and the qualification rate of a batch of brake pad products in an excel chart form and sends the report to the database and the man-machine interaction processing unit.
According to the flatness detecting system for the steel backing of the brake pad in the preferred embodiment of the invention, the number of the pressure detecting probes is 20.
In order to achieve the purpose, the invention also provides a brake pad steel backing flatness detection method, which comprises the following steps:
(1) receiving the operation of a user, and realizing initialization work and parameter setting;
(2) according to the operation of a user, driving an image acquisition device and a pressure detection probe to acquire a brake pad image and pressure field information on a production line in real time respectively;
(3) analyzing and processing the acquired brake pad image by adopting a gabor wavelet transform method, analyzing the defects of the brake pad, and obtaining qualified and unqualified products;
(4) calculating the pressure field distribution condition of the brake pad according to the acquired pressure field information, and calculating the flatness of the brake pad;
(5) and (4) counting the flatness and the qualification rate of the brake pad products of one batch according to the results of the step (3) and the step (4), displaying the detection information and the counting result in real time, and storing the counting result.
According to the method for detecting the flatness of the steel backing of the brake pad, the parameter setting in the step (1) comprises the following steps: the system comprises a parallax coefficient, a segmentation threshold, a region operator, a gabor parameter, a detection point related detection parameter, an effective detection point number, an X-axis correction coefficient and a Y-axis correction coefficient.
According to the method for detecting the flatness of the steel backing of the brake pad, the step (3) specifically comprises the following steps:
firstly, extracting Gabor transformation characteristics of a plurality of qualified samples, calculating the multi-direction and multi-scale Gabor transformation characteristics of each pixel point pixel by pixel, and forming Gabor characteristic representation of the brake pad steel backing;
and then, carrying out Gabor transformation on the defective brake pad products, matching and registering the defective brake pad products and the defective brake pad products, qualitatively analyzing the flatness of the brake pad products, and finding out the unqualified brake pad products.
According to the method for detecting the flatness of the steel backing of the brake pad in the preferred embodiment of the invention, the step (1) and the step (2) further comprise the following steps:
the pressure field information of steel backing products with good flatness is collected, the number of the collected pressure field information is 20, and standard templates for pressure field distribution are created and stored in a database through the standard pressure field information.
According to the method for detecting the flatness of the steel backing of the brake pad, the step (4) is specifically as follows: during measurement, a pressure field distribution diagram of a product to be measured is established by collecting pressure field information of the steel backing product to be measured, the pressure field distribution diagram is compared with a standard pressure field distribution diagram, and a deviation program of a pressure curve is used for calculating a flatness error, wherein the larger the deviation degree is, the lower the flatness is.
According to the method for detecting the flatness of the steel backing of the brake pad, the step (5) further comprises the following steps: and generating a report in the form of an excel chart for displaying and storing the flatness and the qualification rate of the brake pad products in one batch.
The automobile brake pad steel backing flatness detection system and method provided by the invention are simultaneously combined with an image method and a pressure field detection method, the running speed is high, the counting is accurate, and the intelligent judgment of the brake pad flatness and the statistics of the qualification rate are realized. The method acquires the defect condition of the brake pad through image acquisition and analysis, obtains the flatness of the brake pad by combining with pressure field information analysis processing, displays the detection information and the detection result in real time and stores the statistical result in the database. The invention combines the image method and the pressure field detection method, realizes the online real-time detection of the brake pad steel backing product, generates the report and inputs the report into the database for storage, has convenient system operation, greatly improves the accuracy and the efficiency of measurement and reduces the labor intensity. In addition, the invention also provides convenient query processing through the interactive processing of the database, facilitates subsequent query and further improves the accuracy. In addition, the invention can carry out flatness detection only by acquiring images by one CMOS camera and additionally configuring 20 pressure detection probes, has low manufacturing cost, saves a large amount of manpower and material resource costs and effectively reduces the production cost. Therefore, compared with the prior art, the invention has the advantages of no need of manual interference, accurate counting, high precision, high production efficiency, reduced labor intensity, high real-time performance, strong practicability and low cost.
