CN107274407B - Device and method for precise counting and size recognition of steel balls - Google Patents

Abstract

The device and method for accurate counting and size identification of steel balls belong to the technical field of steel ball manufacturing, and aim at solving the problems of poor counting accuracy and inability to identify the size of steel balls existing in the prior art. The invention comprises a material storage unit; a pre-counting unit arranged at the outlet end of the material storage tray, the pre-counting unit includes a pre-counting disc with convex edges on both sides, an area adjustment mechanism for adjusting the working area of the pre-counting disc and driving the pre-counting disc to move up and down The first lifting mechanism; the fine counting unit arranged at the outlet end of the pre-counting disc; the image acquisition unit arranged above the fine counting unit to collect the steel ball image on the fine counting disc; the computer control system connected with the image acquisition unit, computer control The system controls the movement of each motion unit and performs data processing on the steel ball image to obtain the number of steel balls and the size information of the steel balls; and the single compensation system, which performs step compensation for the steel balls in the fine counting disc; the storage tray, The pre-counting disc and the precise counting disc are integrally inclined.

Description

Device and method for accurate counting and size recognition of steel balls

technical field

The invention belongs to the technical field of steel ball manufacturing, and in particular relates to a device and method for precise counting and size identification of steel balls.

Background technique

At present, most of the counting of steel balls at home and abroad adopts the method of weighing and counting. This method uses electronic scales to weigh the weight of steel balls, and the method of manual reading to calculate the number of steel balls. Due to the error of manual reading and the anti-rust oil coated on the surface of the steel ball, the weighing and counting is inaccurate, the counting efficiency is low, and the work intensity is high. At the same time, manual counting will also bring problems such as ball scratches and mixed balls. Mixed balls refer to the mixing of steel balls of other specifications and sizes due to operational errors during manual operation. Once steel balls of different specifications and sizes are loaded into the bearing, it will bring serious safety hazards. If a major accident occurs, it will have a great impact on the enterprise.

Aiming at the problems of inaccurate counting, low counting efficiency and high work intensity in the weighing of electronic scales, the existing counting adopts the method of image acquisition for counting. The Chinese patent with the publication number CN 103164740 discloses an invention titled a The counting scheme of the steel ball intelligent automatic counting device and its automatic counting method, the automatic counting device includes a counting disc, the counting disc is provided with an industrial camera, the industrial camera is connected to a computer control system, and the computer control system collects the data on the counting disc collected by the industrial camera. Steel balls are used for counting, and an automatic compensation device for steel balls is installed at the entrance of the counting disc. The outer periphery of the roller is arranged with a feeding trough, and the outer periphery of the compensation roller is arranged with a storage single hole, which can only store one steel ball. Due to the structural design of the feeding roller and compensation roller of the automatic compensation device, the compensation amount is inaccurate, which cannot meet the requirements of accurate counting, and the steel ball size cannot be identified at the same time.

Contents of the invention

The object of the present invention is to provide a device and method for accurate counting and size identification of steel balls, which solves the problems of poor counting accuracy and inability to identify the size of steel balls existing in the prior art.

In order to achieve the above object, the steel ball accurate counting and size identification device of the present invention includes:

A material storage unit, which includes a material storage tray with raised edges on both sides;

The pre-counting unit arranged at the outlet end of the storage tray, the pre-counting unit includes a pre-counting disc with convex edges on both sides, an area adjustment mechanism for adjusting the working area of the pre-counting disc, and a first lifting mechanism that drives the pre-counting disc to move up and down ;

The fine counting unit arranged at the outlet end of the pre-counting disc, the fine counting unit includes a fine counting disc with raised edges on both sides and an outlet mechanism arranged at the outlet end of the fine counting disc;

The image acquisition unit arranged above the fine counting unit collects the steel ball image on the fine counting disc;

A computer control system connected to the image acquisition unit, the computer control system controls the movement of each movement unit and performs data processing on the steel ball image to obtain information on the number of steel balls and the size of the steel balls;

And a single compensation system, the single compensation system performs step compensation to the steel balls in the fine counting disc;

The storage tray, the pre-counting tray and the precise counting tray are inclined as a whole, and the inlet end of the stock tray is the highest; when the pre-counting tray is driven to the highest position by the first lifting mechanism, the steel balls can roll from the pre-counting tray to the precise counting tray. In the counting tray, the steel balls of the storage tray cannot roll into the estimated counting tray; when the estimated counting tray is driven to the lowest position by the first lifting mechanism, the steel balls in the storage tray can roll into the estimated counting tray and The steel balls in the counting disc cannot roll into the fine counting disc.

