CN106670127B - Full-automatic visual inspection system of screen defect - Google Patents
Full-automatic visual inspection system of screen defect Download PDFInfo
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- CN106670127B CN106670127B CN201710130989.1A CN201710130989A CN106670127B CN 106670127 B CN106670127 B CN 106670127B CN 201710130989 A CN201710130989 A CN 201710130989A CN 106670127 B CN106670127 B CN 106670127B
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B07—SEPARATING SOLIDS FROM SOLIDS; SORTING
- B07C—POSTAL SORTING; SORTING INDIVIDUAL ARTICLES, OR BULK MATERIAL FIT TO BE SORTED PIECE-MEAL, e.g. BY PICKING
- B07C5/00—Sorting according to a characteristic or feature of the articles or material being sorted, e.g. by control effected by devices which detect or measure such characteristic or feature; Sorting by manually actuated devices, e.g. switches
- B07C5/34—Sorting according to other particular properties
- B07C5/342—Sorting according to other particular properties according to optical properties, e.g. colour
- B07C5/3422—Sorting according to other particular properties according to optical properties, e.g. colour using video scanning devices, e.g. TV-cameras
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B07—SEPARATING SOLIDS FROM SOLIDS; SORTING
- B07C—POSTAL SORTING; SORTING INDIVIDUAL ARTICLES, OR BULK MATERIAL FIT TO BE SORTED PIECE-MEAL, e.g. BY PICKING
- B07C5/00—Sorting according to a characteristic or feature of the articles or material being sorted, e.g. by control effected by devices which detect or measure such characteristic or feature; Sorting by manually actuated devices, e.g. switches
- B07C5/02—Measures preceding sorting, e.g. arranging articles in a stream orientating
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B07—SEPARATING SOLIDS FROM SOLIDS; SORTING
- B07C—POSTAL SORTING; SORTING INDIVIDUAL ARTICLES, OR BULK MATERIAL FIT TO BE SORTED PIECE-MEAL, e.g. BY PICKING
- B07C5/00—Sorting according to a characteristic or feature of the articles or material being sorted, e.g. by control effected by devices which detect or measure such characteristic or feature; Sorting by manually actuated devices, e.g. switches
- B07C5/36—Sorting apparatus characterised by the means used for distribution
- B07C5/361—Processing or control devices therefor, e.g. escort memory
- B07C5/362—Separating or distributor mechanisms
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B07—SEPARATING SOLIDS FROM SOLIDS; SORTING
- B07C—POSTAL SORTING; SORTING INDIVIDUAL ARTICLES, OR BULK MATERIAL FIT TO BE SORTED PIECE-MEAL, e.g. BY PICKING
- B07C2301/00—Sorting according to destination
- B07C2301/0008—Electronic Devices, e.g. keyboard, displays
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Abstract
The invention relates to a full-automatic visual detection system for screen defects, which comprises a controller, and an automatic feeding unit, an automatic detection unit and an automatic classification blanking unit which are respectively connected with the controller, wherein the automatic feeding unit, the automatic detection unit and the automatic classification blanking unit are sequentially arranged to form an automatic assembly line; the automatic feeding unit conveys the screen to be detected to the automatic detection unit, the automatic detection unit carries out automatic defect detection to determine whether the screen belongs to a good product or a defective product, and the automatic classification discharging unit obtains the screen which is detected completely from the automatic detection unit and carries out classification output according to a detection result. Compared with the prior art, the invention has the advantages of high automation degree, simple operation in the whole detection process, reduced labor intensity of workers, saved human capital and improved production efficiency.
Description
Technical Field
The invention relates to a screen defect detection system, in particular to a full-automatic visual detection system for screen defects.
Background
With the rapid development of the scientific and technical level, liquid crystal display electronic products, especially smart phones, become an indispensable important component in people's daily life. There is also a higher demand for the quality of the screen. In the production process of thin electronic products such as liquid crystal screens, mobile phone touch screen glass and the like, various defects (such as screen scratch, glass screen stain, glass screen dimension inconsistency, edge breakage, sawtooth, unfilled corner and the like) cannot be completely avoided due to objective factors such as production process and the like. Therefore, the appearance of the screen needs to be checked before each process.
The appearance defect detection of traditional LCD screen, cell-phone glass class product relies on special light source or the artifical inspection that the projecting apparatus carried out mainly, because the influence factor that artifical detected is more, not only accuracy and the standard unity that not only detect can't guarantee, also can't satisfy the needs of modern enterprise's quick production in batches.
The existing automatic detection device can only detect screens of certain variety sizes, can only detect large defects generally, cannot measure the actual sizes of the defects, cannot set detection standards according to actual production needs, and is low in automation degree. If the patent (publication No. CN205643188U, publication No. CN205301189U) has no automatic loading and unloading mechanism, the efficiency is not high. At present, an efficient, accurate and reliable detection system is urgently needed to replace manual detection.
Disclosure of Invention
The invention aims to overcome the defects of the prior art and provide a full-automatic visual detection system for screen defects.
