CN107274407B - Steel ball accurate counting and size identifying device and method - Google Patents
Steel ball accurate counting and size identifying device and method Download PDFInfo
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- CN107274407B CN107274407B CN201710683914.6A CN201710683914A CN107274407B CN 107274407 B CN107274407 B CN 107274407B CN 201710683914 A CN201710683914 A CN 201710683914A CN 107274407 B CN107274407 B CN 107274407B
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- G—PHYSICS
- G06—COMPUTING; CALCULATING OR COUNTING
- G06T—IMAGE DATA PROCESSING OR GENERATION, IN GENERAL
- G06T7/00—Image analysis
- G06T7/0002—Inspection of images, e.g. flaw detection
- G06T7/0004—Industrial image inspection
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- G—PHYSICS
- G06—COMPUTING; CALCULATING OR COUNTING
- G06M—COUNTING MECHANISMS; COUNTING OF OBJECTS NOT OTHERWISE PROVIDED FOR
- G06M1/00—Design features of general application
- G06M1/22—Design features of general application for visual indication of the result of count on counting mechanisms, e.g. by window with magnifying lens
- G06M1/24—Drums; Dials; Pointers
- G06M1/248—Discs
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- G—PHYSICS
- G06—COMPUTING; CALCULATING OR COUNTING
- G06T—IMAGE DATA PROCESSING OR GENERATION, IN GENERAL
- G06T2207/00—Indexing scheme for image analysis or image enhancement
- G06T2207/30—Subject of image; Context of image processing
- G06T2207/30242—Counting objects in image
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- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
- Y02P—CLIMATE CHANGE MITIGATION TECHNOLOGIES IN THE PRODUCTION OR PROCESSING OF GOODS
- Y02P90/00—Enabling technologies with a potential contribution to greenhouse gas [GHG] emissions mitigation
- Y02P90/30—Computing systems specially adapted for manufacturing
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Abstract
The device and the method for accurately counting and identifying the size of the steel ball belong to the technical field of steel ball manufacturing and aim to solve the problems that the counting accuracy is poor and the size of the steel ball cannot be identified in the prior art. The invention comprises a storage unit; the pre-counting unit is arranged at the outlet end of the storage disc and comprises a pre-counting disc with convex edges on two sides, an area adjusting mechanism for adjusting the working area of the pre-counting disc and a first lifting mechanism for driving the pre-counting disc to move up and down; the fine counting unit is arranged at the outlet end of the pre-counting disc; the image acquisition unit is arranged above the fine counting unit and is used for acquiring the steel ball image on the fine counting disc; the computer control system is connected with the image acquisition unit, controls each motion unit to move and processes the steel ball image to obtain the number of steel balls and the size information of the steel balls; the single compensation system performs stepping compensation on the steel balls in the precise counting disc; the storage disc, the pre-counting disc and the fine counting disc are integrally inclined.
Description
Technical Field
The invention belongs to the technical field of steel ball manufacturing, and particularly relates to a device and a method for accurately counting and identifying the size of a steel ball.
Background
At present, most of the steel balls at home and abroad are counted by adopting a weighing counting method, and the method adopts an electronic scale to weigh the steel balls and calculates the number of the steel balls by adopting a manual reading method. Due to errors of manual reading and the fact that rust-proof oil and the like are coated on the surface of the steel ball, weighing and counting are inaccurate, counting efficiency is low, and working strength is high. Meanwhile, manual counting also causes the problems of sphere scratch, sphere mixing and the like. The ball mixing means that steel balls with other specifications and sizes are mixed in due to misoperation in manual operation. Once the steel balls with different specifications and sizes are installed in the bearing, serious potential safety hazards are brought, and if serious accidents occur, great influence is brought to enterprises.
Aiming at the problems of inaccurate counting, low counting efficiency and high working strength of electronic scale weighing, the existing counting adopts an image acquisition mode to count, and the Chinese patent with the publication number of CN 103164740 discloses an intelligent automatic steel ball counting device and a counting scheme of an automatic counting method thereof. Because of the structural design of the feeding roller and the compensating roller of the automatic compensating device, the compensating quantity is inaccurate, the requirement of accurate counting cannot be met, and meanwhile, the steel ball size cannot be identified.