The single compensation system includes:

A feeding channel arranged at one end of the outlet of the storage tray, and a compensation groove is opened at the upper end of the feeding channel;

A compensation pusher arranged at one end of the outlet of the storage tray, the compensation pusher is a push plate driven by a cylinder to lift up and down along the side wall of the feed channel, the push plate is inclined to the end close to the feed channel, and the push plate is at the lowest position It is lower than the upper end surface of the storage tray when it is at the highest position, and is higher than the side wall of the feeding channel when it is at the highest position;

A compensation tube connected at one end to the outlet end of the compensation tank, the other end of the compensation tube is supported on the side of the inlet end of the fine counting disk through a tube support, and a sensor is provided at the ball end of the compensation tube;

A compensation plate arranged at the end of the compensation tube at the inlet end of the fine counting disc, the compensation plate is provided with a compensation channel communicating with the fine counting disc;

A stepper motor set on the compensation plate through the motor bracket;

And a compensation dial fixedly connected to the output shaft of the stepping motor, the compensation dial is a disc structure, and a plurality of notches are evenly distributed on the outer circumference of the side opposite to the port of the compensation tube, and each notch accommodates A steel ball, the notch is located above the compensation channel of the compensation plate.

The steel ball accurate counting and size identification device also includes a second lifting mechanism, the second lifting mechanism includes an upper support plate and a lower support plate oppositely arranged and a lifting block connected between the upper support plate and the lower support plate, The lifting block adjusts the inclination angle of the upper supporting plate, and the storage unit, the pre-counting unit and the precise counting unit are all arranged on the upper supporting plate.

The storage unit also includes an outlet adjustment mechanism arranged at the outlet end of the storage tray, and the outlet adjustment mechanism includes:

A stopper arranged on the right-angle side of the outlet end of the storage tray and in contact with the upper surface of the storage tray. The length direction of the stopper is provided with a chute, and the chute is slidably matched with the sliding pin fixed on the storage tray. , the sliding pin is fixed at a position close to the protruding edge on one side of the storage tray, and one end of the stopper is flush with the outlet end of the storage tray;

A first polished rod hinged to one end of the stopper close to the outlet end of the storage tray, and the other end of the first polished rod passes through the convex edge of the storage tray;

And a fixing nut threadedly connected with the convex edge of the material storage tray, the fixing nut is perpendicular to the first polished rod, the fixing nut passes through the convex edge, and the end contacts with the first polished rod.

The area adjustment mechanism includes:

An adjustment plate placed on the upper end surface of the pre-counting disk, the adjustment plate is parallel to the convex edge of the pre-counting disk;

A plurality of second polished rods with one end respectively connected to one side of the adjustment plate, the second polished rods pass through the convex edge on one side of the pre-counter disc and protrude;

And a plurality of locking nuts, each locking nut is threadedly connected with the convex edge, the locking nut passes through the convex edge, and the end part is in contact with the second polished rod.

The number of the second polished rods is two, and one end of the two second polished rods is respectively fixedly connected to the two ends of the side wall of the adjustment plate.

The first lifting mechanism is a linear cylinder, and the output end of the linear cylinder is fixedly connected to the lower end surface of the pre-counter disk.

The outlet mechanism is a rotating baffle, and the tops of both ends of the rotating baffle are rotatably connected to the convex edges on both sides of the outlet end of the fine counting disc, and the rotating shaft on one side of the rotating baffle is connected to the output shaft of the rotating cylinder;

The image acquisition unit is an industrial camera.

The steel ball accurate counting and size recognition method based on the steel ball precise counting and size recognition device comprises the following steps:

Step 1: Adjust the inclination angles of the storage tray, the pre-counting tray and the precise counting tray through the second lifting mechanism, so that the steel balls are rolled in sequence and arranged in a single layer, and the pre-counting tray is adjusted to a low position through the first lifting mechanism;

Step 2: Adjust the working area S of the pre-counting disk through the area adjustment mechanism, so that the working area of the pre-counting disk S=ND ² , where D is the diameter of the steel balls to be counted, and N is an integer smaller than the number of steel balls actually required;

Step 3: Adjust the size of the outlet of the storage tray through the outlet adjustment mechanism, so that one end of the stopper is in contact with one end of the adjustment plate;

Step 4: Pour the steel balls into the storage tray, and the steel balls in the storage tray enter the pre-counting tray in turn until the working area of the pre-counting tray is filled with steel balls. At the same time, the compensation pusher moves up and down to drive the steel balls Enter the compensation tube until the compensation tube is filled with steel balls;

Step 5: Drive the pre-counting disc to a high position through the first lifting mechanism, so that the steel balls in the pre-counting disc roll into the fine counting disc, until all the steel balls in the pre-counting disc roll into the fine counting disc, pass the first The lifting mechanism drives the expected counter to the low position;

Step 6: collect the steel ball image on the precision counting disc through the industrial camera, and transmit the steel ball image to the computer control system;

Step 7: The computer control system performs image processing on the steel ball image, obtains the quantity Q of steel balls and the size information of the steel balls that actually enter the fine counting disc, and judges whether the steel balls in the fine counting disc are mixed with steel balls of other sizes. If so, Computer control system alarm; if not, perform step eight;

