CN109341550B - Visual inspection integrated module and integration method - Google Patents
Visual inspection integrated module and integration method Download PDFInfo
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- CN109341550B CN109341550B CN201811407983.5A CN201811407983A CN109341550B CN 109341550 B CN109341550 B CN 109341550B CN 201811407983 A CN201811407983 A CN 201811407983A CN 109341550 B CN109341550 B CN 109341550B
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- G—PHYSICS
- G01—MEASURING; TESTING
- G01B—MEASURING LENGTH, THICKNESS OR SIMILAR LINEAR DIMENSIONS; MEASURING ANGLES; MEASURING AREAS; MEASURING IRREGULARITIES OF SURFACES OR CONTOURS
- G01B11/00—Measuring arrangements characterised by the use of optical techniques
- G01B11/02—Measuring arrangements characterised by the use of optical techniques for measuring length, width or thickness
- G01B11/04—Measuring arrangements characterised by the use of optical techniques for measuring length, width or thickness specially adapted for measuring length or width of objects while moving
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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
- Y02P90/02—Total factory control, e.g. smart factories, flexible manufacturing systems [FMS] or integrated manufacturing systems [IMS]
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- General Physics & Mathematics (AREA)
- Length Measuring Devices By Optical Means (AREA)
Abstract
A visual inspection integrated module and an integration method belong to the technical field of industrial visual inspection. The invention aims to solve the problem of poor use flexibility of an industrial machine vision detection system. The invention comprises a case, a camera, a lens, a light source, a two-dimensional rotation adjusting and locking mechanism, a hanging structure, an industrial personal computer and a PLC module; the inside of the case is provided with two cabins, the hanging structure is positioned on the top surface of the case, the camera, the lens, the light source and the two-dimensional rotation adjusting and locking mechanism are positioned in one cabin of the case, and the industrial personal computer and the PLC module are fixedly arranged in the other cabin of the case; the camera, the lens and the light source are fixedly connected together and are connected with a two-dimensional rotation adjusting and locking mechanism which is connected to the top wall of the case through a revolute pair; the industrial personal computer is electrically connected with the PLC module and used for controlling the camera to realize detection. The invention has wide application range, can be used for special detection of single small-batch products and can also be used in production lines of large-batch products.
Description
Technical Field
The invention relates to a visual inspection integrated module and an integration method, and belongs to the technical field of industrial visual inspection.
Background
At present, china has become one of the most active areas of machine vision development, and the industrial field is the field with the greatest specific gravity of machine vision application, and is mainly used for product quality detection, classification, robot positioning, packaging and the like, and is used for replacing artificial vision on one hand and improving the flexibility and the automation degree of production on the other hand. The method has the characteristics of non-contact property, real-time property, flexibility, accuracy and the like, and can effectively solve the problems of the traditional detection method.
The industrial machine vision detection system in the current market mainly adopts the forms of special detection machines, intelligent cameras and the like. The special detection machine has strong performance, can rapidly and accurately measure certain parts produced in a large scale, but has expensive price, large volume, heavy weight and poor flexibility. The intelligent camera is a highly integrated microminiature machine vision system which integrates the functions of image acquisition, processing and communication into a single camera, thereby providing a multifunctional, modularized and easy-to-implement machine vision solution. However, if the resolution of the smart camera is too large, the amount of image data to be processed is also relatively large, and due to the compact structure of the smart camera, the heat dissipation performance of the smart camera is limited, and too high resolution can cause too high temperature of the device, which results in degradation of imaging quality of a camera chip, deterioration of system stability and the like, so that the resolution detected by the smart camera is limited and the performance is poor.
Therefore, a visual detection integrated module which is suitable for various production lines, flexible in installation and configuration, convenient to maintain, wide in application range, high in cost performance, high in resolution and high in heat dissipation capability is needed.
Disclosure of Invention
The invention provides a visual detection integrated module and an integration method aiming at the defects in the prior art. The following presents a simplified summary of the invention in order to provide a basic understanding of some aspects of the invention. It should be understood that this summary is not an exhaustive overview of the invention. It is not intended to identify key or critical elements of the invention or to delineate the scope of the invention.
