CN110639843B - High-precision LED support material strip online detection punching system - Google Patents
High-precision LED support material strip online detection punching system Download PDFInfo
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- CN110639843B CN110639843B CN201911056198.4A CN201911056198A CN110639843B CN 110639843 B CN110639843 B CN 110639843B CN 201911056198 A CN201911056198 A CN 201911056198A CN 110639843 B CN110639843 B CN 110639843B
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- led support
- blanking
- linear displacement
- support material
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- 239000000463 material Substances 0.000 title claims abstract description 93
- 238000001514 detection method Methods 0.000 title claims abstract description 55
- 238000004080 punching Methods 0.000 title abstract description 20
- 230000002950 deficient Effects 0.000 claims abstract description 29
- 230000007246 mechanism Effects 0.000 claims description 91
- 238000006073 displacement reaction Methods 0.000 claims description 52
- 230000005540 biological transmission Effects 0.000 claims description 9
- 238000005520 cutting process Methods 0.000 claims description 7
- 238000003825 pressing Methods 0.000 claims description 5
- 238000012546 transfer Methods 0.000 claims description 4
- 230000002159 abnormal effect Effects 0.000 claims description 3
- 238000009434 installation Methods 0.000 claims description 3
- 238000007689 inspection Methods 0.000 claims 1
- 238000000034 method Methods 0.000 description 12
- 230000008569 process Effects 0.000 description 8
- 238000004519 manufacturing process Methods 0.000 description 6
- 239000003292 glue Substances 0.000 description 4
- 238000012986 modification Methods 0.000 description 4
- 230000004048 modification Effects 0.000 description 4
- 238000010586 diagram Methods 0.000 description 3
- 238000007599 discharging Methods 0.000 description 3
- 230000004075 alteration Effects 0.000 description 2
- 229910000831 Steel Inorganic materials 0.000 description 1
- 238000004026 adhesive bonding Methods 0.000 description 1
- 239000002390 adhesive tape Substances 0.000 description 1
- 238000005452 bending Methods 0.000 description 1
- 230000009286 beneficial effect Effects 0.000 description 1
- 230000007547 defect Effects 0.000 description 1
- 238000013461 design Methods 0.000 description 1
- 238000011161 development Methods 0.000 description 1
- 230000000694 effects Effects 0.000 description 1
- 238000005286 illumination Methods 0.000 description 1
- 230000006872 improvement Effects 0.000 description 1
- 238000001746 injection moulding Methods 0.000 description 1
- 239000002184 metal Substances 0.000 description 1
- 239000002245 particle Substances 0.000 description 1
- 238000012545 processing Methods 0.000 description 1
- 230000009467 reduction Effects 0.000 description 1
- 239000010959 steel Substances 0.000 description 1
- 238000004804 winding Methods 0.000 description 1
Classifications
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B07—SEPARATING SOLIDS FROM SOLIDS; SORTING
- B07C—POSTAL SORTING; SORTING INDIVIDUAL ARTICLES, OR BULK MATERIAL FIT TO BE SORTED PIECE-MEAL, e.g. BY PICKING
- B07C5/00—Sorting according to a characteristic or feature of the articles or material being sorted, e.g. by control effected by devices which detect or measure such characteristic or feature; Sorting by manually actuated devices, e.g. switches
- B07C5/34—Sorting according to other particular properties
- B07C5/342—Sorting according to other particular properties according to optical properties, e.g. colour
- B07C5/3422—Sorting according to other particular properties according to optical properties, e.g. colour using video scanning devices, e.g. TV-cameras
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B07—SEPARATING SOLIDS FROM SOLIDS; SORTING
- B07C—POSTAL SORTING; SORTING INDIVIDUAL ARTICLES, OR BULK MATERIAL FIT TO BE SORTED PIECE-MEAL, e.g. BY PICKING
- B07C5/00—Sorting according to a characteristic or feature of the articles or material being sorted, e.g. by control effected by devices which detect or measure such characteristic or feature; Sorting by manually actuated devices, e.g. switches
- B07C5/02—Measures preceding sorting, e.g. arranging articles in a stream orientating
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B07—SEPARATING SOLIDS FROM SOLIDS; SORTING
- B07C—POSTAL SORTING; SORTING INDIVIDUAL ARTICLES, OR BULK MATERIAL FIT TO BE SORTED PIECE-MEAL, e.g. BY PICKING
- B07C5/00—Sorting according to a characteristic or feature of the articles or material being sorted, e.g. by control effected by devices which detect or measure such characteristic or feature; Sorting by manually actuated devices, e.g. switches