Drawings
FIG. 1 is a schematic structural diagram of a brake pad steel backing flatness detection system of the present invention;
fig. 2 is a schematic diagram of a list of flatness of a batch of brake pad steel backs obtained by statistics according to an embodiment of the present invention.
Detailed Description
The present invention will be described in detail below with reference to the accompanying drawings.
Referring to fig. 1, a brake pad steel backing flatness detecting system includes: the device comprises image acquisition devices 1 and 20 pressure detection probes 2, an upper computer module 3 and a power supply 4, wherein the image acquisition devices 1 adopt CMOS color cameras which are connected with the upper computer module 3 and used for acquiring brake pad images on a production line in real time and sending the brake pad images to the upper computer module 3. The pressure detection probe 2 is connected with the upper computer module 3 and used for collecting pressure field information of the brake pad and sending the pressure field information to the upper computer module 3, and the upper computer module 3 is used for analyzing the collected image and the pressure field information, analyzing the defect of the brake pad and obtaining the flatness condition and the qualified rate; the power source 4 is respectively connected with the image acquisition device 1, the pressure detection probe 2 and the upper computer module 3 and is used for providing electric power for the image acquisition device 1, the pressure detection probe 2 and the upper computer module 3.
The upper computer module 3 further includes: the human-computer interaction processing unit 31: the device is used for receiving the operation of a user, realizing initialization work and parameter setting, and displaying detection information and a detection result in real time; the image acquisition unit 32: the device is respectively connected with the human-computer interaction processing unit 31 and the image acquisition device 1, and is used for driving the image acquisition device 1 to acquire a brake pad image on a production line in real time according to user operation received by the human-computer interaction processing unit 31, sending the acquired image to the image processing unit 34, and adjusting parameters such as exposure, gain and the like of a camera; pressure field information acquisition unit 33: the pressure detection probe 2 is respectively connected with the human-computer interaction processing unit 31 and the pressure detection probe 2, and is used for driving the pressure detection probe 2 to collect pressure field information according to user operation received by the human-computer interaction processing unit 31 and sending the collected pressure field information to the pressure field information processing unit 35; the image processing unit 34: the image acquisition unit 32 is connected with the brake pad, and is used for analyzing and processing the received brake pad image, analyzing the defects of the brake pad and obtaining qualified and unqualified products; pressure field information processing unit 35: the pressure field information acquisition unit 33 is connected with the pressure field information acquisition unit to calculate the pressure field distribution condition of the brake pad and calculate the flatness of the brake pad; the statistical processing unit 36: the image processing unit 34 and the pressure field information processing unit 35 are connected to count the flatness and the qualification rate of the brake pad product of one batch according to the processing results of the image processing unit 34 and the pressure field information processing unit 35, and generate a report of the flatness and the qualification rate of the brake pad product of one batch in the form of an excel chart to be sent to the database 37 and the human-computer interaction processing unit 31. The database 37: the method is used for storing the flatness and the qualification rate information of one batch of brake pad products.
Specifically, the image processing unit comprises a Gabor filter subunit, the two-dimensional Gabor filter can capture local structure information corresponding to spatial position, spatial frequency and direction selectivity, the two-dimensional Gabor filter has the property similar to a two-dimensional perception visual field profile of simple cells of a visual cortex of a mammal, and has stronger spatial position and direction selectivity, so that the two-dimensional Gabor filter is a very good feature extraction algorithm. The invention utilizes a Gabor filter to extract the characteristics: firstly, extracting Gabor transformation characteristics of a plurality of qualified samples, calculating the multi-direction and multi-scale Gabor transformation characteristics of each pixel point pixel by pixel, and forming Gabor characteristic representation of the brake pad steel backing; and then carrying out Gabor transformation on the defective brake pad product, and carrying out matching registration on the defective brake pad product and the defective brake pad product to obtain accurate flatness information. If a conventional matching registration strategy is adopted, matching information is difficult to obtain accurately, and further effective matching cannot be achieved, so that accurate defect information cannot be obtained.
