CN109516067B - Part detection system and detection method - Google Patents
Part detection system and detection method Download PDFInfo
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- CN109516067B CN109516067B CN201811337363.9A CN201811337363A CN109516067B CN 109516067 B CN109516067 B CN 109516067B CN 201811337363 A CN201811337363 A CN 201811337363A CN 109516067 B CN109516067 B CN 109516067B
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- 238000001514 detection method Methods 0.000 title abstract description 25
- 238000004891 communication Methods 0.000 claims abstract description 8
- 230000001960 triggered effect Effects 0.000 claims abstract description 4
- 238000000034 method Methods 0.000 claims description 16
- 238000007689 inspection Methods 0.000 claims description 9
- 230000001360 synchronised effect Effects 0.000 claims description 8
- 230000001681 protective effect Effects 0.000 claims description 5
- 238000000926 separation method Methods 0.000 claims description 4
- 239000003086 colorant Substances 0.000 claims description 3
- 230000005540 biological transmission Effects 0.000 description 3
- 230000004888 barrier function Effects 0.000 description 2
- 238000010586 diagram Methods 0.000 description 2
- 239000006185 dispersion Substances 0.000 description 1
- 230000000694 effects Effects 0.000 description 1
- 238000005516 engineering process Methods 0.000 description 1
- 230000002349 favourable effect Effects 0.000 description 1
- 238000004519 manufacturing process Methods 0.000 description 1
- 238000011084 recovery Methods 0.000 description 1
Classifications
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B65—CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
- B65G—TRANSPORT OR STORAGE DEVICES, e.g. CONVEYORS FOR LOADING OR TIPPING, SHOP CONVEYOR SYSTEMS OR PNEUMATIC TUBE CONVEYORS
- B65G15/00—Conveyors having endless load-conveying surfaces, i.e. belts and like continuous members, to which tractive effort is transmitted by means other than endless driving elements of similar configuration
- B65G15/30—Belts or like endless load-carriers
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B65—CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
- B65G—TRANSPORT OR STORAGE DEVICES, e.g. CONVEYORS FOR LOADING OR TIPPING, SHOP CONVEYOR SYSTEMS OR PNEUMATIC TUBE CONVEYORS
- B65G21/00—Supporting or protective framework or housings for endless load-carriers or traction elements of belt or chain conveyors
- B65G21/20—Means incorporated in, or attached to, framework or housings for guiding load-carriers, traction elements or loads supported on moving surfaces
- B65G21/2045—Mechanical means for guiding or retaining the load on the load-carrying surface
- B65G21/2063—Mechanical means for guiding or retaining the load on the load-carrying surface comprising elements not movable in the direction of load-transport
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B65—CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
- B65G—TRANSPORT OR STORAGE DEVICES, e.g. CONVEYORS FOR LOADING OR TIPPING, SHOP CONVEYOR SYSTEMS OR PNEUMATIC TUBE CONVEYORS
- B65G47/00—Article or material-handling devices associated with conveyors; Methods employing such devices
- B65G47/02—Devices for feeding articles or materials to conveyors
- B65G47/16—Devices for feeding articles or materials to conveyors for feeding materials in bulk
Abstract
The invention discloses a part detection system and a detection method, wherein the detection system comprises a conveying device, a camera and image processing equipment, wherein baffle blocks with equal intervals are arranged on a first conveying belt, a sensor is fixedly arranged on the outer side of the first conveying belt, the sensor is in communication connection with a control mechanism for controlling opening and closing of the baffle plates and the camera, when each baffle block advances to the end face or the vertex of the baffle block to form a vertical line with the center of an outlet of a first feed hopper, the baffle plates are triggered to open, parts in the first feed hopper drop, and signals of the sensor trigger the camera to shoot at the same time. The rear baffle is closed after a certain time delay. By utilizing the technical scheme of the invention, the parts can be well scattered on the first conveyor belt, the photographing time of the camera can be controlled, the phenomena of shielding, stacking and the like among the parts are avoided, no stop block appears in the pictures acquired by the camera, and the full-automatic detection without manual intervention is realized.