- B07C5/36—Sorting apparatus characterised by the means used for distribution
- B07C5/361—Processing or control devices therefor, e.g. escort memory
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
- B21C—MANUFACTURE OF METAL SHEETS, WIRE, RODS, TUBES OR PROFILES, OTHERWISE THAN BY ROLLING; AUXILIARY OPERATIONS USED IN CONNECTION WITH METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL
- B21C51/00—Measuring, gauging, indicating, counting, or marking devices specially adapted for use in the production or manipulation of material in accordance with subclasses B21B - B21F
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
- B21D—WORKING OR PROCESSING OF SHEET METAL OR METAL TUBES, RODS OR PROFILES WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
- B21D28/00—Shaping by press-cutting; Perforating
- B21D28/002—Drive of the tools
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
- B21D—WORKING OR PROCESSING OF SHEET METAL OR METAL TUBES, RODS OR PROFILES WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
- B21D28/00—Shaping by press-cutting; Perforating
- B21D28/02—Punching blanks or articles with or without obtaining scrap; Notching
Abstract
The invention discloses a high-precision LED support material strip on-line detection punching system which comprises a frame, a controller, a feeding unit, an on-line detection unit and a punching unit. By arranging the special light source assembly, the shadow is not generated due to the fact that a strong light area and a weak light area are formed on the LED support material belt, the fact that an image shot by machine vision equipment can accurately reflect the real state of the LED support material belt is ensured, and therefore high-precision detection is achieved. According to the high-precision LED support material strip on-line detection punching system, the identification precision is 0.02mm, the LED support material strip with the single-side size of 1.0mm of the LED support can be detected, and the defective product identification rate can reach 100%.
Description
Technical Field
The invention belongs to the technical field of LED automatic production equipment, and particularly relates to a high-precision LED support material strip on-line detection punching system.
Background
The LED bracket is widely applied to manufacturing a display screen backlight source, and with the development of domestic and foreign technological economy, the types and the number of the LED bracket are larger and larger, and the standard of the requirements on the external surface size parameter and the surface perfection is higher and higher. For the manufacturing enterprises of the LED brackets, the detection procedures of appearance shapes, sizes and surface defects of products occupy important positions in the whole process flow, and occupy large manpower, sites and fund resources.
In the production process of the LED support, in order to accelerate the production speed, the LED supports are not produced individually, but a plurality of rows of conductive pins are punched and formed on the same metal sheet, and then the insulating base and the conductive pins are embedded and formed together in an injection molding mode, so that a plurality of rows and columns of LED supports are manufactured, and the plate which is not cut off by the LED supports is called an LED support material belt.
One of the working procedures of the LED support material belt processing process is to glue the corresponding area on the material belt, glue particles cannot appear on the bonding pad, the area outside the bonding pad cannot be lacked, and meanwhile, the two conditions are met, namely, the qualified product is obtained, and otherwise, the qualified product is obtained. At present, the prior art generally adopts a manual detection mode for detecting the lack of glue of the LED bracket material belt, and a detection person with abundant experience can rapidly judge the product on line or manually perform spot check after one procedure. The method has the advantages of high labor intensity, low efficiency, poor precision and high probability of missed detection and false detection. Affecting the improvement of the overall quality of the product and the reduction of the production cost.
Disclosure of Invention
In order to solve the technical problems, the invention provides the high-precision LED support material strip online detection punching system which can carry out non-contact, high-precision and high-efficiency online detection on the LED support material strip and can automatically punch defective products.