The purpose of the invention can be realized by the following technical scheme:
a full-automatic visual detection system for screen defects comprises a controller, and an automatic feeding unit, an automatic detection unit and an automatic classification blanking unit which are respectively connected with the controller, wherein the automatic feeding unit, the automatic detection unit and the automatic classification blanking unit are sequentially arranged to form an automatic production line;
the automatic feeding unit conveys the screen to be detected to the automatic detection unit, the automatic detection unit carries out automatic defect detection to determine whether the screen belongs to a good product or a defective product, and the automatic classification discharging unit obtains the screen which is detected completely from the automatic detection unit and carries out classification output according to a detection result.
The automatic feeding unit comprises a Y-direction full-load tray feeding mechanism, a first X-direction tray conveying mechanism, a first tray fixing mechanism, a Y-direction empty tray discharging mechanism and a feeding manipulator which are respectively connected with the controller, the direction in which the automatic feeding unit, the automatic detection unit and the automatic classification discharging unit are sequentially arranged is determined as a Y direction, the direction perpendicular to the Y direction on the horizontal plane is determined as an X direction, the direction perpendicular to the horizontal plane is a Z direction, the Y-direction full-load tray feeding mechanism and the Y-direction empty tray discharging mechanism are arranged in parallel along the Y direction and move along the Y direction, the first X-direction tray conveying mechanism stretches across the Y-direction full-load tray feeding mechanism and the Y-direction empty tray discharging mechanism, the first tray fixing mechanism is arranged on the first X-direction tray conveying mechanism, and in an initial working state, the first tray fixing mechanism is positioned above the Y-direction full-load tray feeding mechanism, the feeding manipulator is arranged above the first X-direction tray conveying mechanism;
y is to full-load tray feed mechanism drive fill with the tray of waiting to detect the screen to being close to the motion of automated inspection unit direction and carrying the tray to first tray fixed establishment, and feeding manipulator absorbs the screen that waits to detect to automated inspection unit from the tray, treats that the screen that waits to detect in the sucking disc is whole to have absorbed the back, and first X is to tray transport mechanism drive first tray fixed establishment along X direction motion to Y to empty tray unloading mechanism top, and Y exports empty tray to empty tray unloading mechanism.
The automatic detection unit comprises a screen front detection mechanism, a turnover mechanism, a screen carrying mechanism and a screen back detection mechanism which are respectively connected with the controller, wherein the screen front detection mechanism and the screen back detection mechanism are distributed in the diagonal direction, the turnover mechanism is arranged at the tail end of the screen front detection mechanism, the screen carrying mechanism is arranged between the turnover mechanism and the screen back detection mechanism, and the tail end of the screen carrying mechanism is aligned to the front end of the screen back detection mechanism.
The front detection mechanism of screen and the reverse detection mechanism of screen structure the same, all include screen conveying tray, Y to transmission module, detection camera, light source and camera support, the detection camera set up at camera support top, light source set up under the detection camera and fix on camera support, Y transversely set up in light source below to transmission module, screen transmission tray set up on Y is to transmission module, Y all connect to transmission module, detection camera and light source the controller.
The turnover mechanism comprises a screen turnover suction claw and a U-direction servo motor which are respectively connected with the controller, and the U-direction servo motor is connected with the screen turnover suction claw;
the screen overturning suction claw sucks and conveys the screen to the tail end of the front detection mechanism, and the U drives the screen overturning suction claw to overturn for 180 degrees to realize screen overturning to the servo motor.
The screen carrying mechanism comprises a screen carrying suction claw and an X-direction transmission module which are respectively connected with the controller, the X-direction transmission module is arranged along the X direction, and the screen carrying suction claw is arranged at one end, close to the turnover mechanism, of the X-direction transmission module.
The automatic sorting and blanking unit comprises a Y-direction empty tray feeding mechanism, a second X-direction tray conveying mechanism, a second tray fixing mechanism, a good tray blanking mechanism, a defective tray blanking mechanism and a blanking manipulator which are respectively connected with the controller, the Y-direction empty tray feeding mechanism, the good tray blanking mechanism and the defective tray blanking mechanism are arranged in parallel along the Y direction, the Y-direction empty tray feeding mechanism is arranged between the good tray blanking mechanism and the defective tray blanking mechanism, the Y-direction empty tray feeding mechanism, the good tray blanking mechanism and the defective tray blanking mechanism are arranged along the Y direction in a moving way, the second X-direction tray conveying mechanism stretches over the Y-direction empty tray feeding mechanism, the good tray blanking mechanism and the defective tray blanking mechanism, the second tray fixing mechanism is arranged on the second X-direction tray conveying mechanism and moves along the X direction, the blanking manipulator is arranged above the middle part of the second X-direction tray conveying mechanism and above the second tray fixing mechanism, and the motion direction of the Y-direction empty tray feeding mechanism is opposite to that of the good-product tray blanking mechanism and the defective-product tray blanking mechanism;
the automatic detection device comprises an initial position, a second tray fixing mechanism is located right below the tail end of a Y-direction empty tray feeding mechanism, the Y-direction empty tray feeding mechanism drives an empty tray to move to the position below the second tray fixing mechanism, the second tray fixing mechanism fixes the empty tray, a second X-direction tray conveying mechanism drives the second tray fixing mechanism to move along the X direction, the tray is conveyed to a good product tray discharging mechanism or a defective product tray discharging mechanism, a discharging mechanical arm sucks a detected screen according to the detection result of an automatic detection unit and places the detected screen in the tray in the good product tray discharging mechanism or the defective product tray discharging mechanism, and after the screen is filled in the tray in the good product tray discharging mechanism or the defective product tray discharging mechanism, the tray discharging mechanism or the defective product tray discharging mechanism moves along the Y direction to discharge the tray.