Description
Technical Field
The invention relates to the field of automatic detection, in particular to a part detection system and a detection method.
Background
In the field of part classification and detection, although the machine vision technology is used for identification and sorting, the parts in the picture are not easy to identify by a computer in the image processing process due to the phenomena of shielding, stacking and the like easily existing between the parts, so that judgment errors are caused, and the accuracy is not high. In the part conveying process, manual intervention is also needed to manually separate parts with shielding and stacking conditions, and the semi-automatic detection system and method solve part of problems, improve the production efficiency, still have no thorough liberation labor force, and still have the advantages that the accuracy and the efficiency of part detection are still to be further improved.
Disclosure of Invention
In order to solve the problems, the invention provides the part detection system, the whole process is fully automatic, the parts do not need to be manually placed in an auxiliary mode, the accuracy of detection results is high, and the efficiency is improved.
The component detection system comprises component channels and conveying equipment, wherein the component channels are positioned above the conveying equipment, the component channels comprise a first feeding hopper and baffles arranged at the bottom end of the first feeding hopper, the conveying equipment comprises a first conveying belt, baffle plates with equal intervals are arranged on the first conveying belt, a sensor is fixedly arranged on the outer side of the first conveying belt, the sensor is in communication connection with a control mechanism for controlling the opening and closing of the baffles, and when each baffle plate moves to the end face or the top of the baffle plate to form a vertical line with the center of an outlet of the first feeding hopper, the baffle plates are triggered to be opened, so that components in the first feeding hopper fall down, and the baffles are closed after a certain time delay; the system also comprises a camera and image processing equipment, wherein the camera is positioned above the first conveyor belt, and is positioned behind the component channel and is in communication connection with the sensor when seen along the travelling direction of the first conveyor belt, and a trigger signal of the sensor triggers the camera to photograph the area between two stop blocks below the camera; the image processing device is in communication connection with the camera. Set up the dog on first conveyer belt, through accurate control, make spare part fall on terminal surface or the summit of dog just, because the reaction force bullet falls on first conveyer belt, because first conveyer belt is in operation, the spare part of falling can not fall in the same position of dog, consequently can guarantee to bullet and fall to different directions and the position of first conveyer belt, can not appear piling up, the phenomenon of stacking.
The stop block is a cone. The cone, the triangular cone and the like are commonly used, so long as the top of the cone is not a plane, the parts cannot stay on the cone.
Further, the system also comprises an output device for outputting the result of processing the image by the image processing device. The output device may be a display screen.
Further, the system also comprises a synchronous controller, wherein the signal input end of the synchronous controller is connected with the sensor, and the signal output end of the synchronous controller is simultaneously connected with the control mechanism of the baffle plate and the photographing switch of the camera. The synchronous controller is used for enabling the trigger signal sent by the sensor to synchronously trigger the opening and closing of the baffle and the photographing of the camera.
Furthermore, the two sides of the first conveyor belt are provided with protective sidebands for preventing parts on the first conveyor belt from scattering outside the conveyor belt.
Further, a primary separation device is arranged above the first feeding hopper, and comprises a second conveyor belt and a second feeding hopper above the second conveyor belt; the second conveyor belt travels in the same direction as the first conveyor belt and at a slower speed than the first conveyor belt. The first-stage separating equipment is additionally arranged, so that the falling speed of parts in the first feeding hopper is more controllable, and the position dispersion of the parts scattered on the first conveyor belt is ensured.
Further, a separating wheel is arranged between the lower outlet of the second feeding hopper and the second conveyor belt, and comprises a plurality of blades, and along with the rotation of the separating wheel, parts fall on the blades.
By utilizing the technical scheme of the invention, the parts can be well scattered on the first conveyor belt, the photographing time of the camera can be controlled, the phenomena of shielding, stacking and the like among the parts are avoided, no stop block appears in the pictures acquired by the camera, and the full-automatic detection without manual intervention is realized.