Further, the parameter setting includes setting a parallax coefficient, a segmentation threshold, a region operator, a Gabor parameter, the number of detection points, an X-axis correction coefficient, and a Y-axis correction coefficient. Wherein,
the parallax coefficient is used for balancing space position conversion parameters between the image acquired by the CMOS and the signal value acquired by the detector, the parameters influence the fusion result of the two data, and the value range is 1-3.
The segmentation threshold is used for segmenting the area of the brake pad from the collected color image, the optimal brake pad area is obtained through graying and binaryzation of the color image, and the threshold range is 0.3-0.8.
The region operator is to reserve a characteristic edge region by using block region segmentation operation, remove a large-area flat region, and set a threshold value within a range of 3-8.
The Gabor parameters are changed by the size of a frequency domain window of an inline Gabor filter and a directional operator, the prominent local features and the general global flat features are obtained through Gabor transformation in different directions and scales, and the value range of the operator is 2-6.
The number of the detection points is the number of effective detectors of the device, and the larger the size of the brake pad steel back is, the larger the detection points are required.
And the X-axis correction coefficient performs X-axis correction on the acquired effective signal value of the detection point so as to eliminate the interference of the mounting position on the detection signal.
And the Y-axis correction coefficient performs Y-axis correction on the acquired effective signal value of the detection point so as to eliminate the interference of the mounting position on the detection signal.
Based on the system, the invention also provides a brake pad steel backing flatness detection method, which comprises the following steps:
(1) and receiving the operation of a user, and realizing initialization work and parameter setting.
The user sets parameters through the human-computer interaction processing unit 21, and the specific parameter setting includes: the system comprises a parallax coefficient, a segmentation threshold, a region operator, a gabor parameter, a detection point related detection parameter, an effective detection point number, an X-axis correction coefficient and a Y-axis correction coefficient.
(2) According to the operation of a user, the image acquisition device and the pressure detection probe are respectively driven to acquire the brake pad image and the pressure field information on the production line in real time.
The image acquisition unit 32 and the pressure field information acquisition unit 33 respectively drive the CMOS color camera and the corresponding pressure detection probe 2 to acquire the brake pad image and the pressure field information of the brake pad on the production line in real time according to the relevant parameters set in the step (1).
(3) And analyzing and processing the acquired brake pad image by adopting a gabor wavelet transform method, analyzing the defects of the brake pad, and obtaining qualified and unqualified products. The method specifically comprises the following steps:
firstly, extracting Gabor transformation characteristics of a plurality of qualified samples, calculating the multi-direction and multi-scale Gabor transformation characteristics of each pixel point pixel by pixel, and forming Gabor characteristic representation of the brake pad steel backing;
and then, carrying out Gabor transformation on the defective brake pad products, matching and registering the defective brake pad products and the defective brake pad products, qualitatively analyzing the flatness of the brake pad products, and finding out the unqualified brake pad products.
(4) And calculating the pressure field distribution condition of the brake pad according to the acquired pressure field information, and calculating the flatness of the brake pad.
During measurement, a pressure field distribution diagram of a product to be measured is established by collecting pressure field information of the steel backing product to be measured, the pressure field distribution diagram is compared with a standard pressure field distribution diagram, and a deviation program of a pressure curve is used for calculating a flatness error, wherein the larger the deviation degree is, the lower the flatness is.
(5) And (4) counting the flatness and the qualification rate of the brake pad products of one batch according to the results of the step (3) and the step (4), displaying the detection information and the counting result in real time, and storing the counting result.