Disclosure of Invention
The invention aims to provide a device and a method for accurately counting and identifying the size of a steel ball, which solve the problems of poor counting accuracy and incapability of identifying the size of the steel ball in the prior art.
In order to achieve the above object, the steel ball accurate counting and size identifying device of the present invention comprises:
the storage unit comprises a storage disc with convex edges at two sides;
the pre-counting unit is arranged at the outlet end of the storage disc and comprises a pre-counting disc with convex edges on two sides, an area adjusting mechanism for adjusting the working area of the pre-counting disc and a first lifting mechanism for driving the pre-counting disc to move up and down;
the fine counting unit is arranged at the outlet end of the pre-counting disc and comprises a fine counting disc with convex edges on two sides and an outlet mechanism arranged at the outlet end of the fine counting disc;
the image acquisition unit is arranged above the fine counting unit and is used for acquiring the steel ball image on the fine counting disc;
the computer control system is connected with the image acquisition units, controls the motion units 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 performs stepping compensation on the steel balls in the precise counting disc;
the storage disc, the pre-counting disc and the fine counting disc are integrally inclined, and the inlet end of the storage disc is highest; when the pre-counting disc is driven to the highest position by the first lifting mechanism, the steel balls can roll from the pre-counting disc to the fine counting disc, and the steel balls of the storage disc cannot roll into the pre-counting disc; when the pre-counting disc is driven to the lowest position by the first lifting mechanism, steel balls in the storage disc can roll into the pre-counting disc, and steel balls in the pre-counting disc cannot roll into the fine-counting disc.
The single compensation system includes:
the feeding channel is arranged at one end of the outlet of the storage disc, and the upper end of the feeding channel is provided with a compensation groove;
the compensation pusher is arranged at one end of the outlet of the storage disc, the compensation pusher drives a push plate which is lifted along the side wall of the feeding channel through a cylinder, the push plate inclines towards one end close to the feeding channel, the push plate is lower than the upper end surface of the storage disc when being at the lowest position, and is higher than the side wall of the feeding channel when being at the highest position;
one end of the compensation tube is connected with the outlet end of the compensation groove, the other end of the compensation tube is supported at one side of the inlet end of the fine counting disc through a tube bracket, and a sensor is arranged at the ball inlet end of the compensation tube;
the compensating plate is arranged at the end part of the compensating pipe at the inlet end of the fine counting disc, and a compensating channel communicated with the fine counting disc is arranged on the compensating plate;
a stepping motor arranged on the compensation plate through a motor bracket;
and the compensation driving plate is fixedly connected with the output shaft of the stepping motor, the compensation driving plate 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, each notch accommodates one steel ball, and the notches are positioned above the compensation channel of the compensation plate.
The steel ball accurate counting and size identifying device further comprises a second lifting mechanism, the second lifting mechanism comprises an upper supporting plate, a lower supporting plate and a lifting block, the upper supporting plate and the lower supporting plate are oppositely arranged, the lifting block is connected between the upper supporting plate and the lower supporting plate, the lifting block is used for adjusting the inclination angle of the upper supporting plate, and the material storage unit, the pre-counting unit and the accurate counting unit are all arranged on the upper supporting plate.
The storage unit still includes the export guiding mechanism of setting at the storage tray exit end, export guiding mechanism includes:
the sliding pin is fixed at a position close to a convex edge on one side of the storage disc, and one end of the stop block is flush with the outlet end of the storage disc;
the first polished rod is hinged with one end of the stop block, which is close to the outlet end of the storage disc, and the other end of the first polished rod penetrates through the convex edge of the storage disc;
and the fixing nut is in threaded connection with the convex edge of the storage disc, the fixing nut is vertical to the first polished rod, and the fixing nut passes through the convex edge, and the end part of the fixing nut is in contact with the first polished rod.
The area adjustment mechanism includes:
the adjusting plate is arranged on the upper end face of the pre-counting disc, and the adjusting plate is parallel to the convex edge of the pre-counting disc;
a plurality of second polished rods, one ends of which are respectively connected with one side of the adjusting plate, and the second polished rods penetrate through the convex edges of one side of the pre-counting disc and extend out;
and a plurality of lock nuts, each lock nut is in threaded connection with the convex edge, the lock nuts penetrate through the convex edge, and the end parts of the lock nuts are in contact with the second polished rod.