Y to full-load tray feed mechanism, Y to empty tray unloading mechanism, Y to empty tray feed mechanism, non-defective products tray unloading mechanism and defective products tray unloading mechanism structure the same, all include support, Y to removing cylinder, Z to lift servo module and Z to the lift fork hand, Y to removing cylinder level setting on the support, the tray setting is on Y to removing the cylinder, Z to the perpendicular setting of lift servo module in support one end, Z to the lift fork hand be on a parallel with Y to remove the cylinder to fix on Z to lift servo module, Y to removing cylinder and Z all connect to lift servo module the controller.
First X all includes X to servo motor, hold-in range and two linear guide along X direction parallel arrangement to tray transport mechanism and second X, first tray fixed establishment or second tray fixed establishment span respectively on two linear guide, X connect the hold-in range to servo motor, the hold-in range connect first tray fixed establishment or second tray fixed establishment, X all connect to servo motor and hold-in range the controller.
First tray fixed establishment and second tray fixed establishment all include carriage and centre gripping cylinder, the carriage slide to set up first X to tray transport mechanism or second X to tray transport mechanism on, the centre gripping cylinder set up a plurality ofly and evenly distributed in the carriage both sides, during the fixed tray, the motion of centre gripping cylinder withstands tray both sides lateral wall, the centre gripping cylinder connect the controller.
Compared with the prior art, the invention has the following advantages:
(1) according to the invention, the automatic feeding unit is arranged to realize automatic feeding of the screen to be detected, the automatic detection unit automatically detects defects, the automatic classification blanking unit outputs good products and defective products in a classification manner according to detection results after detection is finished, the whole process integrates automatic feeding, automatic classification of the rear-end good products and defective products and production information statistics, the whole detection process is simple to operate, the labor intensity of workers is reduced, the manpower and capital are saved, and the production efficiency is improved;
(2) according to the automatic feeding unit, the Y-direction full-load tray feeding mechanism and the Y-direction empty tray discharging mechanism are arranged in parallel, the tray is circularly transferred through the first X-direction tray conveying mechanism and the first tray fixing mechanism, the structure is compact, the circular operation can be realized, a full-automatic production line is realized, and the working efficiency is improved;
(3) the automatic detection unit is provided with the turnover mechanism, so that the detection of the front side and the back side of the screen is continuously finished, and the working efficiency is further improved;
(4) the screen front detection mechanism and the screen back detection mechanism are provided with the detection camera and the illumination light source, and the screen moves below the illumination light source and shoots images, so that visual detection is realized, detection of multiple defects including edge breakage, corner breakage, scratches, sawteeth and the like can be performed at the same time, the actual size of the defect can be measured, setting is convenient, and the detection precision is high;
(5) the automatic sorting and discharging unit is provided with the Y-direction empty tray feeding mechanism, the good tray discharging mechanism and the defective tray discharging mechanism which are arranged side by side, so that automatic feeding of empty trays and automatic discharging of good products and defective products are realized, the structure is stable and compact, and the implementation is convenient.
Drawings
FIG. 1 is a front view of a fully automatic visual inspection system for screen defects according to the present invention;
FIG. 2 is a schematic perspective view of an automatic loading unit according to the present invention;
FIG. 3 is a schematic perspective view of a Y-direction full-loading tray feeding mechanism according to the present invention;
FIG. 4 is a schematic perspective view of a first X-direction tray conveying mechanism and a first tray fixing mechanism according to the present invention;
FIG. 5 is a schematic perspective view of an automatic detection unit according to the present invention;
FIG. 6 is a schematic perspective view of the automatic sorting and blanking unit according to the present invention;
FIG. 7 is a schematic perspective view of the Y-direction empty pallet feeding mechanism of the present invention;
fig. 8 is a schematic perspective view of the second X-direction tray conveying mechanism and the second tray fixing mechanism.