Step 8: The computer control system calculates the number of steel balls required for single compensation, that is, M-Q, where M is the actual number of steel balls required;

Step 9: Control the rotation of the stepper motor according to the actual number of steel balls required in step 8 until the number of steel balls entering the fine counting disc through the single compensation system is M-Q;

Step 10: The industrial camera takes another image of the steel balls in the fine counting tray, counts again, and confirms that the number of steel balls is M;

Step 11: Open the rotary baffle at the outlet end of the fine counting disc, release the steel balls in the fine counting disc, and complete a count and size recognition;

Step 12: Repeat steps 4-11 to realize continuous counting.

The concrete method of carrying out image processing to the steel ball described in step seven is:

1) Determine the effective area of the image, and replace it with black outside the effective area;

2) The fine counting disk is black, and the collected steel ball image is binarized; the center of each steel ball is the brightest, and the gray value is the largest, reaching more than 250. Find the point with the largest gray value and search for it Points with a gray value above 220, and replace them all with green. After processing the image by computer, get the number of steel balls and find out the steel balls with different specifications, mark the steel balls with different specifications as red , the machine alarms, and the steel balls with different specifications are manually taken out.

Adjust the inclination angles of the storage tray, the pre-counting tray and the precise counting tray described in step 1 to ensure that the steel balls roll down smoothly and at the same time ensure that the steel balls are arranged in a single layer.

The beneficial effects of the present invention are: the pre-counting plate in the precise counting and size recognition device and method of steel balls of the present invention can make the number of pre-counting steel balls as close as possible and smaller than the target number, that is, the actual number of steel balls required, by adjusting the area. In this way, the number of compensation can be reduced and the efficiency can be improved; the precision counting disc can accurately count the number through the industrial camera, calculate the number that needs to be compensated, and then perform accurate compensation by the single compensation system to achieve the purpose of collecting accurate numbers. The large and small balls are determined by comparing the adjacent radii with the average value, so as to realize the identification of the steel ball size and avoid the problem of major accidents caused by mixing steel balls of different specifications.

Description of drawings

Fig. 1 is a schematic diagram of the overall structure of the steel ball accurate counting and size recognition device of the present invention;

Fig. 2 is a schematic structural diagram of the single compensation system in the steel ball accurate counting and size recognition device of the present invention;

Fig. 3 is a schematic diagram of the outlet adjustment mechanism in the steel ball accurate counting and size recognition device of the present invention;

Fig. 4 is a schematic diagram of the area adjustment mechanism in the steel ball accurate counting and size recognition device of the present invention;

Fig. 5 is a schematic diagram of steel ball size identification in the steel ball accurate counting and size identification method of the present invention;

Fig. 6 is a principle diagram of size recognition in the steel ball accurate counting and size recognition method of the present invention;

Among them: 1. Material storage unit, 101, material storage tray, 102, outlet adjustment mechanism, 103, first polished rod, 104, fixed nut, 105, stopper, 2, pre-counting unit, 201, pre-counting disc, 202, Area adjustment mechanism, 203, adjustment plate, 204, second polished rod, 205, lock nut, 3, fine counting unit, 301, fine counting disc, 302, exit mechanism, 303, rotating baffle, 4, image acquisition unit, 401. Industrial camera, 5. Single compensation system, 501. Stepping motor, 502. Motor bracket, 503. Compensation dial, 504. Compensation plate, 505. Tube holder, 506. Compensation tube, 507. Compensation tank, 508. Feed channel, 509, compensation pusher, 6, second lifting mechanism, 601, upper support plate, 602, lifting block, 603, lower support plate.

Detailed ways

Embodiments of the present invention will be further described below in conjunction with the accompanying drawings.

Referring to accompanying drawing 1, steel ball accurate counting, size identification device of the present invention comprises:

A storage unit 1, the storage unit 1 includes a storage tray 101 with raised edges on both sides;

The pre-counting unit 2 arranged at the outlet end of the storage tray 101, the pre-counting unit 2 includes a pre-counting disc 201 with convex edges on both sides, an area adjustment mechanism 202 for adjusting the working area of the pre-counting disc 201 and driving the pre-counting disc 201 The first lifting mechanism that moves up and down;

The fine counting unit 3 arranged at the outlet end of the pre-counting disc 201, the fine counting unit 3 includes a fine counting disc 301 with convex edges on both sides and an outlet mechanism 302 arranged at the outlet end of the fine counting disc 301;

The image acquisition unit 4 arranged above the fine counting unit 3 collects the steel ball image on the fine counting disc 301;

A computer control system connected to the image acquisition unit 4, the computer control system controls the movement of each movement unit and performs data processing on the steel ball image to obtain steel ball quantity and steel ball size information;

And a single compensation system 5, the single compensation system 5 performs step compensation to the steel balls in the fine counting disc 301;

The storage tray 101, the pre-counting tray 201 and the precise counting tray 301 are inclined as a whole, and the inlet end of the stock tray 101 is the highest; when the pre-counting tray 201 is driven to the highest position by the first lifting mechanism, the steel ball can move from the estimated The counting disc 201 rolls into the fine counting disc 301 and the steel balls of the material storage tray 101 cannot roll into the pre-counting disc 201; Balls can roll into the pre-counting disc 201 and the steel balls in the pre-counting disc 201 cannot roll into the precise counting disc 301 .