The invention also provides a part detection method, which comprises the following steps:
s1, along with the advancing of a first conveyor belt, when a sensor senses that the end face or the vertex of a triangular stop block and the center of a first feed hopper outlet above the first conveyor belt form a vertical line, a first control signal is sent out to trigger a baffle at the bottom end of the first feed hopper to be opened, so that parts in the first feed hopper fall down, are sprung out after contacting the triangular stop block, finally fall onto the first conveyor belt, and the baffle is closed after a certain time delay; the sensor sends a second control signal to a camera positioned above the first conveyor belt and behind the first feeding hopper at the same time, the camera is controlled to take a picture, and the shooting range is an area between two triangular check blocks below the camera;
s2, the pictures acquired by the camera are sent to image processing equipment, and the image processing equipment identifies, classifies and counts parts in the pictures;
s3, repeating the steps S1-S2, enabling all parts in the first feeding hopper to fall onto the first conveyor belt, collecting images, and completing image identification and statistics.
Further, every two parts between the triangular stop blocks are provided with gaps, and the gap size needs to meet the condition: the gap is imaged in the picture to not less than one full pixel.
Further, step S4 is further included after step S3, and the output device located after the image processing device outputs the classification and statistical result.
The detection method of the invention is based on the detection system, realizes automatic detection of parts, comprises machine identification, classification, statistics and result output, has high accuracy and greatly saves labor cost.
Drawings
FIG. 1 is a schematic diagram of an embodiment of an automatic component inspection system according to the present invention;
FIG. 2 is a schematic diagram of an automatic component inspection system according to another embodiment of the present invention;
FIG. 3 is a flow chart of a method of detecting components of the present invention;
reference numerals illustrate:
11-first feeder hopper, 12-baffle, 13-first conveyer belt, 14-triangle dog, 15-sensor, 16-motor, 17-collection box, 21-second feeder hopper, 22-inclined plane, 23-second conveyer belt, 24-separator wheel, 2-camera, 3-image processing equipment.
Detailed Description
The present invention will be described in further detail with reference to the drawings and examples, in order to make the objects, technical solutions and advantages of the present invention more apparent. It should be understood that the specific embodiments described herein are for purposes of illustration only and are not intended to limit the scope of the invention.
Example 1
In the component detection system, as shown in fig. 1, the components take building blocks as examples, and a set of building blocks have various colors, shapes and sizes, so that each building block needs to be identified and classified and counted according to the conditions.
The system comprises a component channel, a conveying device, an image acquisition device and an image processing device, wherein the component channel is a first feeding hopper 11, a baffle 12 capable of opening and closing is arranged at the bottom end of the component channel, the conveying device is arranged below the first feeding hopper 11 and is a first conveying belt 13, the conveying device is driven by a motor 16, and baffle blocks with equal intervals are arranged on the first conveying belt 13, and the baffle blocks are triangular baffle blocks 14 in the embodiment. A sensor 15 is arranged outside the first conveyor 13 at the centre line of the first hopper 11 for sensing the relationship between the triangular stop 14 and the centre vertical line of the first hopper 11, typically a laser sensor. The sensor 15 is communicatively connected to the barrier 12 and the camera 2, and may be connected by a signal line or may be connected wirelessly to send a trigger signal to the control mechanism that controls the opening and closing of the barrier 12 and the camera 2. When the sensor 15 detects that the vertex of the current triangular stop block 14 and the center of the discharge hole of the first feeding hopper 11 are in a vertical line, and at least the end face of the current triangular stop block 14 is positioned on the vertical line of the center of the discharge hole of the first feeding hopper 11, the sensor 15 generates a trigger signal and transmits the trigger signal to the control mechanism of the baffle 12, and the control mechanism opens the baffle 12 to enable the building blocks in the first feeding hopper 11 to fall. The sensor 15 also sends a trigger signal to the camera 2, triggering the camera 2 to take a picture, which is then sent to the image processing device 3. In some embodiments, since the image capturing device such as a camera has a certain storage space, the photo can be temporarily stored on a memory card inside the camera 2, and then sent to the image processing device 3 after receiving the command; the method can also be used for setting a memory in addition, temporarily storing pictures on the memory, waiting for operation commands, and then carrying out the next processing, and the structure can be adopted when the number of building blocks is large, the operation capacity of a processor is insufficient or the network transmission speed is limited.