In the figure, 1 is a Y-direction full-loading tray feeding mechanism, 2 is a first X-direction tray conveying mechanism, 3 is a Y-direction empty tray discharging mechanism, 4 is a feeding manipulator, 5 is a first Y-direction conveying cylinder, 6 is a first Z-direction lifting servo module, 7 is a first Z-direction lifting fork, 8 is a full-loading tray, 9 is a first X-direction servo motor, 10 is a first synchronous belt, 11 is a first linear guide rail, 12, 13, 14, 15, 16, 17, 18 and 19 are first clamping cylinders, 20 is a first screen conveying tray, 21 is a first Y-direction transmission module, 22 is a first detection camera, 23 is a first illumination light source, 24 is a first camera bracket, 25 is a screen overturning suction claw, 26 is a U-direction servo motor, 27 is a screen conveying suction claw, 28 is an X-direction transmission module, 29 is a second screen conveying tray, 30 is a second Y-direction transmission module, 31 is a second detection camera, reference numeral 32 denotes a second illumination light source, 33 denotes a second camera holder, 34 denotes a Y-direction empty tray feeding mechanism, 35 denotes a second X-direction tray conveying mechanism, 36 denotes a good product tray blanking mechanism, 37 denotes a defective product tray blanking mechanism, 38 denotes a blanking robot, 39 denotes a second Y-direction conveying cylinder, 40 denotes a second Z-direction elevation servo module, 41 denotes a second Z-direction elevation fork, 42 denotes an empty tray, 43 denotes a second X-direction servo motor, 44 denotes a second timing belt, 45 denotes a second linear guide, and 46, 47, 48, 49, 50, and 51 denote second clamping cylinders.
Detailed Description
The invention is described in detail below with reference to the figures and specific embodiments.
Examples
As shown in fig. 1, a full-automatic visual inspection system for screen defects comprises a controller, and an automatic feeding unit, an automatic detection unit and an automatic classification discharging unit which are respectively connected with the controller, wherein the automatic feeding unit, the automatic detection unit and the automatic classification discharging unit are sequentially arranged to form an automatic assembly line; the automatic feeding unit conveys the screen to be detected to the automatic detection unit, the automatic detection unit carries out automatic defect detection to determine whether the screen belongs to a good product or a defective product, and the automatic classification discharging unit obtains the screen which is detected completely from the automatic detection unit and carries out classification output according to a detection result.
As shown in FIG. 2, the automatic feeding unit comprises a Y-direction full-loaded tray feeding mechanism 1, a first X-direction tray conveying mechanism 2, a first tray fixing mechanism, a Y-direction empty tray discharging mechanism 3 and a feeding manipulator 4 which are respectively connected with a controller, the direction in which the automatic feeding unit, the automatic detection unit and the automatic sorting discharging unit are sequentially arranged is determined as a Y direction, the direction perpendicular to the Y direction on the horizontal plane is determined as an X direction, the direction perpendicular to the horizontal plane is a Z direction, the Y-direction full-loaded tray feeding mechanism 1 and the Y-direction empty tray discharging mechanism 3 are arranged in parallel along the Y direction and are movably arranged along the Y direction, the first X-direction tray conveying mechanism 2 crosses over the Y-direction full-loaded tray feeding mechanism 1 and the Y-direction empty tray discharging mechanism 3, the first tray fixing mechanism is arranged on the first X-direction tray conveying mechanism 2, and in an initial working state, the first tray fixing mechanism is positioned above the Y-direction full-loaded tray feeding mechanism 1, the feeding manipulator 4 is arranged above the first X-direction tray conveying mechanism 2; y is to full-load tray feed mechanism 1 drive fill with the tray of waiting to detect the screen to being close to the motion of automated inspection unit direction and carrying the tray to first tray fixed establishment, and feeding manipulator 4 absorbs the screen that waits to detect to the automated inspection unit from the tray, treats that the screen that waits to detect in the sucking disc is whole to have absorbed the back, and first X is to tray transport mechanism 2 and drive first tray fixed establishment along X direction motion to Y to empty tray unloading mechanism 3 top, and Y exports empty tray 42 to empty tray unloading mechanism 3.
As shown in fig. 3, the Y-direction full-load tray feeding mechanism 1 includes a first support, a first Y-direction conveying cylinder 5, a first Z-direction lifting servo module 6 and a first Z-direction lifting fork 7, the first Y-direction conveying cylinder 5 is horizontally disposed on the first support, the full-load tray 8 is disposed on the Y-direction conveying cylinder, the first Z-direction lifting servo module 6 is vertically disposed at one end of the first support, the first Z-direction lifting fork 7 is parallel to the first Y-direction conveying cylinder 5 and fixed on the first Z-direction lifting servo module 6, and the first Y-direction conveying cylinder 5 and the first Z-direction lifting servo module 6 are both connected to a controller. The Y-direction empty tray discharging mechanism 3 and the Y-direction full-load tray feeding mechanism 1 are identical in structure, but the moving directions of the Y-direction empty tray discharging mechanism and the Y-direction full-load tray feeding mechanism are opposite, one of the Y-direction empty tray discharging mechanism and the Y-direction full-load tray feeding mechanism moves along the positive Y direction, and the other Y-direction full-load tray feeding mechanism moves along the negative Y direction.
As shown in fig. 4, the first X-direction tray conveying mechanism 2 includes a first X-direction servo motor 9, a first synchronous belt 10, and two first linear guide rails 11 arranged in parallel in the X direction, a first tray fixing mechanism straddles the two linear guide rails, the first X-direction servo motor 9 is connected to the first synchronous belt 10, the first synchronous belt 10 is connected to the first tray fixing mechanism, and both the first X-direction servo motor 9 and the first synchronous belt 10 are connected to the controller. First tray fixed establishment includes carriage and first die clamping cylinder, and including 12, 13, 14, 15, 16, 17, 18 and 19 in the first die clamping cylinder picture, the carriage slides and sets up on first X is to tray transport mechanism 2, and first die clamping cylinder sets up a plurality ofly and evenly distributed in the carriage both sides, and during the fixed tray, first die clamping cylinder moves and withstands tray both sides lateral wall, first die clamping cylinder connection director.