Referring to accompanying drawing 2, described single compensation system 5 comprises:

A feed channel 508 arranged at one end of the outlet of the storage tray 101, the upper end of the feed channel 508 is provided with a compensation groove 507;

The compensation pusher 509 arranged at one end of the outlet of the storage tray 101, the compensation pusher 509 is a push plate driven by a cylinder to lift along the side wall of the feed channel 508, and the push plate is inclined to the end close to the feed channel 508, so When the push plate is at the lowest position, it is lower than the upper surface of the storage tray 101, and when it is at the highest position, it is higher than the side wall of the feed channel 508;

One end of the compensation tube 506 connected to the outlet end of the compensation tank 507, the other end of the compensation tube 506 is supported on the side of the inlet end of the fine counting disk 301 through the tube support 505, and the ball end of the compensation tube 506 is provided with a sensor;

The compensation plate 504 arranged at the end of the compensation pipe 506 at the inlet end of the fine counting disc 301 is provided with a compensation channel communicating with the fine counting disc 301;

The stepping motor 501 installed on the compensating board 504 through the motor bracket 502;

And the compensation dial 503 fixedly connected to the output shaft of the stepping motor 501, the compensation dial 503 is a disc structure, and a plurality of notches are evenly distributed on the outer circumference of the side opposite to the port of the compensation tube 506, each A steel ball is accommodated in a notch, and the notch is located above the compensation channel of the compensation plate 504 .

The precise counting and size recognition device for steel balls also includes a second elevating mechanism 6, and the second elevating mechanism 6 includes an upper support plate 601 and a lower support plate 603 that are oppositely arranged, and the upper support plate 601 and the lower support plate 603 are connected to each other. The lifting block 602 in between, the lifting block 602 adjusts the inclination angle of the upper support plate 601, and the storage unit 1, the pre-counting unit 2 and the precise counting unit 3 are all arranged on the upper support plate 601.

Referring to Figure 3, the storage unit 1 also includes an outlet adjustment mechanism 102 arranged at the outlet end of the storage tray 101, and the outlet adjustment mechanism 102 includes:

The stopper 105 that is arranged on the right-angled side of the outlet end of the storage tray 101 and contacts the upper end surface of the storage tray 101, the length direction of the stopper 105 is provided with a chute, and the chute is fixed on the storage tray 101 The sliding pin is slidingly fitted, and the sliding pin is fixed at a position close to the protruding edge on one side of the storage tray 101, and one end of the stopper 105 is flush with the outlet end of the storage tray 101;

and the first polished rod 103 hinged at one end of the stopper 105 near the outlet end of the storage tray 101, the other end of the first polished rod 103 passes through the convex edge of the storage tray 101;

And a fixing nut 104 threadedly connected to the convex edge of the storage tray 101 , the fixing nut 104 is perpendicular to the first polished rod 103 , the fixing nut 104 passes through the convex edge, and its end contacts with the first polished rod 103 .

Referring to accompanying drawing 4, described area adjusting mechanism 202 comprises:

The adjustment plate 203 placed on the upper end surface of the pre-counting disk 201, the adjustment plate 203 and the convex edge of the pre-counting disk 201 are parallel;

A plurality of second polished rods 204 connected to one side of the adjustment plate 203 at one end respectively, the second polished rods 204 pass through the convex edge on one side of the pre-counter disk 201 and protrude;

And a plurality of locking nuts 205 , each locking nut 205 is threadedly connected with the convex edge, the locking nut 205 passes through the convex edge, and the end part contacts with the second polished rod 204 .

The number of the second polished rods 204 is two, and one end of the two second polished rods 204 is respectively fixedly connected to two ends of the side wall of the adjustment plate 203 .

The first lifting mechanism is a linear cylinder, and the output end of the linear cylinder is fixedly connected to the lower end surface of the pre-counter disk 201 .

The outlet mechanism 302 is a rotating baffle 303, and the top of the two ends of the rotating baffle 303 is rotationally connected with the convex edges on both sides of the outlet end of the fine counting disk 301, and the rotating shaft on one side of the rotating baffle 303 is connected to the side of the rotating cylinder. output shaft connection;

The image acquisition unit 4 is an industrial camera 401 .