The technical scheme adopted for achieving the purpose of the invention is that the high-precision LED support material strip online detection punching system comprises a frame, a controller, a feeding unit, an online detection unit and a punching unit, wherein the feeding unit, the online detection unit and the punching unit are arranged on the frame, and the feeding unit, the online detection unit and the punching unit are arranged on the frame, wherein:
the feeding unit is used for conveying the LED bracket material belt along a first direction;
the on-line detection unit comprises machine vision equipment and a light source assembly, wherein the light source assembly comprises a surface light source and a coaxial light source, the surface light source and the coaxial light source are arranged at intervals, and the LED bracket material belt is positioned between the surface light source and the coaxial light source; the machine vision equipment is arranged on the rack, and the shooting range of the machine vision equipment covers the LED bracket material belt positioned between the surface light source and the coaxial light source;
the blanking unit comprises a first linear displacement mechanism, a second linear displacement mechanism and a blanking die, wherein:
the blanking die is connected with the movable part of the first linear displacement mechanism, and is driven by the first linear displacement mechanism to move along a second direction perpendicular to the first direction;
the fixed part of the first linear displacement mechanism is connected with the movable part of the second linear displacement mechanism, and the first linear displacement mechanism and the blanking die are driven by the second linear displacement mechanism together to move along a third direction perpendicular to the first direction and the second direction;
the fixed part of the second linear displacement mechanism is arranged on the frame;
the controller is respectively and electrically connected with the feeding unit, the machine vision equipment, the first linear displacement mechanism and the second linear displacement mechanism.
Preferably, the surface light source includes a flat plate-shaped LED array and a light-splitting plate through which the flat plate-shaped LED array is packaged.
Preferably, the coaxial light source comprises a light emitting element, a prism and a light source support, the light emitting element and the prism are both installed on the light source support, the prism is located at the edge of the light source support, so that a shooting channel is formed in an installation area of the coaxial light source, and the machine vision equipment shoots the LED support material belt through the shooting channel.
Preferably, the on-line detection unit further comprises a light source telescopic mechanism, the light source assembly is fixed on the light source telescopic mechanism, and the light source assembly is driven by the light source telescopic mechanism to move in a direction approaching to or far from the LED support material belt.
Preferably, the blanking unit further comprises a blanking bracket connected to the movable part of the second linear displacement mechanism, and the first linear displacement mechanism is mounted on the blanking bracket.
Preferably, the blanking die comprises a blanking head and a blanking lower die, the blanking lower die is fixed on the blanking support, and the blanking head is connected with the movable part of the first linear displacement mechanism.
Preferably, the device further comprises a joint sensing unit, wherein the joint sensing unit is mounted on the rack; the joint sensing unit comprises a deflector rod and a micro switch, wherein the middle part of the deflector rod is rotatably arranged on the rack to form a lever mechanism, the micro switch is arranged beside a resistance arm of the lever mechanism, and the micro switch is electrically connected with the controller;
the power arm of the lever mechanism is positioned beside the transferring area of the LED support material belt, and when the LED support material belt is abnormal in transferring, the LED support material belt touches the power arm.
Preferably, the feeding unit is a roller feeder.
Preferably, the roller feeder comprises a feeding motor, a transmission mechanism, an upper feeding roller and a lower feeding roller, wherein the feeding motor drives the upper feeding roller and the lower feeding roller to rotate through the transmission mechanism, and the LED bracket material belt is clamped and transferred through the upper feeding roller and the lower feeding roller.
Preferably, the roller feeder further comprises a pressing mechanism for adjusting the clamping force of the upper feeding roller and the lower feeding roller.