The technical scheme of the invention is as follows:
the visual detection integrated module comprises a case, a camera, a lens, a light source, a two-dimensional rotation adjusting and locking mechanism, a hanging structure, an industrial personal computer and a PLC module; the inside of the case is provided with two cabins, the hanging structure is positioned on the top surface of the case, the camera, the lens, the light source and the two-dimensional rotation adjusting and locking mechanism are positioned in one cabin of the case, and the industrial personal computer and the PLC module are fixedly arranged in the other cabin of the case; the camera, the lens and the light source are fixedly connected together and are connected with a two-dimensional rotation adjusting and locking mechanism which is connected to the top wall of the case through a revolute pair; the industrial personal computer is electrically connected with the PLC module and used for controlling the camera to realize detection.
And the camera, the light source and the PLC module are connected with the industrial personal computer through data and power supply cables and controlled by the industrial personal computer.
Further, the hanging structure comprises a hanging hole on a hanging hook mounting plate and a chassis connected with the production line, and the visual detection integrated module is mounted on the production line through the cooperation of the hanging hook and the hanging hole.
Further, two-dimensional rotation regulation locking mechanism include two-dimensional revolving stage, regulating hand wheel, locking mechanism, reducing gear and accommodate the lead screw, length direction and the width direction of two-dimensional revolving stage on set up respectively and install locking mechanism, the inside wall of quick-witted case on still install reducing gear, accommodate the lead screw's one end and install in locking mechanism's inside, accommodate the lead screw's the other end and the reducing gear cooperation installation back wear out the quick-witted case, regulating hand wheel and accommodate the lead screw cooperation installation.
Further, the chassis is provided with a three-dimensional heat dissipation structure at one side of the industrial personal computer and is provided with a heat dissipation device such as a fan.
The visual detection integration method is realized by a visual detection integration module, and comprises the following steps:
step 1: fixedly connecting a camera, a lens and a light source together and mounting the camera, the lens and the light source on a two-dimensional turntable;
step 2: the camera, the lens, the light source, the two-dimensional rotation adjusting and locking mechanism, the industrial personal computer and the PLC module are respectively arranged at the respective positions inside the case;
step 3: connecting a camera, a light source, a PLC module and an industrial personal computer through cables, and connecting the PLC module to an automatic production line system;
step 4: the hanging plate of the hanging structure is fixedly arranged on the production line, and the visual detection integrated module is arranged at a proper detection position on the production line and is fixed by being matched with a hanging hole on the chassis;
step 5, installing two detachable angle adjusting handwheels with scales of a two-dimensional rotation adjusting and locking mechanism on a visual detection integrated module, placing a detection workpiece under a lens of the detection module, starting up the detection module to run, adjusting a camera optical axis through the detachable angle adjusting handwheels with scales installed in two directions and a speed reducing mechanism thereof, observing an imaging effect through an external display until the optical axis is vertical to a plane where the measured size of the workpiece is located, and locking and fixing the two-dimensional turntable through the locking mechanism;
and 6, after the adjustment is finished, the visual detection integrated module is used as a part of a production line, the PLC module is used for controlling the movement and stop of the workpiece at the detection position, and the special measuring software and algorithm are used for automatically detecting the outline dimension of the part and judging whether the product is qualified.
The invention has the following beneficial effects:
1. the invention has simple structure, small volume, light weight and flexible installation and configuration, can be arranged at any position on a production line, and can realize the accurate measurement of the external dimension of the product after any procedure;
2. the invention has wide application range, can be used for special detection of single small-batch products and can also be used in production lines of large-batch products;
3. the camera has high resolution, strong performance and strong heat radiation capability, and can provide higher-precision visual detection;
4. the invention has the advantages of convenient installation and disassembly, convenient maintenance and high cost performance, and the internal module can be adjusted and replaced according to specific detected parts.
Drawings
Fig. 1: the arrangement schematic diagram of the invention;
fig. 2: a structural schematic diagram of the locking mechanism;
fig. 3: a structural schematic diagram of the speed reducing mechanism;
wherein: 1-a case; 2-cameras; 3-lens; 4-a light source; 5-two-dimensional rotation adjusting and locking mechanism; 51-a two-dimensional turntable; 52-a detachable angle adjusting hand wheel with scales; 53-locking mechanism; 54-a speed reduction mechanism; 55-adjusting a screw rod; 6-hanging structure; 7-an industrial personal computer; an 8-PLC module; 9-revolute pairs.