The statistical processing unit 36 performs statistics on the flatness and the qualification rate of a batch of brake pad products according to the processing results of the image processing unit 34 and the pressure field information processing unit 35, and generates a report of the flatness and the qualification rate of a batch of brake pad products in the form of an excel chart to be sent to the database 37 and the human-computer interaction processing unit 31. As shown in fig. 2, which is a schematic diagram of a list of flatness of a batch of brake pad steel backs statistically obtained according to an embodiment of the present invention, the flatness value in the table represents the flatness of a steel back product, and a smaller value indicates a smaller error and a better flatness.
In the above method, between the step (1) and the step (2), further comprising: the pressure field information of steel backing products with good flatness is collected, the number of the collected pressure field information is 20, and standard templates for pressure field distribution are created and stored in a database through the standard pressure field information.
The invention combines the image method and the pressure field detection method, realizes the online real-time detection of the brake pad steel backing product, generates the report and inputs the report into the database for storage, has convenient system operation, greatly improves the accuracy and the efficiency of measurement and reduces the labor intensity. In addition, the invention also provides convenient query processing through the interactive processing of the database, facilitates subsequent query and further improves the accuracy. In addition, the invention can carry out flatness detection only by acquiring images by one CMOS camera and additionally configuring 20 pressure detection probes, has low manufacturing cost, saves a large amount of manpower and material resource costs and effectively reduces the production cost. Therefore, compared with the prior art, the invention has the advantages of no need of manual interference, accurate counting, high precision, high production efficiency, reduced labor intensity, high real-time performance, strong practicability and low cost.
The above description is only a preferred embodiment of the present invention, and is not intended to limit the present invention in any way, and any simple modification, equivalent change and modification made to the above embodiment according to the technical spirit of the present invention are within the scope of the present invention without departing from the content of the technical solution of the present invention.
Claims (10)
1. The utility model provides a brake block steel backing flatness detecting system which characterized in that includes: the device comprises an image acquisition device, a plurality of pressure detection probes, an upper computer module and a power supply, wherein the image acquisition device is connected with the upper computer module and used for acquiring brake pad images on a production line in real time and sending the brake pad images to the upper computer module; the pressure detection probe is connected with the upper computer module and used for collecting pressure field information of the brake pad and sending the pressure field information to the upper computer module, and the upper computer module is used for analyzing the collected image and the pressure field information, analyzing the defects of the brake pad and obtaining the flatness condition and the qualified rate; the power supply is respectively connected with the image acquisition device, the pressure detection probe and the upper computer module and is used for providing electric power for the image acquisition device, the pressure detection probe and the upper computer module; wherein, the host computer module further includes:
a human-computer interaction processing unit: the device is used for receiving the operation of a user, realizing initialization work and parameter setting, and displaying detection information and a detection result in real time;
an image acquisition unit: the image acquisition device is respectively connected with the human-computer interaction processing unit and the image acquisition device and used for driving the image acquisition device to acquire the brake pad image on the assembly line in real time according to the user operation received by the human-computer interaction processing unit and sending the acquired image to the image processing unit;
pressure field information acquisition unit: the pressure detection probe is respectively connected with the human-computer interaction processing unit and the pressure detection probe and is used for driving the pressure detection probe to collect pressure field information according to the user operation received by the human-computer interaction processing unit and sending the collected pressure field information to the pressure field information processing unit;
an image processing unit: the image acquisition unit is connected with the brake pad and used for analyzing and processing the received brake pad image, analyzing the defects of the brake pad and obtaining qualified and unqualified products;
pressure field information processing unit: the pressure field information acquisition unit is connected with the pressure field information acquisition unit, the pressure field distribution condition of the brake pad is calculated, and the flatness of the brake pad is calculated;
a statistical processing unit: the system is connected with the image processing unit and the pressure field information processing unit, is used for counting the flatness and the qualification rate of a batch of brake pad products according to the processing results of the image processing unit and the pressure field information processing unit, and sends the flatness and the qualification rate to the man-machine interaction processing unit and the database; and the number of the first and second groups,
a database: the method is used for storing the flatness and the qualification rate information of one batch of brake pad products.