The working principle of the steel ball accurate counting and size recognition device of the present invention: when it is necessary to count M steel balls, the area of the pre-counting disk 201 can be changed by adjusting the extension length of the second polished rod 204, and after the adjustment is completed, use the lock The tight nut 205 is locked so that the number of steel balls entering the pre-counting disc 201 is within M each time, the working area of the pre-counting disc 201 is S=ND ² , and N is the largest integer value less than M, because the pre-counting disc 201 The area cannot be exactly N times the square area occupied by each rigid ball, and the number of steel balls actually entering the pre-counting disc 201 is Q, and the difference between Q and M is compensated by the single compensation mechanism behind to achieve for exact counting purposes. It is estimated that the counting disc 201 descends to a low position under the drive of the cylinder, and gets back to the initial state. The stroke of the cylinder is set as follows: when it rises, the steel balls can smoothly roll into the precise counting disc 301 and the steel balls of the storage tray 101 cannot roll into the pre-counting disc 201. When the cylinder is lowered, The steel balls of the storage tray 101 can smoothly roll into the pre-counting tray 201 but cannot roll into the precise counting tray 301. Since the adjustment of the area of the counting disc 201 is expected to bring certain dead angles, the flow of the steel balls is not very smooth, so the outlet adjustment mechanism 102 is used to adjust the width of the outlet of the storage tray 101. The position of the baffle is adjusted by adjusting the length of the polished rod so that the balls can flow into the pre-counting disk 201 smoothly. Then the counting disc 201 is expected to rise to a high position, so that the height of the counting disc 201 is higher than the storage tray 101 and the fine counting disc 301, and a certain amount of steel balls in the initial counting disc will enter the fine counting disc 301 for accurate counting. The image of the steel balls in the precise counting disc 301 is captured by a CCD camera above the precise counting disc 301, and the steel balls are accurately counted after image processing. For example: when M steel balls are needed, through the adjustment of the pre-counting disc 201, the number of steel balls arriving at the precise counting disc 301 is Q, and Q is less than or equal to the target number M. The single compensation system 5 is started, and the single compensation mechanism automatically compensates MQ steel balls and enters the precision counting disc 301 through the signal given by the computer, so as to achieve the purpose of accurately counting M steel balls. The compensating pusher 509 pushes the steel ball on one edge of the material storage channel above the compensating groove 507 , slides freely along the inclined plane into the compensating groove 507 , and then enters the compensating pipe 506 for storage. Compensation pusher 509 returns, and pushes next time, until the sensor that is installed in the beginning of compensation pipe 506 detects that the steel ball in the pipe is full. The steel ball quantity that pushes each time is determined by the push plate length of compensation pusher 509. The width of the compensation push plate can only accommodate a row of steel balls. When compensation is required, the compensation dial 503 is driven to rotate by the stepper motor 501 to perform single-ball compensation, and the required number of compensation steel balls is MQ. In order to improve the compensation efficiency, the area of the pre-counter disk 201 is adjusted so that the value of Q is smaller but closer to M, the better.

The steel ball accurate counting and size recognition method based on the steel ball precise counting and size recognition device comprises the following steps:

Step 1: Adjust the inclination angles of the storage tray 101, the pre-counting tray 201 and the precise counting tray 301 through the second lifting mechanism 6 according to the size specifications of the steel balls. Since each package is to pack the same type of steel balls for a long time, so The angle will not be adjusted frequently, so adjust the height of the second lifting mechanism 6 before use, so that the steel ball can roll down from the storage channel by its own weight. The angle is 6-10 degrees, so that the steel balls roll sequentially, and the pre-counting disc 201 is adjusted to a low position through the first lifting mechanism;

Step 2: Adjust the working area S of the pre-counting disc 201 through the area adjustment mechanism 202, so that the working area S of the pre-counting disc 201 = ND ² , where D is the diameter of the steel balls to be counted, and N is less than the actual number of steel balls required An integer of , this embodiment takes the actual number of 3000 steel balls as an example;

Step 3: Adjust the size of the outlet of the storage tray 101 through the outlet adjustment mechanism 102, so that one end of the stopper 105 is in contact with one end of the adjustment plate 203, so as to ensure that the width of the outlet of the storage tray 101 is the same as that of the entrance of the pre-counting tray 201. same width;

Step 4: Pour the steel balls into the storage tray 101, and the steel balls in the storage tray 101 enter the pre-counting tray 201 in turn until the working area of the pre-counting tray 201 is filled with steel balls. At the same time, the compensation pusher 509 The up and down movement drives the steel balls into the compensating pipe 506 until the compensating pipe 506 is filled with steel balls. Initially, the pre-counting disc 201 is at a low position, and the steel balls in the storage tray 101 roll into the pre-counting disc 201 by their own weight, and Because the rolling is distributed on the pre-counting disc 201 in a single layer, the area of the pre-counting disc 201 can be adjusted, and the number of steel balls can be roughly calculated according to the area of the pre-counting disc 201 and the diameter of the steel balls. When the pre-counting disc 201 is full of steel balls , the steel balls stop feeding naturally, by adjusting the area of the pre-counting plate 201, you can have a rough estimate of the number of steel balls in the plate, but it must be less than or equal to the number of required steel balls;