As shown in fig. 5, the automatic detection unit includes a screen front detection mechanism, a turnover mechanism, a screen carrying mechanism and a screen back detection mechanism, which are respectively connected with the controller, the screen front detection mechanism and the screen back detection mechanism are distributed in opposite directions, the turnover mechanism is arranged at the end of the screen front detection mechanism, the screen carrying mechanism is arranged between the turnover mechanism and the screen back detection mechanism, and the end of the screen carrying mechanism is aligned with the front end of the screen back detection mechanism.
The front detection mechanism of the screen and the back detection mechanism of the screen are identical in structure and comprise a screen conveying tray, the Y-direction transmission module, a detection camera, an illuminating light source and a camera support, the detection camera is arranged at the top of the camera support, the illuminating light source is arranged under the detection camera and fixed on the camera support, the Y-direction transmission module is transversely arranged below the illuminating light source, the screen transmission tray is arranged on the Y-direction transmission module, and the Y-direction transmission module, the detection camera and the illuminating light source are all connected with a controller. Specifically, the screen front side detection mechanism includes a first screen conveying tray 20, a first Y-direction transmission module 21, a first detection camera 22, a first illumination light source 23, and a first camera support 24, and the screen back side detection mechanism includes a second screen conveying tray 29, a second Y-direction transmission module 30, a second detection camera 31, a second illumination light source 32, and a second camera support 33, which are connected in the same manner as described above. The turnover mechanism comprises a screen turnover suction claw 25 and a U-direction servo motor 26 which are respectively connected with the controller, and the U-direction servo motor 26 is connected with the screen turnover suction claw 25; the screen overturning suction claw 25 sucks the screen conveyed to the tail end of the front detection mechanism, and the U drives the screen overturning suction claw 25 to overturn for 180 degrees to realize screen overturning to the servo motor 26. The screen conveying mechanism comprises a screen conveying suction claw 27 and an X-direction transmission module 28 which are respectively connected with the controller, the X-direction transmission module 28 is arranged along the X direction, and the screen conveying suction claw 27 is arranged at one end, close to the turnover mechanism, of the X-direction transmission module 28.
As shown in fig. 6, the automatic sorting and feeding unit includes a Y-direction empty tray 42 feeding mechanism 34, a second X-direction tray conveying mechanism 35, a second tray fixing mechanism, a good tray discharging mechanism 36, a defective tray discharging mechanism 37 and a feeding robot 38, which are connected to the controller, respectively, the Y-direction empty tray 42 feeding mechanism 34, the good tray discharging mechanism 36 and the defective tray discharging mechanism 37 are arranged in parallel in the Y direction, the Y-direction empty tray 42 feeding mechanism 34 is arranged between the good tray discharging mechanism 36 and the defective tray discharging mechanism 37, the Y-direction empty tray 42 feeding mechanism 34, the good tray discharging mechanism 36 and the defective tray discharging mechanism 37 are arranged to move in the Y direction, the second X-direction tray conveying mechanism 35 is arranged to cross over the Y-direction empty tray 42 feeding mechanism 34, the good tray discharging mechanism 36 and the defective tray discharging mechanism 37, the second tray fixing mechanism is arranged on the second X-direction tray conveying mechanism 35 and moves in the X direction, the blanking manipulator 38 is arranged above the middle part of the second X-direction tray conveying mechanism 35, the blanking manipulator 38 is arranged above the second tray fixing mechanism, and the movement direction of the Y-direction empty tray 42 feeding mechanism 34 is opposite to that of the good-product tray blanking mechanism 36 and the bad-product tray blanking mechanism 37; in the initial position, the second tray fixing mechanism is located right below the tail end of the Y-direction empty tray 42 feeding mechanism 34, the Y-direction empty tray 42 feeding mechanism 34 drives the empty tray 42 to move to the position below the second tray fixing mechanism, the second tray fixing mechanism fixes the empty tray 42, the second X-direction tray conveying mechanism 35 drives the second tray fixing mechanism to move along the X direction, the tray is conveyed to the good product tray blanking mechanism 36 or the defective product tray blanking mechanism 37, the blanking manipulator 38 sucks the detected screen according to the detection result of the automatic detection unit and places the screen in the good product tray blanking mechanism 36 or the defective product tray blanking mechanism 37, and after the screen is filled in the tray in the good product tray blanking mechanism 36 or the defective product tray blanking mechanism 37, the tray blanking mechanism or the defective product tray blanking mechanism 37 moves along the Y direction to discharge the tray.