The building blocks fall onto the triangular stop blocks 14 to be sprung or slide onto the first conveyor belt 13 along the inclined planes of the stop blocks, and after a certain time delay, the baffle plates 12 are closed to wait for the next triggering. The delay time can be set according to the running speed of the first conveyor belt 13, and the maximum time is not longer than the time from the top of the current triangular block 14 to the position completely outside the triangular block 14, and the optional range is preferably (0, 5 s.) when the top of the next triangular block 14 forms a vertical line with the center of the discharge port, the baffle 12 is triggered again, the building blocks fall down and are sprung or slide onto the first conveyor belt 13 from an inclined plane, the baffle 12 is opened, the camera 2 automatically shoots, and the baffle 12 is closed after the same delay time, the circulation is performed until the building blocks in the first feed hopper 11 fall onto the first conveyor belt 13 completely and the image is acquired by the camera 2, and a recovery box 17 is usually arranged at the tail end of the first conveyor belt 13 for holding the conveyed building blocks.
Along the travelling direction of the first conveyor belt 13, the camera 2 is positioned at a certain position behind the first feeding hopper 11, the height of the camera 2 is adjusted so that the field of view of the camera is positioned right between the two triangular stop blocks 14, and the camera is fixed by a supporting frame. Thus, when the trigger signal of the sensor 15 comes, the camera 2 photographs the area between every two triangular stoppers 14 right below, and only the building blocks are in the acquired image, and the triangular stoppers 14 are not present.
The image processing device 3 is connected with the camera 2 through a communication network or a wired connection, and is used for processing the acquired pictures, including identifying the building blocks in the pictures, classifying according to the sizes, shapes and colors of the building blocks, counting the number of the building blocks in each category, detecting the integrity of the complete set of building blocks, and the like. The image processing apparatus 3 may be a processor, a local server, a cloud server, or the like.
In some embodiments, protective webbing 18 is provided on both sides of the first conveyor 13 to prevent the building blocks from bouncing off the first conveyor 13.
Example 2
The difference from embodiment 1 is that above the first feed hopper 11 there is also included a primary separating and conveying device comprising a second conveyor belt 23 and a second feed hopper 21 above, as shown in fig. 3. The second conveyor belt 23 runs in the same direction as the first conveyor belt 13 but at a slower speed than the first conveyor belt 13. Through two-stage separation and transmission, the effect of separating the building blocks on the first conveyor belt 13 is better.
In some embodiments, the bottom of the second feeding hopper 21 is designed into an inclined plane 22, which is favorable for the building blocks to slide down automatically, the sliding process is buffered, and the included angle between the inclined plane 22 and the horizontal direction is preferably 10-60 degrees. If necessary, a vibration device can be further arranged on the second feeding hopper 21 to further assist the building blocks to slide down.
The working process of the embodiment is as follows: the two conveyor motors are activated to place the building blocks into the second hopper 21 and then onto the second conveyor 23, and as the conveyor travels to the end, it drops into the first hopper 11. When the sensor 15 detects that the vertex of the current triangular stop block 14 and the center of the discharge hole of the first feeding hopper 11 are in a vertical line, and at least the end face of the current triangular stop block 14 is positioned on the vertical line of the center of the discharge hole of the first feeding hopper 11, the sensor 15 generates a trigger signal and transmits the trigger signal to the control mechanism of the baffle 12, and the control mechanism opens the baffle 12 to enable the building blocks in the first feeding hopper 11 to fall. The sensor 15 also sends a trigger signal to the camera 2, triggering the camera 2 to take a picture, which is then sent to the image processing device 3. In some embodiments, since the image capturing device such as a camera has a certain storage space, the photo can be temporarily stored on a memory card inside the camera 2, and then sent to the image processing device 3 after receiving the command; the method can also be used for setting a memory in addition, temporarily storing pictures on the memory, waiting for operation commands, and then carrying out the next processing, and the structure can be adopted when the number of building blocks is large, the operation capacity of a processor is insufficient or the network transmission speed is limited.