Detailed Description
The first embodiment is as follows: referring to fig. 1, a visual inspection integrated module of the present embodiment includes a chassis 1, a camera 2, a lens 3, a light source 4, a two-dimensional rotation adjustment locking mechanism 5, a hanging structure 6, an industrial personal computer 7, and a PLC module 8; the inside of the case 1 is provided with two cabins, the hanging structure 6 is positioned on the top surface of the case 1, the camera 2, the lens 3, the light source 4 and the two-dimensional rotation adjusting and locking mechanism 5 are positioned in one cabin of the case, and the industrial personal computer 7 and the PLC module 8 are fixedly arranged in the other cabin of the case; the camera 2, the lens 3 and the light source 4 are fixedly connected together and are connected with the two-dimensional rotation adjusting and locking mechanism 5, and the two-dimensional rotation adjusting and locking mechanism 5 is connected to the top wall of the case 1 through a revolute pair 9; the industrial personal computer 7 is electrically connected with the PLC module 8 and used for controlling the camera 2 to realize detection.
The second embodiment is as follows: referring to fig. 1, a visual inspection integrated module of the present embodiment is described, where the camera 2, the light source 4 and the PLC module 8 are all connected to the industrial personal computer 7 through data and power supply cables, and controlled by the industrial personal computer 7.
And a third specific embodiment: referring to fig. 1, the present embodiment is described as a visual inspection integrated module, and the hanging structure 6 includes a hook mounting plate connected to a production line and a hanging hole on a chassis, and the visual inspection integrated module is mounted on the production line by matching the hook with the hanging hole.
The specific embodiment IV is as follows: referring to fig. 1 to 3, a visual inspection integrated module according to this embodiment is described, the two-dimensional rotation adjustment locking mechanism 5 includes a two-dimensional turntable 51, an adjustment hand wheel 52, a locking mechanism 53, a speed reducing mechanism 54 and an adjustment screw 55, the locking mechanism 53 is installed in the length direction and the width direction of the two-dimensional turntable 51, the speed reducing mechanism 54 is also installed on the inner side wall of the case 1, one end of the adjustment screw 55 is installed in the locking mechanism 53, the other end of the adjustment screw 55 is installed in cooperation with the speed reducing mechanism 54, and then penetrates out of the case 1 to be installed, and the adjustment hand wheel 52 is installed in cooperation with the adjustment screw 55.
To further explain the operation principle and structure of the lock mechanism 53 and the reduction mechanism 54 of this embodiment, one of the implementation structures is disclosed below;
the locking mechanism 53 comprises a locking nut 531 and a locking sleeve 532, the locking sleeve 532 is an end face flange type locking sleeve, the locking sleeve 532 is a clamping-type locking sleeve, the outer end face of the locking sleeve 532 is a conical outer threaded sleeve ring, a conical inner hole surface is formed in the locking nut 531, an inner thread is machined on the conical inner hole surface, the locking nut 531 is screwed on the locking sleeve 532, the adjusting screw 55 is arranged in the locking sleeve 532 of the locking mechanism 53, the locking nut 531 is screwed, the clamping-type clamping part of the locking sleeve 532 can lock the adjusting screw 55, and thus under the action of the adjusting locking mechanism 53, the two-dimensional turntable 51 and modules such as a camera lens fixedly connected with the two-dimensional turntable 51 are locked and fixed;
the reduction mechanism 54 comprises a reduction gear box body 541, a reduction gear wheel 542 and a reduction pinion 543, the reduction gear wheel 542 and the reduction pinion 543 are rotatably arranged in the reduction gear box body 541 through bearings, the reduction gear wheel 542 and the reduction pinion 543 are arranged in a meshed mode, a gear shaft 544 is arranged at the center position of the reduction pinion 543, an adjusting hand wheel 52 is arranged on the gear shaft 544, a nut 545 is arranged at the center position of the reduction gear wheel 542, an adjusting screw 55 is arranged in the nut 545 in a matched mode, in the working process, the adjusting hand wheel 52 is manually rotated, the reduction pinion 543 is driven by the adjusting hand wheel 52 through the gear shaft 544, the reduction gear wheel 542 is rotated under the meshing effect of the reduction gear wheel 543 and the reduction gear wheel 542, the nut 545 arranged in the reduction gear wheel 542 is rotated at the moment, lateral displacement of the adjusting screw 55 is achieved, the adjusting screw 55 pushes the two-dimensional turntable 51 to swing left and right relatively under the lateral displacement effect of the adjusting screw 55, and the measuring light source of the camera 2 arranged under the two-dimensional turntable 51 is perpendicular to the plane of the outline dimension of a measured workpiece.