Step 5: Drive the pre-counting disc 201 to a high position through the first lifting mechanism, so that the steel balls in the pre-counting disc 201 roll into the fine counting disc 301. The first lifting mechanism drives the pre-counter 201 to the low position;

Step 6: collect the steel ball image on the precise counting disc 301 through the industrial camera 401, and transmit the steel ball image to the computer control system;

Step 7: The computer control system performs image processing on the steel ball image, obtains the quantity Q of steel balls and the size information of the steel balls actually entering the fine counting disc 301, and judges whether the steel balls in the fine counting disc 301 are mixed with steel balls of other sizes, If so, the computer control system reports to the police; If not, perform step eight;

Step 8: The computer control system calculates the number of steel balls required for single compensation, that is, M-Q, where M is the actual number of steel balls required;

Step 9: Control the stepper motor 501 to rotate according to the actual required steel ball quantity obtained in step 8 until the number of steel balls entering the fine counting disc 301 through the single compensation system 5 is M-Q;

Step 10: The industrial camera 401 takes another image of the steel balls in the fine counting disc 301, counts again, and confirms that the number of steel balls is M;

Step 11: Open the rotary baffle 303 at the outlet end of the fine counting disc 301, release the steel balls in the fine counting disc 301, and complete a technical and size identification;

Step 12: Repeat steps 4-11 to realize continuous counting.

Referring to accompanying drawing 5, the concrete method of carrying out image processing to steel ball described in step 7 is:

1) Determine the effective area of the image, and replace it with black outside the effective area;

2) The fine counting disc 301 is black, and the collected steel ball image is binarized; the characteristic that the steel ball is brighter than the fine counting disc 301 is used, that is, the steel ball and the fine counting disc 301 have a larger gray scale difference, and each The center of a steel ball is the brightest and has the largest gray value, which can reach more than 250. Find the point with the largest gray value, and then retrieve the points near it with a gray value above 220, and replace them all with green, so that The steel ball can be replaced by a small green spot, and at the same time, the position of the center of the ball, that is, the coordinate with the largest gray value, can be known, which is convenient for the judgment of the size of the ball later. Through the computer processing of the image, after the steel balls with different specifications are found, they are marked in red, and the machine alarms, and the steel balls with different specifications are manually taken out to achieve the purpose of identifying the size of the steel balls. It is a small ball, and the rest are normal balls. The dotted ball in the middle of the right picture in Figure 5 is a big ball, and the rest are normal balls.

On the inclined fine counting disc 301, the steel balls roll down due to their own weight, so the steel balls do not exist in isolation, but are closely connected with other steel balls. Therefore, take the steel ball to be judged as the center, determine the counting area, select a part of the steel ball and find the center of the ball, which is the brightest point.

The method of size identification is as follows: due to the inclination of the fine counting disc and the steel balls rolling down a certain distance and then stopping, each steel ball in the fine counting disc is close to at least one other steel ball. In order to eliminate the influence of industrial camera aberration and distortion, the precise counting disk is divided into multiple square areas according to the coordinates before the size recognition, and the image processing calculation and size recognition of the steel ball are performed in each area. In an area, the distance between the center of the first steel ball and all adjacent steel balls is calculated through the processing of the steel ball image by the computer control system, and their minimum value is calculated, and the minimum value must be close to The distance between the centers of two steel balls together. The minimum value is to remove the distance between the steel balls that are not adjacent to it, because the minimum value must be the distance between the steel balls that are closely adjacent to it, and the distance between the steel balls that are not adjacent to him must be greater than this value, as shown in Figure 6. Among the three steel balls, a is the distance between the steel balls that are close together, so a is smaller than b and c, and a is the minimum value. Then calculate the center distance between the second steel ball adjacent to the first steel ball and all adjacent steel balls, and so on, search according to the two directions of plane coordinates X and Y, until all the steel balls in the area are calculated . Then calculate the average value of these minimum values. If there are large balls in the plate, the average value is greater than the center distance of normal balls; heart distance. Starting from the first ball, compare each minimum value with the average value in order. When a certain value is greater than the average value, the steel ball is a big ball. If a certain value is smaller than the average value, then the steel ball is a small ball. ball.