2. The brake pad steel backing flatness detection system of claim 1, wherein said image capture device employs a CMOS color camera.
3. The brake pad steel backing flatness detection system of claim 1, wherein the statistical processing unit sends a flatness and yield condition generation report of a batch of brake pad products to the database and the man-machine interaction processing unit in the form of an excel chart.
4. The brake pad steel backing flatness detecting system of claim 1, wherein the number of said pressure detecting probes is 20.
5. A method for detecting flatness of a steel backing of a brake pad based on the system for detecting flatness of a steel backing of a brake pad of any one of claims 1 to 4, comprising the steps of:
(1) receiving the operation of a user, and realizing initialization work and parameter setting;
(2) according to the operation of a user, driving an image acquisition device and a pressure detection probe to acquire a brake pad image and pressure field information on a production line in real time respectively;
(3) analyzing and processing the acquired brake pad image by adopting a gabor wavelet transform method, analyzing the defects of the brake pad, and obtaining qualified and unqualified products;
(4) calculating the pressure field distribution condition of the brake pad according to the acquired pressure field information, and calculating the flatness of the brake pad;
(5) and (4) counting the flatness and the qualification rate of the brake pad products of one batch according to the results of the step (3) and the step (4), displaying the detection information and the counting result in real time, and storing the counting result.
6. The method for detecting the flatness of the steel backing of the brake pad according to claim 5, wherein the parameter setting in the step (1) comprises the following steps: the system comprises a parallax coefficient, a segmentation threshold, a region operator, a gabor parameter, a detection point related detection parameter, an effective detection point number, an X-axis correction coefficient and a Y-axis correction coefficient.
7. The method for detecting the flatness of the steel back of the brake pad according to claim 5, wherein the step (3) specifically comprises the following steps:
firstly, extracting Gabor transformation characteristics of a plurality of qualified samples, calculating the multi-direction and multi-scale Gabor transformation characteristics of each pixel point pixel by pixel, and forming Gabor characteristic representation of the brake pad steel backing;
and then, carrying out Gabor transformation on the defective brake pad products, matching and registering the defective brake pad products and the defective brake pad products, qualitatively analyzing the flatness of the brake pad products, and finding out the unqualified brake pad products.
8. The method for detecting the flatness of the steel back of the brake pad according to claim 5, wherein the steps (1) and (2) further comprise:
the pressure field information of steel backing products with good flatness is collected, the number of the collected pressure field information is 20, and standard templates for pressure field distribution are created and stored in a database through the standard pressure field information.
9. The method for detecting the flatness of the steel back of the brake pad according to claim 8, wherein the step (4) is specifically as follows: during measurement, a pressure field distribution diagram of a product to be measured is established by collecting pressure field information of the steel backing product to be measured, the pressure field distribution diagram is compared with a standard pressure field distribution diagram, and a deviation program of a pressure curve is used for calculating a flatness error, wherein the larger the deviation degree is, the lower the flatness is.
10. The method for detecting the flatness of the steel backing of the brake pad according to claim 5, wherein the step (5) further comprises: and generating a report in the form of an excel chart for displaying and storing the flatness and the qualification rate of the brake pad products in one batch.
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| CN103743367A (en) * | 2014-02-07 | 2014-04-23 | 通富热处理(昆山)有限公司 | Automatic detection device of automobile brake disc |
| CN105258727B (en) * | 2015-10-28 | 2017-07-04 | 中国计量学院 | Brake block backboard automatic detection device based on machine vision |
| CN112834515B (en) * | 2020-12-30 | 2022-09-23 | 常州创度信息技术有限公司 | Product surface detection system based on image processing |
| CN114184143A (en) * | 2021-11-22 | 2022-03-15 | 惠州高盛达科技有限公司 | PCB flatness measuring method and device |
| CN118268986B (en) * | 2024-06-03 | 2024-09-10 | 江苏甬金金属科技有限公司 | Polishing device with flatness detection function for stainless steel belt surface |
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