The number of the second polished rods is two, and one end parts of the two second polished rods are fixedly connected with two ends of the side wall of the adjusting plate respectively.
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.
The outlet mechanism is a rotary baffle, the upper parts of the two ends of the rotary baffle are rotationally connected with the convex edges on the two sides of the outlet end of the fine counting disc, and the rotary shaft on one side of the rotary baffle is connected with the output shaft of the rotary cylinder;
the image acquisition unit is an industrial camera.
The steel ball accurate counting and size identification method based on the steel ball accurate counting and size identification device comprises the following steps:
step one: the inclination angles of the storage disc, the pre-counting disc and the fine counting disc are adjusted through the second lifting mechanism, so that the steel balls roll in sequence and are arranged in a single layer, and the pre-counting disc is adjusted to be at a low position through the first lifting mechanism;
step two: the working area S of the pre-counting disc is adjusted by the area adjusting mechanism, so that the working area S=ND of the pre-counting disc 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 is adjusted through the outlet adjusting mechanism, so that one end part of the stop block is contacted with one end part of the adjusting plate;
step four: pouring the steel balls into a storage disc, sequentially entering the steel balls in the storage disc into a pre-counting disc until the steel balls are filled in the working area of the pre-counting disc, and simultaneously driving the steel balls to enter a compensation tube by the up-and-down motion of a compensation pusher until the steel balls are filled in the compensation tube;
step five: driving the pre-counting disc to a high position through a first lifting mechanism, enabling steel balls in the pre-counting disc to roll into the fine counting disc until the steel balls in the pre-counting disc roll into the fine counting disc completely, and driving the pre-counting disc to a low position through the first lifting mechanism;
step six: acquiring steel ball images on the precise counting disc through an industrial camera, and transmitting the steel ball images 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 and the size information of the steel balls, judges whether the steel balls in the fine counting disc 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 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 through the single compensation system is M-Q;
step ten: the industrial camera shoots the image of the steel balls in the fine counting disc again, counts again, and confirms that the number of the steel balls is M;
step eleven: opening a rotary baffle plate at the outlet end of the fine counting disc, releasing steel balls in the fine counting disc, and finishing one-time counting and size identification;
step twelve: repeating the fourth step and the eleventh step to realize continuous counting.
The specific method for carrying out image processing on the steel ball in the seventh step comprises the following steps:
1) Determining an effective area of the image, wherein the effective area is replaced by black;
2) The fine counting disc adopts black color to carry out binarization processing on 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.
In the first step, the inclination angles of the storage disc, the pre-counting disc and the fine counting disc are adjusted to ensure that the steel balls roll downwards smoothly, and meanwhile, the single-layer arrangement of the steel balls is ensured.
The beneficial effects of the invention are as follows: the steel ball accurate counting and size identifying device and method provided by the invention have the advantages that the number of the steel balls to be counted in advance can be made to be as close as possible to or smaller than the target number, namely the number of the steel balls actually needed through the adjustment of the area, so that the compensation number can be reduced, and the efficiency is improved; the precise counting disc counts the number precisely through the industrial camera, calculates the number to be compensated, and then precisely compensates by the single compensation system, thereby achieving the purpose of collecting the precise number. The large ball and the small ball are determined through the comparison of the adjacent radius and the average value, so that the identification of the size of the steel ball is realized, and the problem of serious accidents caused by mixing steel balls with different specifications is avoided.
Drawings
FIG. 1 is a schematic diagram of the whole structure of a steel ball accurate counting and size identifying device;
FIG. 2 is a schematic diagram of a single compensation system in the steel ball accurate counting and size recognition device of the invention;
FIG. 3 is a schematic view of an outlet adjustment mechanism in the steel ball accurate counting and size recognition device of the invention;
FIG. 4 is a schematic view of an area adjusting mechanism in the steel ball accurate counting and size identifying device of the invention;
FIG. 5 is a schematic diagram of the steel ball size recognition in the steel ball accurate counting and size recognition method of the invention;
FIG. 6 is a schematic diagram of the size recognition in the steel ball accurate counting and size recognition method of the invention;
wherein: 1. the device comprises a storage unit, 101, a storage disc, 102, an outlet adjusting mechanism, 103, a first polish rod, 104, a fixing nut, 105, a stop block, 2, a pre-counting unit, 201, a pre-counting disc, 202, an area adjusting mechanism, 203, an adjusting plate, 204, a second polish rod, 205, a lock nut, 3, a fine counting unit, 301, a fine counting disc, 302, an outlet mechanism, 303, a rotary baffle plate, 4, an image acquisition unit, 401, an industrial camera, 5, a single compensation system, 501, a stepping motor, 502, a motor bracket, 503, a compensation driving plate, 504, a compensation plate, 505, a pipe bracket, 506, a compensation pipe, 507, a compensation groove, 508, a feeding channel, 509, a compensation pusher, 6, a second lifting mechanism, 601, an upper support plate, 602, a lifting block, 603 and a lower support plate.