The building blocks fall onto the triangular stop blocks 14 to be sprung or slide onto the first conveyor belt 13 along the inclined planes of the stop blocks, and after a certain time delay, the baffle plates 12 are closed to wait for the next triggering. The delay time can be set according to the running speed of the first conveyor belt 13, and the maximum time is not longer than the time from the top of the current triangular block 14 to the position completely outside the triangular block 14, and the optional range is preferably (0, 5 s).
The second conveyor belt 23 can be provided with a triangular block and a protective side band, like the first conveyor belt 13, the triangular block is used for bouncing off the falling building blocks, and the protective side band is used for preventing the building blocks from falling out of the second conveyor belt 23.
In some embodiments, a separating wheel 24 is arranged between the lower outlet of the second feeding hopper 21 and the second conveying belt 23, the separating wheel 24 and the second conveying belt 23 are fixed on the same bracket, and a plurality of blades are arranged on the separating wheel 24 in a radial shape. With the rotation of the separating wheel 24, the building blocks fall onto the respective vanes and onto the second conveyor belt 23. By adding the separating wheel 24, the frequency of the building blocks falling and conveying is further controlled.
Both embodiments may include a synchronous controller, the signal input end of which is connected to the sensor 15, and the signal output end of which is connected to the control mechanism of the baffle 12 and the photographing switch of the camera 2 at the same time. The synchronization controller synchronizes the two trigger signals from the sensor 15.
Example 3
A method for automatically inspecting components using embodiment 1, the flow of which is shown in fig. 3.
Starting a motor of the first conveyor belt 13, along with the advancing of the first conveyor belt 13, when the sensor 15 senses that the end face or the top point of the triangular stop block 14 is vertical to the center of the outlet of the first feed hopper 11 above the first conveyor belt 13, sending a control signal, and triggering the baffle 12 at the bottom end of the first feed hopper 11 to be opened by the first control signal, so that building blocks in the first feed hopper 11 fall down, are sprung out after contacting the triangular stop block 14, and finally fall onto the first conveyor belt 13;
the second control signal sent by the sensor 15 triggers the camera 2 to take a picture, and the shooting range is the area between the two triangular stop blocks 14 below the camera 2;
after a certain delay, the rear baffle 12 is closed, and the next trigger of the sensor 15 is waited;
the pictures acquired by the camera 2 are sent to the image processing equipment 3, and the image processing equipment 3 identifies, classifies and counts the building blocks in the pictures;
when the building blocks in the first feeding hopper 11 fall onto the first conveyor belt 13 completely, images are collected, and after identification and statistics by the image processing device 3 are completed, the detection process is finished.
If the two-stage separating conveyor of embodiment 2 is used, the detection method is not different from the above-described process, except that the blocks on the first conveyor belt 13 are more dispersed.
Example 4
The difference from example 3 is that: an output device is arranged behind the image processing device 3 for outputting the building block classification and statistics. May be a display screen and/or a voice output device. The user compares the output result with the detected specification of the complete set of building blocks, and can directly obtain the conclusion whether the complete set of building blocks is complete or not, if the complete set of building blocks is incomplete, the specification of the missing building blocks can be clearly known.
In the technical solutions of embodiment 3 and embodiment 4, in order to make the blocks easily and accurately identified by the computer in the image, the following conditions are satisfied for the gaps between the blocks falling on the first conveyor belt 13: the gap is imaged in the picture to not less than one full pixel. The structural design of the system, such as the triangular stop block 14 and the two-stage separation conveying device, ensures that the building blocks are not stacked and are more dispersed, thereby ensuring that the conditions are met and enabling the building blocks to be recognized and judged by the image processing equipment 3 more quickly and accurately.
The technical means disclosed by the scheme of the invention is not limited to the technical means disclosed by the embodiment, and also comprises the technical scheme formed by any combination of the technical features.