According to the technical scheme, the high-precision LED support material strip on-line detection punching system provided by the invention integrally comprises a frame, a controller, a feeding unit, an on-line detection unit and a punching unit, wherein: the feeding unit is used for transferring the LED bracket material belt along the first direction so as to realize online treatment; the on-line detection unit is used for detecting the LED support material belt on line and comprises machine vision equipment and a light source assembly, the light source assembly comprises a surface light source and a coaxial light source which are arranged at intervals, the LED support material belt passes through an area between the surface light source and the coaxial light source in the transferring process, the surface light source is used for providing shooting backlight so as to be convenient for identifying the outline of the LED support material belt and the outline of a single LED support, and the surface light source utilizes the principle of a shadowless lamp to avoid generating shadows in a strong and weak light area on the LED support material belt; the light rays of the coaxial light source vertically irradiate the LED bracket material belt, and the coaxial light source has the functions of improving the brightness of a shooting area and improving the shooting definition; the machine vision device is aligned with the LED support tape between the surface light source and the coaxial light source, and the shooting range of the machine vision device can cover the part of the LED support tape for shooting the illuminated image of the part of the LED support tape. The blanking unit is used for cutting defective products, and the blanking unit comprises a first linear displacement mechanism, a second linear displacement mechanism and a blanking die, wherein the blanking die is driven by the first linear displacement mechanism to cut the defective products in a direction perpendicular to the plane of the LED support material belt, and the first linear displacement mechanism and the blanking die are driven by the second linear displacement mechanism together and are used for positioning the row where the defective products are located. The controller controls all functional units of the whole system to coordinate, the pictures shot by the machine vision equipment are transmitted to the controller, the controller judges whether the LED support material strips in the pictures have defective products or not, positions the row numbers and the column numbers of the defective products, and the controller sends out instructions to the second linear displacement mechanism according to the positions of the defective products so that the blanking dies are aligned with the defective products, and then the controller controls the first linear displacement mechanism to drive the blanking dies to blank the defective products.
Compared with the prior art, the invention adopts the machine vision equipment and the controller to detect the LED support material belt on line, can efficiently and accurately identify defective products in the LED support material belt, and efficiently and accurately position the defective products. By arranging the special light source assembly, the shadow is not generated due to the fact that a strong light area and a weak light area are formed on the LED support material belt, the fact that an image shot by machine vision equipment can accurately reflect the real state of the LED support material belt is ensured, and therefore high-precision detection is achieved. According to the high-precision LED support material strip on-line detection punching system, the identification precision is 0.02mm, the LED support material strip with the single-side size of 1.0mm of the LED support can be detected, and the defective product identification rate can reach 100%.
Drawings
FIG. 1 is a schematic structural diagram of an on-line detection punching system for a high-precision LED support material strip in an embodiment of the invention;
FIG. 2 is a schematic diagram of the feeding unit in FIG. 1;
FIG. 3A is a front view of the online detection unit of FIG. 1;
FIG. 3B is a side view of the in-line detection unit of FIG. 1;
fig. 4 is a schematic structural view of the blanking unit in fig. 1;
FIG. 5 is a schematic diagram of the structure of the joint sensing unit in FIG. 1;
reference numerals illustrate: 10-a frame; 20-a controller; 30-feeding units, 31-feeding motors, 32-transmission mechanisms, 33-upper feeding rollers, 34-lower feeding rollers and 35-pressing mechanisms; 40-an online detection unit, 41-a machine vision device; 42-light source components, 43-light source telescopic mechanisms, 44-guide rails, 45-connecting plates, 46-surface light sources and 47-coaxial light sources; 50-blanking units, 51-first linear displacement mechanisms, 52-second linear displacement mechanisms, 53-blanking heads, 54-blanking lower dies and 55-blanking supports; the device comprises a 60-joint sensing unit, a 61-deflector rod, a 62-micro switch, a 63-power arm, a 64-resistance arm and a 65-contact; 70-a discharging machine; 80-a material receiving machine; 90-material belt guide plates; 100-LED support material belt.
Detailed Description
In order to make the present invention more clearly understood by those skilled in the art, the following detailed description of the technical scheme of the present invention will be given by way of specific examples with reference to the accompanying drawings.
In the embodiment of the invention, the high-precision LED support material strip on-line detection punching system is used for carrying out on-line detection on the LED support material strips after gluing and before bending, and detecting and removing defective products of the glue shortage. A blanking machine 70 and a collecting machine 80 are respectively arranged in front of and behind the system and are respectively used for automatically unwinding the LED support material strip coil and automatically winding the LED support material strip.
Referring to fig. 1, the system includes a frame 10, a controller 20, and a feeding unit 30, an in-line detecting unit 40, and a blanking unit 50 mounted on the frame 10, and the structure of each functional unit is described in detail as follows:
referring to fig. 1, a rack 10 is a mounting base of an overall system, and the rack 10 is constructed in a steel structure, and is sized according to equipment mounted thereon.