Detailed Description
Embodiments of the present invention will be further described with reference to the accompanying drawings.
Referring to fig. 1, the steel ball accurate counting and size identifying device of the invention comprises:
the storage unit 1, wherein 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 on 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;
a fine counting unit 3 arranged at the outlet end of the pre-counting disc 201, wherein 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;
the image acquisition unit 4 is arranged above the fine counting unit 3 and is used 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;
and a single compensation system 5, wherein the single compensation system 5 performs step 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 the 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.
Referring to fig. 2, the single compensation system 5 includes:
a feeding channel 508 arranged at one end of the outlet of the storage disc 101, wherein a compensation groove 507 is arranged at the upper end of the feeding channel 508;
the compensation pusher 509 is arranged at one end of the outlet of the storage disc 101, the compensation pusher 509 is a push plate which is driven by a cylinder to lift along the side wall of the feed channel 508, the push plate inclines towards one end close to the feed channel 508, the push plate is lower than the upper end surface of the storage disc 101 when in the lowest position, and is higher than the side wall of the feed channel 508 when in 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 at 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 pipe 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 stepper motor 501 mounted on a compensation plate 504 by a motor mount 502;
and a compensation driving plate 503 fixedly connected with the output shaft of the stepper motor 501, wherein the compensation driving plate 503 has a disc structure, a plurality of notches are uniformly distributed on the outer circumference of a side surface opposite to the port of the compensation tube 506, each notch accommodates a steel ball, and the notch is positioned above the compensation channel of the compensation plate 504.
The steel ball accurate counting and size identifying device further comprises a second lifting mechanism 6, the second lifting mechanism 6 comprises an upper supporting plate 601, a lower supporting plate 603 and a lifting block 602, the upper supporting plate 601 and the lower supporting plate 603 are oppositely arranged, the lifting block 602 is connected between the upper supporting plate 601 and the lower supporting plate 603, the inclination angle of the upper supporting plate 601 is adjusted, and the material storage unit 1, the pre-counting unit 2 and the accurate counting unit 3 are all arranged on the upper supporting plate 601.
Referring to fig. 3, the storage unit 1 further includes an outlet adjustment mechanism 102 disposed at an outlet end of the storage tray 101, and the outlet adjustment mechanism 102 includes:
the stop block 105 is arranged on the right-angle edge at one side of the outlet end of the storage disc 101 and is contacted with the upper end surface of the storage disc 101, a chute is arranged in the length direction of the stop block 105, the chute 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 convex edge at one side of the storage disc 101, and one end of the stop block 105 is flush with the outlet end of the storage disc 101;
the first polish rod 103 is hinged with one end of the stop block 105, which is close to the outlet end of the storage disc 101, and the other end of the first polish rod 103 passes through the convex edge of the storage disc 101;
and the fixing nut 104 is in threaded connection with the protruding 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 protruding edge, and the end part of the fixing nut is in contact with the first polished rod 103.
Referring to fig. 4, the area adjusting mechanism 202 includes:
an adjusting plate 203 placed 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 polish rods 204, one ends of which are respectively connected with one side of the adjusting plate 203, wherein the second polish 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 flange, the lock nut 205 passes through the flange, and the end part of the lock nut is in contact with the second polished rod 204.
The number of the second polish rods 204 is two, and one end of each of the two second polish rods 204 is fixedly connected with two ends of the side wall of the adjusting plate 203.