The swinging angles of the two-dimensional turntable 51 in two directions are finely adjusted by rotating the adjusting hand wheel 52, the hand wheel rotates for one circle, and the turntable angle is adjusted by 1 degree.
Fifth embodiment: referring to fig. 1, a visual inspection integrated module according to the present embodiment is described, in which a chassis 1 is provided with a three-dimensional heat dissipation structure on a side of an industrial personal computer 7, and a heat dissipation device such as a fan is disposed.
Specific embodiment six: referring to fig. 1, a visual inspection integrated module and a visual inspection integrated method according to the present embodiment are described, and the method is implemented by means of a visual inspection integrated module, and includes the following steps:
step 1: the camera 2, the lens 3 and the light source 4 are fixedly connected together and are mounted on the two-dimensional turntable 51;
step 2: the camera 2, the lens 3, the light source 4, the two-dimensional rotation adjusting and locking mechanism 5, the industrial personal computer 7 and the PLC module 8 are respectively arranged at the respective positions inside the case 1;
step 3: the camera 2, the light source 4, the PLC module 8 and the industrial personal computer 7 are connected through cables, and the PLC module 8 is connected into an automatic production line system;
step 4: the hanging plate of the hanging structure 6 is fixedly arranged on the production line, and the visual detection integrated module is arranged at a proper detection position on the production line and is fixed by being matched with the hanging hole on the chassis;
step 5, installing two detachable angle adjusting handwheels 52 with scales of a two-dimensional rotation adjusting and locking mechanism 5 on a visual detection integrated module, placing a detection workpiece under a lens of the detection module, starting up the detection module to run, adjusting a camera optical axis through the detachable angle adjusting handwheels 52 with scales, a speed reducing mechanism 54 and an adjusting screw rod 55 which are installed in two directions, observing an imaging effect through an external display until the optical axis is perpendicular to a plane where a measured size of the workpiece is located, and locking and fixing the two-dimensional turntable 51 through a locking mechanism 53;
and 6, after the adjustment is finished, the visual detection integrated module is used as a part of a production line, the PLC module is used for controlling the movement and stop of the workpiece at the detection position, and the special measuring software and algorithm are used for automatically detecting the outline dimension of the part and judging whether the product is qualified.