The controller 20 may be a PLC, a single chip microcomputer, a computer, etc., and a man-machine interface is required to be set on the controller 20 for convenient control. The controller 20 is electrically connected to the feeding unit 30, the machine vision device 41, the light source telescopic mechanism 43, the first linear displacement mechanism 51, the second linear displacement mechanism 52 and the micro switch 62, respectively, and coordinates the actions of the respective components.
The feeding unit 30 is used for transferring the LED support tape 100 along the first direction. In this embodiment, the LED support tape 100 is transported in a horizontal direction, i.e., the first direction is the X-axis direction. For convenient arrangement, the feeding unit 30 is disposed at the rear side of the frame 10, and the feeding unit 30 cooperates with the discharging machine 70 to jointly establish a certain tension, so as to facilitate the transfer of the LED support material strip 100. In this embodiment, the feeding unit 30 adopts a roller feeder.
Referring to fig. 2, the roller feeder includes a feeding motor 31, a transmission mechanism 32, an upper feeding roller 33 and a lower feeding roller 34, the feeding motor 31 drives the upper feeding roller 33 and the lower feeding roller 34 to rotate through the transmission mechanism 32, and the upper feeding roller 33 and the lower feeding roller 34 clamp and move the LED support material belt 100, so that the movement stability is ensured, and the upper feeding roller 33 and the lower feeding roller 34 are both provided.
Specifically, the transmission mechanism 32 includes a belt transmission mechanism and a gear rotation mechanism, the torque output by the feeding motor 31 is transmitted to the gear rotation mechanism via the belt transmission mechanism, the gear rotation mechanism includes an upper gear and a lower gear which are meshed, wherein the upper gear rotates coaxially with the upper feeding roller 33, and the lower gear rotates coaxially with the lower feeding roller 34.
In a preferred embodiment, the roller feeder further comprises a pressing mechanism 35, the pressing mechanism 35 adopts a wire spring, and the upper feeding roller 33 and the lower feeding roller 34 are pressed tightly by elastic force, so that the upper feeding roller 33 and the lower feeding roller 34 are tightly attached to the LED support material belt 100, and slipping is prevented in the moving process.
In order to ensure that the LED support material belt 100 passes straight and stably in the transferring process, a material belt guide plate 90 is further arranged on the frame, the material belt guide plate 90 is two guide rails symmetrically arranged, and the LED support material belt 100 is tightly attached to the material belt guide plate 90 in the transferring process.
Referring to fig. 3A and 3B, the in-line detecting unit 40 includes a machine vision device 41 and a light source assembly for in-line photographing an image of the LED support tape 100. For convenience of arrangement, the in-line detecting unit 40 is disposed at the front side of the frame 10, i.e., the LED support tape 100 passes through the in-line detecting unit 40 first and then the feeding unit 30.
Referring to fig. 3B, the light source assembly includes a surface light source 46 and a coaxial light source 47, the surface light source 46 and the coaxial light source 47 being spaced apart, preferably in parallel, and the LED support tape 100 being positioned between the surface light source 46 and the coaxial light source 47. Specifically, the surface light source 46 is located above the LED support material strip 100, the coaxial light source 47 is located below the LED support material strip 100, and the interval between the surface light source 46 and the coaxial light source 47 is 5mm to 50mm, preferably 10mm to 30mm.
Specifically, the surface light source 46 includes a flat-plate LED array and a light-splitting plate, the flat-plate LED array is packaged by the light-splitting plate, the width of the flat-plate LED array should be greater than the width of the LED support strip 100, and the length is greater than the shooting range of the machine vision device 41.
The coaxial light source 47 comprises a light emitting element, a prism and a light source support, wherein the light emitting element and the prism are both arranged on the light source support, light rays emitted by the light emitting element are refracted by the prism to obtain horizontal light beams, and the horizontal light beams vertically irradiate on the LED support material strip 100. The refraction of light by the prism can also be avoided from the photographing channel of the machine vision device 41, specifically, the prism is located at the edge of the light source bracket, so as to avoid a photographing channel without any shielding object in the installation area of the coaxial light source 47.