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 rotating baffle 303, the upper parts of the two ends of the rotating 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 rotating shaft on one side of the rotating baffle 303 is connected with the output shaft of the rotating cylinder;
the image acquisition unit 4 is an industrial camera 401.
The working principle of the steel ball accurate counting and size identifying device is as follows: when M steel balls need to be counted, the area of the pre-counting disc 201 can be changed by adjusting the extension length of the second polished rod 204, and after adjustment, the steel balls entering the pre-counting disc 201 each time are locked by a locking nut 205Within M, the working area s=nd of the pre-counting disc 201 2 N is the maximum integer value smaller than M, because the area of the pre-counting disc 201 cannot be just N times of the square area occupied by each rigid ball, and finally the number of steel balls actually entering the pre-counting disc 201 is Q, and the difference between Q and M is compensated by a single compensation mechanism at the back so as to achieve the purpose of accurate counting. The pre-counting disc 201 is lowered to a low position under the driving of the cylinder and returns to the initial state. The stroke of the cylinder is set as follows: when the cylinder is lowered, the steel balls of the storage disc 101 can smoothly roll into the pre-counting disc 201 and cannot roll into the fine counting disc 301. Since the adjustment of the area of the pre-counting disc 201 brings a certain dead angle, the flow of the steel balls is not smooth, so the outlet adjusting mechanism 102 is adopted to adjust the width of the outlet of the storage disc 101. The position of the baffle is adjusted by adjusting the length of the extended polish rod so that the pellets can smoothly flow into the pre-counting disc 201. The pre-counting disc 201 is then raised to a high position, so that the pre-counting disc 201 is higher than the storage disc 101 and the fine counting disc 301, and a certain number of steel balls in the pre-counting disc enter the fine counting disc 301 for accurate counting. The CCD camera above the fine counting disc 301 is used for shooting images of the steel balls in the fine counting disc 301, and the steel balls are precisely counted through image processing. For example: when M steel balls are needed, the number of the steel balls reaching the fine counting disc 301 is Q, and Q is less than or equal to the target number M through adjustment of the pre-counting disc 201. The single compensation system 5 is started, and the single compensation mechanism automatically compensates M-Q steel balls to enter the precise counting disc 301 through signals given by a computer, so that the purpose of precisely counting the M steel balls is achieved. The compensating pusher 509 pushes the steel ball at one side edge of the stock channel to above the compensating groove 507, and freely slides down the inclined plane into the compensating groove 507, and then enters the compensating pipe 506 for storage. The compensating pusher 509 returns to the home position and pushes it next until a sensor mounted at the beginning of the compensating tube 506 detects that the steel ball in the tube is full. The number of steel balls per push is determined by the push plate length of the compensating pusher 509. The width of the compensating push plate can only accommodate one row of steel balls. When compensation is required, the compensation dial 503 is driven to rotate by a stepping motor 501 to perform single-ball compensation, and the number of the required compensation steel balls is M-Q. To improve the compensation efficiency, the area of the pre-counting disk 201 is adjusted so that the value of Q is smaller than but closer to M.
The steel ball accurate counting and size identification method based on the steel ball accurate counting and size identification device comprises the following steps:
step one: according to the size and specification of the steel balls, 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, and as the steel balls of the same type are packed for a long time each time, the angles are not adjusted frequently, so that the height of the second lifting mechanism 6 is adjusted before use, the steel balls can roll downwards from the storage channel by self weight, in the embodiment, the steel balls with the diameter of 7.938mm are taken as an example, the inclination angles are 6-10 degrees, the steel balls roll in sequence, and the pre-counting disc 201 is adjusted to be at a low position through the first lifting mechanism;
step two: the operating area S of the pre-counter plate 201 is adjusted by the area adjusting mechanism 202 such that the operating area s=nd of the pre-counter plate 201 2 Wherein, D is the diameter of the steel balls to be counted, N is an integer smaller than the number of the steel balls actually needed, and 3000 is taken as an example of the number of the steel balls actually needed in the embodiment;
step three: 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, and the width of the outlet of the storage disc 101 is ensured to be the same as the width of the inlet of the pre-counting disc 201;
step four: the steel balls are poured into the storage disc 101, the steel balls in the storage disc 101 sequentially enter the pre-counting disc 201 until the working area of the pre-counting disc 201 is filled with the steel balls, meanwhile, the compensation pusher 509 moves up and down to drive the steel balls to enter the compensation tube 506 until the compensation tube 506 is filled with the steel balls, the pre-counting disc 201 is at a low position initially, the steel balls in the storage disc 101 roll into the pre-counting disc 201 by self weight, and the rolling is distributed on the pre-counting disc 201 in a single layer, the area of the pre-counting disc 201 is adjustable, the number of the 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 filled with the steel balls, the steel balls naturally stop feeding, and the number of the steel balls in the disc can be roughly estimated through the adjustment of the area of the pre-counting disc 201, but the number of the steel balls is not more than required;
step five: the first lifting mechanism drives the pre-counting disc 201 to be at a high position, so that steel balls in the pre-counting disc 201 roll into the fine counting disc 301, and after all steel balls in the primary counting disc roll into the fine counting disc, the first lifting mechanism drives the pre-counting disc 201 to be at a low position;
step six: acquiring a steel ball image on the 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, and releasing the steel balls in the fine counting disc 301 to finish one-time technology and size identification;
step twelve: repeating the fourth step and the eleventh step to realize continuous counting.