As shown in fig. 7, the Y-direction empty tray feeding mechanism includes a second bracket, a second Y-direction conveying cylinder 39, a second Z-direction lifting servo module 40 and a second Z-direction lifting fork 41, the second Y-direction conveying cylinder 39 is horizontally disposed on the second bracket, the empty tray 42 is disposed on the Y-direction conveying cylinder, the second Z-direction lifting servo module 40 is vertically disposed at one end of the second bracket, the second Z-direction lifting fork 41 is parallel to the second Y-direction conveying cylinder 39 and fixed on the second Z-direction lifting servo module 40, and the second Y-direction conveying cylinder 39 and the second Z-direction lifting servo module 40 are both connected with the controller. The good product tray blanking mechanism 36, the defective product tray blanking mechanism 37 and the Y-direction empty tray feeding mechanism have the same structure, but the Y-direction empty tray feeding mechanism, the good product tray blanking mechanism 36 and the defective product tray blanking mechanism 37 have different moving directions.
As shown in fig. 8, the second X-direction tray conveying mechanism 35 includes a second X-direction servo motor 43, a second timing belt 44, and two second linear guide rails 45 arranged in parallel in the X direction, a second tray fixing mechanism straddles the two linear guide rails, the second X-direction servo motor 43 is connected to the second timing belt 44, the second timing belt 44 is connected to the second tray fixing mechanism, and the second X-direction servo motor 43 and the second timing belt 44 are both connected to the controller. The second tray fixing mechanism comprises a sliding frame and a second clamping cylinder, the second clamping cylinder comprises 46, 47, 48, 49, 50 and 51, the sliding frame is arranged on the second X-direction tray carrying mechanism 35 in a sliding mode, the second clamping cylinder is arranged on two sides of the sliding frame in a plurality of and uniformly distributed modes, and when the tray is fixed, the second clamping cylinder moves and abuts against side walls on two sides of the tray and is connected with the controller.
The controller comprises an industrial personal computer and a programmable logic controller. The industrial personal computer is used for processing the digital images acquired by the camera module, setting various detection parameters aiming at different batches or varieties respectively, and judging whether the piece to be detected is a good product or not according to the operation result of the visual detection algorithm; the defect image can be displayed in real time, the defect position (x and y coordinates) can be recorded, defect statistics (defective product type, quantity, qualified rate and the like) and report printing can be carried out, and the SPC statistical analysis function is achieved. In summary, the vision inspection system and the vision inspection method of the invention can realize automatic feeding and discharging of the pieces to be inspected, can quickly perform front and back inspection of various types of pieces to be inspected, can classify and filter defects according to set parameters, and have the advantages of stable, accurate, efficient and high repeatability of the whole system, convenient operation of equipment and easy maintenance.
The working principle of the invention is as follows: the full-load tray 8 full of screen is placed on the Y-direction full-load tray feeding mechanism 1, the tray is lifted to the working position through the first Y-direction conveying cylinder 5 and the first Z-direction lifting servo module 6, and the full-load tray 8 is fixed by the first clamping cylinder of the first X-direction tray conveying mechanism 2, wherein the clamping cylinders comprise 12, 13, 14, 15, 16, 17, 18 and 19. The feeding manipulator 4 sucks screens one by one from the full-load tray 8, and puts the screen to the first screen transfer tray of the detection section. After the screen in the full tray 8 is picked up, the first X-direction servo motor 9 drives the first synchronous belt 10 to operate, the full tray 8 is conveyed to the Y-direction empty tray feeding mechanism 3 by the first X-direction tray conveying mechanism 2, and the empty tray 42 is discharged by the Y-direction empty tray feeding mechanism 3, and the operation is repeated in this way. As shown in fig. 5, the screen sucked by the feeding manipulator 4 is placed on the first screen conveying tray 20, the front surface of the screen passes through the first illumination light source 23 at a uniform speed from the start position and reaches the end position of the front surface detection of the screen, the first detection camera 22 collects a uniform image of the front surface of the screen to be detected, and information such as the length and the width of the image is acquired. And recording the defect type, size and position of the front side of the workpiece according to the operation result of the detection algorithm. And then entering a screen back detection process. U drives the screen upset to servo motor 26 and inhales the claw 25 with the screen, and after the upset 180, X is to the back that the module drive screen carried the screen and is inhaled claw 27 and absorb the screen, places on second screen conveying tray 29, and the screen back passes through second light source 32 from the initial position uniform speed, reaches the screen back and detects the final position, passes through the even image at the screen back that awaits measuring by second detection camera 31 collection. And recording the defect type, size and position of the front side of the workpiece according to the operation result of the detection algorithm. And according to the defects detected by the front and back detection algorithm, the blanking device sends the to-be-detected piece to a good product area and a defective product area respectively. As shown in fig. 6, 7, and 8, the empty tray 42 is placed on the Y-direction empty tray 42 feeding mechanism 34, the empty tray 42 is raised to the operating position by the second Y-direction conveying cylinder 39 and the second Z-direction elevation servo module 40, and is clamped by the second clamping cylinder 46, 47, 48, 49, 50, and 51, the second X-direction servo motor 43 drives the second timing belt 44, and the second X-direction tray conveying mechanism 35 conveys the empty tray 42 to the good-product tray blanking mechanism 36 