The machine vision device 41 is preferably a CCD, and is disposed on the frame 10 in alignment with the LED support strip 100 between the surface light source 46 and the coaxial light source 47. In this embodiment, the machine vision device 41 is installed below the coaxial light source 47 and faces the LED support strip 100, and the shooting range thereof can cover the LED support strip 100 between the surface light source 46 and the coaxial light source 47, and the machine vision device 41 shoots the LED support strip 100 through the shooting channel.
Because in this system, the light source is set above and below the LED support strip 100, and the area of the light source component is larger, and the system lacks the operation space when it needs to be overhauled, in order to solve this problem, in this embodiment, the on-line detection unit 40 further includes a light source telescoping mechanism 43, the light source component is connected with the movable part of the light source telescoping mechanism 43, and the light source component is driven by the light source telescoping mechanism 43 and moves along the third direction.
Specifically, the light source telescopic mechanism 43 adopts an air cylinder, and the air cylinder drives the light source assembly to longitudinally move along the horizontal direction, namely, the third direction is the Y-axis direction. Since the illumination effect of the light source assembly directly affects the detection accuracy of the system, the light source assembly is required to be still located at the design position when moving to the detection position, and the spacing between the surface light source 46 and the coaxial light source 47 and the LED support material strip 100 remains unchanged. In this embodiment, two high-precision linear guide rails are installed at corresponding positions of the frame 10, a connecting plate 45 is installed on a slide block of each linear guide rail, and the surface light source 46 and the coaxial light source 47 are both installed on the connecting plate, so that the surface light source 46 and the coaxial light source 47 move together, and the relative positions of the surface light source 46 and the coaxial light source 47 are ensured to be unchanged.
Referring to fig. 4, the blanking unit 50 is used for blanking defective products from the LED support material tape 100, and the blanking operation is performed based on the detection result of the on-line detection unit 40, so that the blanking unit 50 is disposed behind the on-line detection unit 40, specifically between the on-line detection unit 40 and the feeding unit 30.
Referring to fig. 4, the blanking unit 50 includes a first linear displacement mechanism 51, a second linear displacement mechanism 52, and a blanking die connected to a movable portion of the first linear displacement mechanism 51, the blanking die being driven by the first linear displacement mechanism 51 to move in a second direction perpendicular to the first direction; the fixed part of the first linear displacement mechanism 51 is connected with the movable part of the second linear displacement mechanism 52, and the first linear displacement mechanism 51 and the blanking die are driven by the second linear displacement mechanism 52 together to move along a third direction perpendicular to the first direction and the second direction; the fixed portion of the second linear displacement mechanism 52 is mounted to the frame 10.
Specifically, in this embodiment, the first linear displacement mechanism 51 employs an air cylinder to drive the blanking die to move in the vertical direction, that is, the second direction is the Z-axis direction. The second linear displacement mechanism 52 adopts a motor-driven ball screw pair, a blanking bracket 55 is arranged on a nut of the ball screw pair, and an air cylinder is fixed on the blanking bracket 55.
Specifically, the blanking die comprises a blanking head 53 and a blanking lower die 54, the blanking lower die 54 is suspended and fixed on a blanking bracket 55, and the blanking head 53 is connected with a piston of an air cylinder. When the motor-driven ball screw pair moves, the cylinder, the blanking head 53, the blanking lower die 54 and the blanking support 55 move together along the Y axis, so that the blanking die reaches the row where the defective products are located, then the cylinder acts to drive the blanking head 53 to punch downwards, and the blanking head 53 is matched with the blanking lower die 54 to punch out the defective products.
The high-precision on-line detection punching system for the LED support material strips of the embodiment is used for continuous and on-line detection of the LED support material strips, so that continuous feeding is needed. When current LED support material strip coil is about to detect, need to uncoil the feeding with next LED support material strip coil, in the junction department of two LED support material strips, the problem of feeding card is blocked easily, influences entire system operation.
For this reason, in this embodiment, the high-precision on-line detecting and punching system for LED support material strips is further provided with a joint sensing unit 60, and the joint sensing unit 60 is mounted on the frame 10 and located at the forefront of the frame, that is, the LED support material strips 100 first pass through the joint sensing unit 60 and then enter the on-line detecting unit 40, and the transferring direction is shown by arrow a in fig. 5.