Claims (9)
1. The utility model provides a spare part detecting system, includes part passageway and conveying equipment, the part passageway is located the conveying equipment top, including first feeder hopper and the baffle of establishing in first feeder hopper bottom, its characterized in that: the conveying equipment comprises a first conveying belt, wherein baffle blocks with equal intervals are arranged on the first conveying belt, a sensor is fixedly arranged on the outer side of the first conveying belt, the sensor is in communication connection with a control mechanism for controlling the baffle plates to open and close, when each baffle block moves to the end face or the top of the baffle block to form a vertical line with the center of an outlet of the first feeding hopper, the baffle plates are triggered to open, so that parts in the first feeding hopper fall down, and the baffle plates are closed after a certain time delay; the parts fall on the end surface or the top point of the stop block, and are sprung onto the first conveyor belt due to the reaction force; the stop block is a cone;
the system also comprises a camera and image processing equipment, wherein the camera is positioned above the first conveyor belt, and is positioned behind the component channel and is in communication connection with the sensor when seen along the travelling direction of the first conveyor belt, and a trigger signal of the sensor triggers the camera to photograph the area between two stop blocks below the camera; the image processing equipment is in communication connection with the camera and is used for processing the acquired pictures, including recognizing the building blocks in the pictures, classifying according to the sizes, shapes and colors of the building blocks, counting the number of the building blocks in each category, and detecting the integrity of the complete set of building blocks.
2. The component inspection system of claim 1, wherein: the system further comprises an output device for outputting the result of the image processing device for processing the image.
3. The component inspection system of claim 1, wherein: the system also comprises a synchronous controller, wherein the signal input end of the synchronous controller is connected with the sensor, and the signal output end of the synchronous controller is simultaneously connected with the control mechanism of the baffle plate and the photographing switch of the camera.
4. The component inspection system of claim 1, wherein: and protective sidebands are arranged on two sides of the first conveyor belt and used for preventing parts on the first conveyor belt from scattering outside the conveyor belt.
5. The component inspection system of claim 1, wherein: a primary separation device is arranged above the first feeding hopper and comprises a second conveyor belt and a second feeding hopper above the second conveyor belt; the second conveyor belt travels in the same direction as the first conveyor belt and at a slower speed than the first conveyor belt.
6. The component inspection system according to claim 5, wherein: and a separating wheel is arranged between the lower outlet of the second feeding hopper and the second conveying belt and comprises a plurality of blades, and along with the rotation of the separating wheel, parts fall on the blades.
7. A method of detecting a component using the component detecting system according to any one of claims 1 to 6, comprising the steps of:
s1, along with the advancing of a first conveyor belt, when a sensor senses that the end face or the top point of a stop block and the center of a first feed hopper outlet above the first conveyor belt form a vertical line, a first control signal is sent out to trigger a baffle at the bottom end of the first feed hopper to be opened, so that parts in the first feed hopper fall down, are sprung out after contacting the stop block, finally fall onto the first conveyor belt, and the baffle is closed after a certain time delay; the sensor sends a second control signal to a camera positioned above the first conveyor belt and behind the first feeding hopper at the same time, the camera is controlled to take a picture, and the shooting range is the area between two stop blocks below the camera;
s2, the pictures acquired by the camera are sent to image processing equipment, and the image processing equipment identifies, classifies and counts parts in the pictures;
s3, repeating the steps S1-S2, enabling all parts in the first feeding hopper to fall onto the first conveyor belt, collecting images, and completing image identification and statistics.
8. The method for component inspection according to claim 7, wherein: every two spare parts between the dog have the clearance between every two, the clearance size needs to satisfy the condition: the gap is imaged in the picture to not less than one full pixel.
9. The method for component inspection according to claim 7, wherein: and S3, the method also comprises a step S4, wherein an output device positioned behind the image processing device outputs the classification and statistical results.
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| CN201811337363.9A CN109516067B (en) | 2018-11-12 | 2018-11-12 | Part detection system and detection method |
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| CN201811337363.9A CN109516067B (en) | 2018-11-12 | 2018-11-12 | Part detection system and detection method |
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| CN110466969A (en) * | 2019-09-16 | 2019-11-19 | 深圳市道元实业有限公司 | Food feeding distribution mechanism and food production line |
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| CN207258655U (en) * | 2017-09-07 | 2018-04-20 | 东北林业大学 | A kind of small ball-shape fruit test experience platform |
| CN209009417U (en) * | 2018-11-12 | 2019-06-21 | 西安火眼猴智能科技研究院有限公司 | Components detection system |
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