Claims (8)

1. Steel ball accurate counting, size recognition device, its characterized in that includes:

the storage unit (1), the storage unit (1) comprises a storage disc (101) with convex edges at two sides;

the pre-counting unit (2) is arranged at the outlet end of the storage disc (101), and the pre-counting unit (2) comprises a pre-counting disc (201) with convex edges at two sides, an area adjusting mechanism (202) for adjusting the working area of the pre-counting disc (201) and a first lifting mechanism for driving the pre-counting disc (201) to move up and down;

the fine counting unit (3) is arranged at the outlet end of the pre-counting disc (201), and the fine counting unit (3) comprises a fine counting disc (301) with convex edges at two sides and an outlet mechanism (302) arranged at the outlet end of the fine counting disc (301);

an image acquisition unit (4) arranged above the fine counting unit (3) for acquiring the steel ball image on the fine counting disc (301);

the computer control system is connected with the image acquisition unit (4) and controls each motion unit to move and performs data processing on the steel ball images to obtain the number of steel balls and the size information of the steel balls;

the single compensation system (5) performs stepping compensation on the steel balls in the fine counting disc (301);

the storage disc (101), the pre-counting disc (201) and the fine counting disc (301) are integrally inclined, and the inlet end of the storage disc (101) is highest; when the pre-counting disc (201) is driven to the highest position by the first lifting mechanism, steel balls can roll from the pre-counting disc (201) to the fine counting disc (301) and steel balls of the storage disc (101) cannot roll into the pre-counting disc (201); when the pre-counting disc (201) is driven to the lowest position by the first lifting mechanism, steel balls in the storage disc (101) can roll into the pre-counting disc (201), and steel balls in the pre-counting disc (201) cannot roll into the fine-counting disc (301);

the single compensation system (5) comprises:

a feeding channel (508) arranged at one end of the outlet of the storage disc (101), wherein a compensation groove (507) is formed at the upper end of the feeding channel (508);

the compensating pusher (509) is arranged at one end of the outlet of the storage disc (101), the compensating pusher (509) is a push plate which is driven by a cylinder to lift along the side wall of the feeding channel (508), the push plate is inclined towards one end close to the feeding channel (508), the push plate is lower than the upper end surface of the storage disc (101) when being at the lowest position, and is higher than the side wall of the feeding channel (508) when being at the highest position;

one end of the compensation tube (506) is connected with the outlet end of the compensation groove (507), the other end of the compensation tube (506) is supported on one side of the inlet end of the fine counting disc (301) through a tube bracket (505), and a sensor is arranged at the ball inlet end of the compensation tube (506);

the compensating plate (504) is arranged at the end part of the compensating tube (506) at the inlet end of the fine counting disc (301), and a compensating channel communicated with the fine counting disc (301) is arranged on the compensating plate (504);

a stepping motor (501) provided on the compensation plate (504) through a motor bracket (502);

the compensation driving plate (503) is fixedly connected with the output shaft of the stepping motor (501), the compensation driving plate (503) is of a disc structure, a plurality of notches are uniformly distributed on the outer circumference of one side surface opposite to the port of the compensation pipe (506), each notch accommodates one steel ball, and the notch is positioned above a compensation channel of the compensation plate (504);

the area adjustment mechanism (202) includes:

an adjusting plate (203) arranged on the upper end surface of the pre-counting disc (201), wherein the adjusting plate (203) is parallel to the convex edge of the pre-counting disc (201);

a plurality of second polished rods (204) with one ends respectively connected with one side of the adjusting plate (203), wherein the second polished rods (204) penetrate through the convex edges of one side of the pre-counting disc (201) and extend out;

and a plurality of lock nuts (205), each lock nut (205) is in threaded connection with the convex edge, the lock nuts (205) penetrate through the convex edge, and the end parts of the lock nuts are in contact with the second polished rod (204).

2. The steel ball accurate counting and size identifying device according to claim 1, further comprising a second lifting mechanism (6), wherein the second lifting mechanism (6) comprises an upper supporting plate (601) and a lower supporting plate (603) which are oppositely arranged, and a lifting block (602) connected between the upper supporting plate (601) and the lower supporting plate (603), the lifting block (602) adjusts the inclination angle of the upper supporting plate (601), and the storage unit (1), the pre-counting unit (2) and the accurate counting unit (3) are all arranged on the upper supporting plate (601).

3. The steel ball accurate counting, size identifying device according to claim 1, characterized in that the storage unit (1) further comprises an outlet adjustment mechanism (102) arranged at the outlet end of the storage tray (101), the outlet adjustment mechanism (102) comprising:

the sliding block (105) is arranged on one right-angle edge of the outlet end of the storage disc (101) and is contacted with the upper end face of the storage disc (101), a sliding groove is formed in the length direction of the block (105), the sliding groove is in sliding fit with a sliding pin fixed on the storage disc (101), the sliding pin is fixed at a position close to the protruding edge of one side of the storage disc (101), and one end of the block (105) is flush with the outlet end of the storage disc (101);

the first polished rod (103) is hinged to one end, close to the outlet end of the storage disc (101), of the stop block (105), and the other end of the first polished rod (103) penetrates through the convex edge of the storage disc (101);

and the fixing nut (104) is in threaded connection with the convex edge of the storage disc (101), the fixing nut (104) is perpendicular to the first polished rod (103), the fixing nut (104) penetrates through the convex edge, and the end part of the fixing nut is in contact with the first polished rod (103).