Referring to fig. 5, the joint sensing unit 60 mainly includes two levers 61 and a micro switch 62, where the levers 61 are symmetrically disposed at two sides of the transferring area of the LED support tape 100 and at a certain height from the LED support tape 100, for example, the LED support tape 100 is 0.2mm thick, the levers 61 are 0.1mm from the upper surface of the LED support tape 100, and if the adhesive tapes overlap, the overlapped tapes cannot pass through the levers 61.
The middle part of the deflector rod 61 is rotatably arranged on the frame 10 to form a lever mechanism, the micro switch 62 is arranged beside a resistance arm 64 of the lever mechanism, and a power arm 63 of the lever mechanism is positioned above the transferring surface of the LED bracket material belt 100. Normally, the LED support tape 100 does not touch the lever 61, and the lever 61 is in the normal position (position b in fig. 5). When the LED support tape 100 is abnormally transferred, such as stacking or stacking, the LED support tape 100 at the abnormal position touches the power arm 63 of the single or simultaneous two levers 61, the levers 61 rotate around the fulcrums, and the power arm 63 touches the contact 65 (position c in fig. 5) of the micro switch 62.
The working process of the high-precision LED support material belt on-line detection punching system provided by the invention is as follows:
(1) The controller controls the feeding unit 30 to cooperate with the discharging machine 70 so that the LED support material strip 100 establishes a certain tension and is continuously transferred. The transfer process is intermittent, i.e. the LED support strip 100 is stopped for a period of time t1, e.g. 0.2s, 0.3s, typically no more than 0.5s, for each transfer end distance for detection and analysis by the on-line detection unit 40.
(2) The online detection unit 40 performs detection and analysis by using the dwell time, the machine vision device 41 shoots images of the LED support material strips 100, and transmits the images to the controller 20, the controller 20 stores qualified product images matched with the currently detected LED support material strips 100 in advance, the controller 20 performs image comparison, judges whether the shot images have defective products, and positions the number of rows and columns where the defective products are located.
(3) Based on the determined number of rows, the controller 20 controls the feeding unit 30 to continuously move the LED support tape 100 forward for a distance so that the row of defective products is located right under the blanking unit 50, and the LED support tape 100 is stopped again for a period of time t2, for example, 0.3s, 0.5s, and generally not more than 1s, for positioning and blanking by the blanking unit 50.
(4) Based on the determined number of columns, the controller 20 controls the second linear displacement mechanism 52 to move the blanking die to a position right above the position of the defective product, and then the controller 20 controls the first linear displacement mechanism 51 to move downwards, so that the blanking die punches out the defective product.
If the row has a plurality of defective products, the LED support tape 100 is stopped for nt2 seconds, where n is the number of defective products, and the blanking unit 50 punches out the plurality of defective products one by one.
Through the embodiment, the invention has the following beneficial effects or advantages:
the invention adopts the machine vision equipment and the controller to detect the LED support material belt on line, can efficiently and accurately identify defective products in the LED support material belt, and efficiently and accurately position the defective products. By arranging the special light source assembly, the shadow is not generated due to the fact that a strong light area and a weak light area are formed on the LED support material belt, the fact that an image shot by machine vision equipment can accurately reflect the real state of the LED support material belt is ensured, and therefore high-precision detection is achieved. According to the high-precision LED support material strip on-line detection punching system, the identification precision is 0.02mm, the LED support material strip with the single-side size of 1.0mm of the LED support can be detected, and the defective product identification rate can reach 100%.
While preferred embodiments of the present invention have been described, additional variations and modifications in those embodiments may occur to those skilled in the art once they learn of the basic inventive concepts. It is therefore intended that the following claims be interpreted as including the preferred embodiments and all such alterations and modifications as fall within the scope of the invention.
It will be apparent to those skilled in the art that various modifications and variations can be made to the present invention without departing from the spirit or scope of the invention. Thus, it is intended that the present invention also include such modifications and alterations insofar as they come within the scope of the appended claims or the equivalents thereof.