or the bad-product tray blanking mechanism 37, respectively. The feeding robot 38 sucks the screen from above the second screen transfer tray 29, and places the screen in a tray in the good tray feeding mechanism 36 or the bad tray feeding mechanism 37 according to the detection result. After the screen is full of the trays, the trays are discharged by the good tray discharging mechanism 36 or the defective tray discharging mechanism 37. The method comprises the following steps of processing images collected by a camera: and extracting the partial image to be measured by threshold segmentation. The graph after the division is a figure. And preliminarily judging whether the acquired image is correct or not according to the area of the image obtained by the segmentation, popping up a warning message if the acquired image is correct, and carrying out the next step if the acquired image is correct. And performing expansion and corrosion operations on the extracted partial image to be detected, filling up pores in the image, and filtering noise interference. And extracting the outer edge profile of the image to be detected. And converting the partial image to be detected into a convex polygon. And calculating the difference value between the convex polygon and the partial image to be detected. And carrying out corrosion operation on the difference value to remove a small noise part. And calculating connectivity, and dividing the connectivity into different areas according to the connectivity. And calculating the area of each part, and judging whether defects exist according to a preset threshold value. If the defect exists, the defect is marked as a defective product, the actual length and width of the defect are marked at the defect position, and the position and the type of the defect are recorded. If no defect exists, the product is marked as good. After the overall image detection is completed, in order to ensure the detection accuracy, the parts with multiple defects (four side lines and four corners of the piece to be detected) need to be subjected to key detection. The detection step is illustrated in the lower left corner. Firstly, selecting a lower left corner region of an image to be sequenced according to the length and width of a graph to be tested, and calculating the area, the length and the width and the like of the region; then, carrying out inscribed circle calculation on the image to be measured at the lower left corner to obtain the radius of the inscribed circle; and selecting area and radius thresholds according to actual product requirements, and judging whether the lower left corner is flawless. And similarly, processing the other key detection areas of the workpiece and judging whether the workpiece has defects.
Claims (7)
1. A full-automatic visual detection system for screen defects is characterized by comprising a controller, an automatic feeding unit, an automatic detection unit and an automatic classification blanking unit, wherein the automatic feeding unit, the automatic detection unit and the automatic classification blanking unit are respectively connected with the controller;
the automatic feeding unit conveys the screen to be detected to the automatic detection unit, the automatic detection unit automatically detects defects to determine whether the screen belongs to good products or defective products, and the automatic classification discharging unit acquires the detected screen from the automatic detection unit and performs classification output according to a detection result;
the automatic feeding unit comprises a Y-direction full-load tray feeding mechanism (1), a first X-direction tray conveying mechanism (2), a first tray fixing mechanism, a Y-direction empty tray discharging mechanism (3) and a feeding manipulator (4) which are respectively connected with the controller, the direction in which the automatic feeding unit, the automatic detection unit and the automatic classification discharging unit are sequentially arranged is determined as the Y direction, the direction perpendicular to the Y direction on the horizontal plane is determined as the X direction, the direction perpendicular to the horizontal plane is the Z direction, the Y-direction full-load tray feeding mechanism (1) and the Y-direction empty tray discharging mechanism (3) are arranged in parallel along the Y direction and move along the Y direction, the first X-direction tray conveying mechanism (2) stretches across the Y-direction full-load tray feeding mechanism (1) and the Y-direction empty tray discharging mechanism (3), the first tray fixing mechanism is arranged on the first X-direction tray conveying mechanism (2), in the initial working state, the first tray fixing mechanism is positioned above the Y-direction full-load tray feeding mechanism (1), and the feeding manipulator (4) is arranged above the first X-direction tray conveying mechanism (2);
the Y-direction full-load tray feeding mechanism (1) drives a tray filled with a screen to be detected to move towards the direction close to the automatic detection unit and conveys the tray to the first tray fixing mechanism, the feeding manipulator (4) sucks the screen to be detected from the tray to the automatic detection unit, after the screen to be detected in the sucker is completely sucked, the first X-direction tray conveying mechanism (2) drives the first tray fixing mechanism to move to the position above the Y-direction empty tray discharging mechanism (3) along the X direction, and the Y-direction empty tray discharging mechanism (3) outputs an empty tray (42);
the automatic detection unit comprises a screen front detection mechanism, a turnover mechanism, a screen carrying mechanism and a screen back detection mechanism which are respectively connected with the controller, wherein the screen front detection mechanism and the screen back detection mechanism are distributed in the diagonal direction;