4. The steel ball accurate counting and size identifying device according to claim 1, wherein the number of the second polished rods (204) is two, and one end of each of the two second polished rods (204) is fixedly connected with two ends of the side wall of the adjusting plate (203).

5. The steel ball accurate counting and size identifying device according to claim 1, wherein the first lifting mechanism is a linear cylinder, and the output end of the linear cylinder is fixedly connected with the lower end surface of the pre-counting disc (201); the outlet mechanism (302) is a rotary baffle (303), the upper parts of the two ends of the rotary baffle (303) are rotationally connected with the convex edges on the two sides of the outlet end of the fine counting disc (301), and the rotary shaft on one side of the rotary baffle (303) is connected with the output shaft of a motor;

the image acquisition unit (4) is an industrial camera (401).

6. The steel ball accurate counting and size identifying method based on the steel ball accurate counting and size identifying device as claimed in claim 1, which is characterized by comprising the following steps:

step one: the inclination angles of the storage disc (101), the pre-counting disc (201) and the fine counting disc (301) are adjusted through the second lifting mechanism (6), so that the steel balls roll in sequence and are arranged in a single layer, and the pre-counting disc (201) is adjusted to be at a low position through the first lifting mechanism;

step two: the working area S of the pre-counting disk (201) is adjusted by an area adjusting mechanism (202) so that the working area S=ND of the pre-counting disk (201) ² Wherein D is the diameter of the steel balls to be counted, and N is an integer smaller than the number of the steel balls actually needed;

step three: the size of the outlet of the storage disc (101) is adjusted through the outlet adjusting mechanism (102), so that one end part of the stop block (105) is contacted with one end part of the adjusting plate (203);

step four: pouring steel balls into a storage disc (101), sequentially entering the steel balls in the storage disc (101) into a pre-counting disc (201) until the working area of the pre-counting disc (201) is filled with the steel balls, and simultaneously, driving the steel balls to enter a compensation tube (506) by up-and-down movement of a compensation pusher (509) until the steel balls are filled in the compensation tube (506);

step five: driving the pre-counting disc (201) to a high position through a first lifting mechanism, enabling steel balls in the pre-counting disc (201) to roll into the fine counting disc (301), and driving the pre-counting disc (201) to a low position through the first lifting mechanism after all steel balls in the pre-counting disc (201) roll into the fine counting disc (301);

step six: acquiring a steel ball image on a precise counting disc (301) through an industrial camera (401), and transmitting the steel ball image to a computer control system;

step seven: the computer control system performs image processing on the steel ball image to obtain the number Q of the steel balls actually entering the fine counting disc (301) and the size information of the steel balls, judges whether the steel balls in the fine counting disc (301) are mixed with steel balls of other sizes, and if yes, the computer control system alarms; if not, executing the step eight;

step eight: the computer control system calculates and obtains the number of the steel balls needing single compensation, namely M-Q, wherein M is the number of the steel balls actually needed;

step nine: controlling the stepping motor (501) to rotate according to the number of the steel balls actually required obtained in the step eight until the number of the steel balls entering the fine counting disc (301) through the single compensation system (5) is M-Q;

step ten: the industrial camera (401) shoots the image of the steel balls in the fine counting disc (301) again, counts again, and confirms that the number of the steel balls is M;

step eleven: opening a rotary baffle (303) at the outlet end of the fine counting disc (301), releasing steel balls in the fine counting disc (301), and completing one-time technology and size identification;

step twelve: repeating the fourth step and the eleventh step to realize continuous counting.

7. The method for accurately counting and identifying the size of the steel ball according to claim 6, wherein the specific method for performing image processing on the steel ball in the seventh step is as follows:

1) Determining an effective area of the image, wherein the effective area is replaced by black;

2) The fine counting disc (301) adopts black, and binarizes the collected steel ball image; the center of each steel ball is brightest, the gray value is the largest, the gray value reaches more than 250, the point with the largest gray value is found, the point with the gray value more than 220 near the point is searched, all the points are replaced with green, the number of the steel balls is obtained through the processing of a computer on an image, after the steel balls with different specifications are found, the steel balls with different specifications are marked as red, a machine is used for alarming, and the steel balls with different specifications are manually taken out.

8. The method for precisely counting and identifying the size of the steel balls according to claim 6, wherein the inclination angles of the storage disc (101), the pre-counting disc (201) and the precise counting disc (301) are adjusted in the first step to ensure that the steel balls roll downwards smoothly and simultaneously ensure single-layer arrangement of the steel balls.