The specific working and use processes of the invention are as follows:
firstly, according to the appearance shape and size of a detected workpiece, a camera, a lens and an industrial personal computer with corresponding performances are selected, special measuring software and algorithm are designed, and then an event detection module is integrated, comprising the following steps:
step 1: the selected camera, the lens and the light source are fixedly connected together through the camera bracket, so that the three can move simultaneously, and then the two-dimensional turntable is mounted;
step 2: as shown in fig. 1, a module composed of a camera, a lens, a light source and a two-dimensional rotation adjusting and locking mechanism is integrally installed in one cabin of a chassis and fixed, and an industrial personal computer and a PLC module are respectively installed at the respective positions of the other cabin of the chassis and fixed;
step 3: connecting a camera, a light source, a PLC module and an industrial personal computer through cables, accessing a power supply, starting up and debugging, ensuring that the detection module works normally, and then accessing the PLC module into an automatic production line system;
step 4: after a detected workpiece passes through a certain process on a production line, detecting the external dimension, selecting a proper detection position above a workpiece conveyor belt after the process, fixedly mounting a hanging plate with a hanging structure at a proper position beside the conveyor belt of the production line, arranging a hanging hole at the back of a case if the hanging plate is in a hanging structure, arranging the hanging hole at the top surface of the case if the hanging plate is in a hanging structure, installing a visual detection integrated module right above the position of the workpiece on the conveyor belt through the cooperation of a hanging hole on the hanging plate and the hanging hole on the case, and fixing the visual detection integrated module;
step 5, placing the detected workpiece on a conveyor belt and under a lens of a detection module, starting up and debugging the detection module, ensuring that the detected workpiece is completely positioned in a visual field of the lens of the camera, installing two detachable angle adjusting handwheels with scales of a two-dimensional rotation adjusting and locking mechanism on a visual detection integrated module, finely adjusting pitching angles of a two-dimensional turntable of the camera through transmission of a speed reducing mechanism and an adjusting screw rod connected with the two-dimensional rotation handwheels, rotating the two-dimensional rotation table to adjust an optical axis of the camera, observing an imaging effect of the detected workpiece in the camera through an external display, adjusting the optical axis to be vertical to a plane of the outline dimension of the detected workpiece, ensuring measurement accuracy, and locking and fixing the two-dimensional turntable and the camera lens and other modules fixedly connected with the two-dimensional rotation table through the two locking mechanisms after adjusting the optical axis to be in place;
and 6, after the adjustment is finished, the vision detection integrated module is used as a part of a production line, the PLC module is connected into an automatic production line system, when a detected workpiece on a conveying belt in the detection process completely enters a camera lens visual field, the controller controls the conveying belt to stop moving, the detection module automatically detects the external dimension of the part through special measurement software and an algorithm, stores data, judges whether the product is qualified, and after the detection is finished, the controller controls the conveying belt to continue to operate, and when the next workpiece completely enters the camera lens visual field, the detection steps are repeated, so that the full-automatic detection of the detection process is formed.
The present embodiment is only exemplary of the present patent, and does not limit the scope of protection thereof, and those skilled in the art may also change the part thereof, so long as the spirit of the present patent is not exceeded, and the present patent is within the scope of protection thereof.
Claims (5)
1. A visual inspection integrated module, characterized in that: the device comprises a case (1), a camera (2), a lens (3), a light source (4), a two-dimensional rotation adjusting and locking mechanism (5), a hanging structure (6), an industrial personal computer (7) and a PLC module (8); the intelligent control system is characterized in that two cabins are arranged in the chassis (1), a hanging structure (6) is arranged on the top surface of the chassis (1), a camera (2), a lens (3), a light source (4) and a two-dimensional rotation adjusting and locking mechanism (5) are arranged in one cabin of the chassis, and an industrial personal computer (7) and a PLC module (8) are fixedly arranged in the other cabin of the chassis; the camera (2), the lens (3) and the light source (4) are fixedly connected together and are connected with the two-dimensional rotation adjusting and locking mechanism (5), and the two-dimensional rotation adjusting and locking mechanism (5) is connected to the top wall of the case (1) through a revolute pair (9); the industrial personal computer (7) is electrically connected with the PLC module (8) and used for controlling the camera (2) to realize detection;
the two-dimensional rotation adjusting and locking mechanism (5) comprises a two-dimensional rotary table (51), an adjusting hand wheel (52), a locking mechanism (53), a speed reducing mechanism (54) and an adjusting screw rod (55), wherein the locking mechanism (53) is respectively arranged in the length direction and the width direction of the two-dimensional rotary table (51), the speed reducing mechanism (54) is further arranged on the inner side wall of the case (1), one end of the adjusting screw rod (55) is arranged in the locking mechanism (53), the other end of the adjusting screw rod (55) passes out of the case (1) after being matched with the speed reducing mechanism (54), and the adjusting hand wheel (52) is matched with the adjusting screw rod (55);
the locking mechanism (53) comprises a locking nut (531) and a locking sleeve (532), the locking sleeve (532) is an end face flange type locking sleeve, the locking sleeve (532) is a clamping-type locking sleeve, the outer end face of the locking sleeve (532) is a conical external thread sleeve ring, the locking nut (531) is internally provided with a conical inner hole face, an internal thread is machined on the conical inner hole face, the locking nut (531) is screwed on the locking sleeve (532), the adjusting screw (55) is arranged in the locking sleeve (532) of the locking mechanism (53), and the clamping-type locking sleeve (532) can be screwed on the adjusting screw (55);
the speed reducing mechanism (54) comprises a speed reducing gear box body (541), a speed reducing large gear (542) and a speed reducing small gear (543), the speed reducing large gear (542) and the speed reducing small gear (543) are rotatably arranged in the speed reducing gear box body (541) through bearings, the speed reducing large gear (542) and the speed reducing small gear (543) are installed in a meshed mode, a gear shaft (544) is arranged at the center position of the speed reducing small gear (543), an adjusting hand wheel (52) is arranged on the gear shaft (544), a nut (545) is arranged at the center position of the speed reducing large gear (542), an adjusting screw rod (55) is arranged in the nut (545) in a matched mode, in the working process, the adjusting hand wheel (52) manually rotates to drive the speed reducing small gear (543) through the gear shaft (544), the speed reducing large gear (542) rotates under the meshing effect of the speed reducing small gear (543), and at the moment, the nut (545) arranged inside the speed reducing large gear (542) rotates, and the adjusting screw rod (55) transversely displaces.