Claims (7)
1. The utility model provides a die-cut system of high accuracy LED support material area on-line measuring which characterized in that: including frame, controller, install feeding unit, joint response unit, on-line measuring unit and blanking unit in the frame, wherein:
the feeding unit is used for conveying the LED bracket material belt along a first direction;
the joint sensing unit is arranged on the frame and positioned in front of the online detection unit, the joint sensing unit comprises two deflector rods and a micro switch, the deflector rods are symmetrically arranged on two sides of a transfer area of the LED support material belt and have a distance from the upper surface of the LED support material belt, the middle part of the deflector rod is rotatably arranged on the frame to form a lever mechanism, and the micro switch is arranged beside a resistance arm of the lever mechanism; the power arm of the lever mechanism is positioned at the side of the transferring area of the LED support material belt, when the LED support material belt is subjected to abnormal transferring conditions of material stacking or material belt stacking, the LED support material belt can touch the power arms of the two shifting levers singly or simultaneously, the shifting levers rotate around the supporting points, and the power arms touch the contacts of the micro switch;
the on-line detection unit comprises machine vision equipment and a light source assembly, wherein the light source assembly comprises a surface light source and a coaxial light source, the surface light source and the coaxial light source are arranged at intervals, and the LED bracket material belt is positioned between the surface light source and the coaxial light source; the machine vision equipment is arranged on the rack, and the shooting range of the machine vision equipment covers the LED bracket material belt positioned between the surface light source and the coaxial light source;
the blanking unit is used for blanking defective products from the LED bracket material belt; the blanking unit comprises a first linear displacement mechanism, a second linear displacement mechanism and a blanking die, wherein:
the blanking die is connected with the movable part of the first linear displacement mechanism, and is driven by the first linear displacement mechanism to move along a second direction perpendicular to the first direction;
the fixed part of the first linear displacement mechanism is connected with the movable part of the second linear displacement mechanism, and the first linear displacement mechanism and the blanking die are driven by the second linear displacement mechanism together to move along a third direction perpendicular to the first direction and the second direction;
the fixed part of the second linear displacement mechanism is arranged on the frame; the blanking unit further comprises a blanking bracket, the blanking bracket is connected with the movable part of the second linear displacement mechanism, and the first linear displacement mechanism is arranged on the blanking bracket; the blanking die comprises a blanking head and a blanking lower die, the blanking lower die is fixed on the blanking bracket, and the blanking head is connected with the movable part of the first linear displacement mechanism;
the controller is respectively and electrically connected with the feeding unit, the micro switch, the machine vision equipment, the first linear displacement mechanism and the second linear displacement mechanism.
2. The high-precision LED support tape on-line detection die-cutting system of claim 1, wherein: the surface light source comprises a flat-plate-shaped LED array and a light splitting plate, and the flat-plate-shaped LED array is packaged through the light splitting plate.
3. The high-precision LED support tape on-line detection die-cutting system of claim 1, wherein: the coaxial light source comprises a light-emitting element, a triangular prism and a light source support, wherein the light-emitting element and the triangular prism are both arranged on the light source support, the triangular prism is positioned at the edge of the light source support so as to form a shooting channel in an installation area of the coaxial light source, and the machine vision equipment shoots the LED support material belt through the shooting channel.
4. A high precision LED support tape on-line inspection die-cutting system as claimed in any one of claims 1 to 3, wherein: the on-line detection unit further comprises a light source telescopic mechanism, the light source assembly is fixed on the light source telescopic mechanism, and the light source assembly is driven by the light source telescopic mechanism to move in a direction close to or far away from the LED support material belt.
5. The high-precision LED support tape on-line detection die-cutting system of claim 1, wherein: the feeding unit is a roller feeder.
6. The high-precision LED support tape on-line detection die-cutting system of claim 5, wherein: the roller feeder comprises a feeding motor, a transmission mechanism, an upper feeding roller and a lower feeding roller, wherein the feeding motor drives the upper feeding roller and the lower feeding roller to rotate through the transmission mechanism, and the LED bracket material belt is clamped and transferred through the upper feeding roller and the lower feeding roller.
7. The high-precision LED support tape on-line detection die-cutting system of claim 6, wherein: the roller feeder further comprises a pressing mechanism for adjusting the clamping force of the upper feeding roller and the lower feeding roller.
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