Referring to fig. 5, a specific method for performing image processing on the steel ball in the step seven 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 color to carry out binarization processing on the collected steel ball image; the characteristic that the steel balls are brighter than the fine counting disc 301 is utilized, namely, the steel balls and the fine counting disc 301 have larger gray level difference, the center of each steel ball is brightest, the gray level value is largest, more than 250 points with the largest gray level value can be found, then the points with the gray level value more than 220 nearby the steel balls are searched, and all the points are replaced by green, so that the steel balls can be replaced by a small green spot, and meanwhile, the position of the center of the steel ball, namely the coordinate with the largest gray level value, can be known, and the judgment of the following large and small balls is facilitated. The computer processes the images, then marks the steel balls with different specifications as red, gives an alarm by a machine, and manually takes out the steel balls with different specifications to achieve the aim of identifying the sizes of the steel balls, wherein the broken line ball in the middle of the left graph in fig. 5 is a small ball, the rest is a normal ball, the broken line ball in the middle of the right graph in fig. 5 is a big ball, and the rest is a normal ball.
On the inclined fine counting disk 301, the steel balls roll downward due to their own weight, so that the steel balls do not exist in isolation but closely lean against other steel balls. Therefore, the steel ball to be judged is taken as the center, a counting area is determined, a part of steel balls are selected, and the center of the small ball, namely the brightest point, is found out.
The size recognition method is as follows: because the fine counting disc is inclined and the steel balls stop after rolling downwards a certain distance, each steel ball in the fine counting disc is at least close to one other steel ball. In order to eliminate the influence of aberration and distortion of an industrial camera, the precise counting disc is divided into a plurality of square areas according to coordinates before size identification, and image processing calculation and size identification are carried out on the steel balls in each area. In one area, the center distances between the first steel ball and all adjacent steel balls are calculated through the processing of the image of the steel balls by the computer control system, and the minimum value of the center distances between the first steel ball and all adjacent steel balls is calculated, wherein the minimum value is necessarily the center distances between the two steel balls which are close together. This minimum is to remove the distance between the steel ball that is not adjacent to it, since the minimum must be the distance between the steel ball that is immediately adjacent to it, and the distance between the steel ball that is not adjacent to it must be greater than this value, as shown in fig. 6. A is the distance between the steel balls which are close together in the three steel balls, so a is smaller than b and c, and a is the minimum value. And calculating the center distances between the second steel ball adjacent to the first steel ball and all the adjacent steel balls, and so on, searching according to the two directions of the plane coordinates X, Y until all the steel balls in the area are calculated. Then calculating the average value of the minimum values, and if a large ball exists in the tray, the average value is larger than the center distance of a normal ball; if there are small balls in the pan, the average value is smaller than the center-to-center distance of normal steel balls that are normally close together. Each minimum value is compared with the average value in sequence from the first ball, when a certain value is larger than the average value, the steel ball is a big ball, and when a certain value is smaller than the average value, the steel ball is a small 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.
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| CN116384435B (en) * | 2023-03-30 | 2024-03-22 | 华能山东石岛湾核电有限公司 | System and method for judging neglected recording of high-temperature gas cooled reactor counter |
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