2. A visual inspection integrated module as claimed in claim 1, wherein: the camera (2), the light source (4) and the PLC module (8) are all connected with the industrial personal computer (7) through data and power supply cables, and are controlled by the industrial personal computer (7).
3. A visual inspection integrated module as claimed in claim 1, wherein: the hanging structure (6) comprises a hanging hook mounting plate connected with the production line and a hanging hole on the case (1), and the visual detection integrated module is mounted on the production line through the cooperation of the hanging hook and the hanging hole.
4. A visual inspection integrated module as claimed in claim 1, wherein: the chassis (1) is provided with a three-dimensional heat dissipation structure at one side of the industrial personal computer (7) and is provided with a fan heat dissipation device.
5. A visual inspection integration method, which is implemented by the visual inspection integration module according to any one of claims 1 to 4, and is characterized in that: the method comprises the following steps:
step 1: the camera (2), the lens (3) and the light source (4) are fixedly connected together and are mounted on the two-dimensional turntable (51);
step 2: the camera (2), the lens (3), the light source (4), the two-dimensional rotation adjusting and locking mechanism (5), the industrial personal computer (7) and the PLC module (8) are respectively arranged at the respective positions inside the case (1);
step 3: the camera (2), the light source (4) and the PLC module (8) are connected with the industrial personal computer (7) through cables, and the PLC module (8) is connected into an automatic production line system;
step 4: the hook plate of the hanging structure (6) is fixedly arranged on the production line, and the visual detection integrated module is arranged at a proper detection position on the production line and is fixed by being matched with a hanging hole on the chassis;
step 5, two detachable angle adjusting handwheels (52) with scales of a two-dimensional rotation adjusting and locking mechanism (5) are installed on a visual detection integrated module, a detection workpiece is placed under a lens of the detection module, the detection module is started to operate, a camera optical axis is adjusted through the detachable angle adjusting handwheels (52) with scales and a speed reducing mechanism (54) installed in two directions, an imaging effect is observed through an external display until the optical axis is perpendicular to a plane where a measured size of the workpiece is located, and a two-dimensional turntable (51) is locked and fixed through a locking mechanism (53);
and 6, after the adjustment is finished, the visual detection integrated module is used as a part of a production line, the PLC module is used for controlling the movement and stop of the workpiece at the detection position, and the special measuring software and algorithm are used for automatically detecting the outline dimension of the part and judging whether the product is qualified.
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| CN201811407983.5A CN109341550B (en) | 2018-11-23 | 2018-11-23 | Visual inspection integrated module and integration method |
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| CN109341550B true CN109341550B (en) | 2023-07-18 |
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2018
- 2018-11-23 CN CN201811407983.5A patent/CN109341550B/en active Active
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| Publication number | Priority date | Publication date | Assignee | Title |
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| CN205102780U (en) * | 2015-10-28 | 2016-03-23 | 南京临点三维科技有限公司 | Single camera structure photoscanner |
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