automatic categorised unloading unit including respectively with Y that the controller is connected to empty tray feed mechanism (34), second X to tray transport mechanism (35), second tray fixed establishment, non-defective products tray unloading mechanism (36), defective products tray unloading mechanism (37) and unloading manipulator (38), Y to empty tray feed mechanism (34), non-defective products tray unloading mechanism (36) and defective products tray unloading mechanism (37) set up side by side along the Y direction, Y to empty tray feed mechanism (34) set up between non-defective products tray unloading mechanism (36) and defective products tray unloading mechanism (37), Y to empty tray feed mechanism (34), non-defective products tray unloading mechanism (36) and defective products tray unloading mechanism (37) along the Y direction motion setting, second X to tray transport mechanism (35) span in Y to empty tray feed mechanism (34), The blanking mechanism (36) of the good product tray and the blanking mechanism (37) of the defective product tray are arranged above, the second tray fixing mechanism is arranged on the second X-direction tray conveying mechanism (35) and moves along the X direction, the blanking manipulator (38) is arranged above the middle part of the second X-direction tray conveying mechanism (35) and the blanking manipulator (38) is arranged above the second tray fixing mechanism, and the movement direction of the Y-direction empty tray feeding mechanism (34) is opposite to the movement direction of the blanking mechanism (36) of the good product tray and the movement direction of the blanking mechanism (37) of the defective product tray;
the initial position, the second tray fixing mechanism is positioned under the tail end of the Y-direction empty tray feeding mechanism (34), the Y-direction empty tray feeding mechanism (34) drives the empty tray (42) to move to the position under the second tray fixing mechanism, the second tray fixing mechanism fixes the empty tray (42), the second X-direction tray conveying mechanism (35) drives the second tray fixing mechanism to move along the X direction, the tray is conveyed to the good product tray blanking mechanism (36) or the defective product tray blanking mechanism (37), the blanking manipulator (38) sucks the detected screen according to the detection result of the automatic detection unit and places the screen into the tray in the good product tray blanking mechanism (36) or the defective product tray blanking mechanism (37), after the screen is filled in the tray in the blanking mechanism (36) of the tray to be qualified or the blanking mechanism (37) of the defective tray, the tray blanking mechanism or the defective tray blanking mechanism (37) moves along the Y direction to discharge the tray.
2. The full-automatic visual inspection system for screen defects according to claim 1, wherein the screen front side inspection mechanism and the screen back side inspection mechanism have the same structure and comprise screen conveying trays, Y-direction transmission modules, inspection cameras, illumination light sources and camera supports, the inspection cameras are arranged at the tops of the camera supports, the illumination light sources are arranged right below the inspection cameras and fixed on the camera supports, the Y-direction transmission modules are transversely arranged below the illumination light sources, the screen transmission trays are arranged on the Y-direction transmission modules, and the Y-direction transmission modules, the inspection cameras and the illumination light sources are all connected with the controller.
3. The full-automatic visual inspection system for screen defects according to claim 1, wherein the turnover mechanism comprises a screen turnover suction claw (25) and a U-direction servo motor (26) which are respectively connected with the controller, the U-direction servo motor (26) is connected with the screen turnover suction claw (25);
the screen overturning suction claw (25) sucks and conveys the screen to the tail end of the front detection mechanism, and the U drives the screen overturning suction claw (25) to overturn for 180 degrees to realize screen overturning to the servo motor (26).
4. The full-automatic visual inspection system for screen defects according to claim 1, wherein the screen conveying mechanism comprises a screen conveying suction claw (27) and an X-direction transmission module (28) which are respectively connected with the controller, the X-direction transmission module (28) is arranged along the X direction, and the screen conveying suction claw (27) is arranged at one end of the X-direction transmission module (28) close to the turnover mechanism.
5. The full-automatic visual inspection system for screen defects according to claim 1, wherein the Y-direction full-load tray feeding mechanism (1), the Y-direction empty tray discharging mechanism (3), the Y-direction empty tray feeding mechanism (34), the good tray discharging mechanism (36) and the defective tray discharging mechanism (37) are the same in structure and respectively comprise a support, a Y-direction conveying cylinder, a Z-direction lifting servo module and a Z-direction lifting fork, the Y-direction conveying cylinder is horizontally arranged on the support, the tray is arranged on the Y-direction conveying cylinder, the Z-direction lifting servo module is vertically arranged at one end of the support, the Z-direction lifting fork is parallel to the Y-direction conveying cylinder and fixed on the Z-direction lifting servo module, and the Y-direction conveying cylinder and the Z-direction lifting servo module are both connected with the controller.
6. The full-automatic visual inspection system for screen defects according to claim 1, wherein the first X-direction tray carrying mechanism (2) and the second X-direction tray carrying mechanism (35) each comprise an X-direction servo motor, a synchronous belt and two linear guide rails arranged in parallel along the X-direction, the first tray fixing mechanism or the second tray fixing mechanism respectively span over the two linear guide rails, the X-direction servo motor is connected with the synchronous belt, the synchronous belt is connected with the first tray fixing mechanism or the second tray fixing mechanism, and the X-direction servo motor and the synchronous belt are both connected with the controller.
7. The full-automatic visual inspection system for screen defects according to claim 1, wherein the first tray fixing mechanism and the second tray fixing mechanism each comprise a sliding frame and a clamping cylinder, the sliding frame is slidably disposed on the first X-direction tray carrying mechanism (2) or the second X-direction tray carrying mechanism (35), the clamping cylinders are disposed in a plurality and uniformly distributed on two sides of the sliding frame, the clamping cylinders move and abut against side walls on two sides of the tray when the tray is fixed, and the clamping cylinders are connected with the controller.
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