Disclosure of Invention
The invention aims to provide general-purpose machine vision detection equipment which is provided with a plurality of vision detection modules, can comprehensively detect various types of defects of materials, has wide detection range, high detection precision, reasonable overall design, compact structure, simple operation and high automation degree, and simultaneously provides a product surface defect detection method, which can realize quick and comprehensive detection of the defects of the materials and improve the detection efficiency.
In order to realize the purpose, the following technical scheme is adopted:
a vision detection device of a universal machine comprises two material transfer mechanisms which are arranged in parallel at intervals, a vision detection mechanism arranged between the two material transfer mechanisms, and a sorting mechanism which is arranged above the discharge end of the two material transfer mechanisms and is vertical to the two material transfer mechanisms; the film coating mechanism is also uniformly arranged on one side of the discharge ends of the two material transfer mechanisms, and the two material transfer mechanisms are used for sequentially and alternately transporting a plurality of materials to a detection area of the visual detection mechanism so that the visual detection mechanism can detect the surface defects of the materials; the sorting mechanism is used for conveying materials which are qualified to be detected and unqualified to a film laminating mechanism respectively, and the film laminating mechanism is used for blanking the detected materials after film laminating.
Furthermore, an ink-jet printer is further arranged at the end of one of the film covering mechanisms for receiving and detecting the unqualified materials and used for spraying codes to the unqualified materials after film covering.
Furthermore, each material transferring mechanism comprises a first translation module, a second translation module which is arranged perpendicular to the first translation module and is in sliding connection with the top of the first translation module, and a material bearing platform which is arranged on the top of the second translation module and is used for bearing materials; one end of the material bearing platform is in driving connection with the second translation module, and a first through hole is formed in the middle of the top of the other end of the material bearing platform; a plurality of fine molybdenum wires are arranged in the first through hole, and the material is placed on the fine molybdenum wires.
Further, the visual detection mechanism comprises a first visual detection module and a mounting frame; the first visual detection module is arranged close to the feeding ends of the two material transfer mechanisms and is positioned below the space between the two material transfer mechanisms; the mounting rack is arranged on one side of one material transfer mechanism, a plurality of first lifting modules are arranged on one side of the mounting rack in parallel at intervals in the length direction, and a second visual detection module is arranged on each first lifting module; the first lifting module is used for driving the second visual inspection module to lift, and the second visual inspection modules are used for being matched with the first visual inspection module to detect the surface defects of the materials.
Furthermore, the first visual inspection module and the second visual inspection module both comprise a camera assembly and a light source assembly.
Furthermore, letter sorting mechanism moves the third translation module that the mechanism was arranged and was located its discharge end top including two perpendicular materials, arranges in third translation module one side and rather than sliding connection's second lift module to and be used for moving the sucking disc module of carrying the material with second lift module drive connection.
Further, general type machine vision check out test set still include the frame, the material moves and carries mechanism, vision detection mechanism, letter sorting mechanism and tectorial membrane mechanism equipartition and arrange in the frame.
In order to achieve the above object, the present invention further provides a method for detecting surface defects of a product, comprising the following steps:
s1: performing area division on the material image according to functions, wherein the area division comprises a silk screen area, a camera area, an IR hole area, an earphone area and a character area;
s2: acquiring material image information, and carrying out incoming material detection and defect detection of each area on the material based on the image information;
s3: and classifying and summarizing the material defect detection result according to the material defect detection result of S2, and outputting the material defect detection result.
Further, the incoming material detection in S2 specifically includes the following steps:
s21: detecting whether materials are placed on the bearing platform, whether the materials are placed reversely and whether the materials are placed in an overlapped mode;
s22: detecting whether different types of materials are placed on the bearing platform and whether the materials are placed beyond the visual field;
further, the defect detection in S2 specifically includes the following steps:
s23: matching and positioning the material image according to the functional areas divided in the S1 based on the shape matching algorithm;
s24: intercepting partial images at the positioned positions according to the size of the functional area, and performing threshold segmentation on the functional area contained in the intercepted images;
s25: comparing the difference information with a pre-stored material standard template and storing the difference information;
s26: based on the difference information held at S25, a defective area of the image is extracted.
By adopting the scheme, the invention has the beneficial effects that:
1) the device has the advantages of reasonable design, compact structure, wide detection range, high detection precision, simple operation and high automation degree, and can comprehensively detect various types of defects of the materials through the plurality of visual detection modules;
2) the mode of placing the material on the fine molybdenum wire is adopted, so that the detection blind area can be avoided, and the comprehensive detection of the material is realized;
3) can realize carrying out automatic sorting to detecting unqualified material, detecting qualified material through letter sorting mechanism, avoid manual operation's numerous and controversial nature, improve detection efficiency.
Detailed Description
The invention is described in detail below with reference to the figures and the specific embodiments.
Referring to fig. 1 to 6, the present invention provides a general machine vision inspection apparatus, which includes two material transfer mechanisms 1 arranged in parallel at intervals, a vision inspection mechanism 2 arranged between the two material transfer mechanisms 1, and a sorting mechanism 3 arranged above a discharge end of the two material transfer mechanisms 1; a film coating mechanism 4 is further uniformly arranged on one side of the discharging ends of the two material transfer mechanisms 1, and the two material transfer mechanisms 1 are used for sequentially and alternately transporting a plurality of materials to a detection area of the visual detection mechanism 2 so that the visual detection mechanism 2 can detect surface defects of the materials; sorting mechanism 3 is used for transporting qualified, the unqualified material that detects respectively to a tectorial membrane mechanism 4 on, tectorial membrane mechanism 4 is used for carrying out unloading after the tectorial membrane to the material after detecting.
The end part of one laminating mechanism 4 for receiving and detecting the unqualified materials is also provided with an ink-jet printer 5, and the ink-jet printer 5 is used for spraying ink to the unqualified materials after laminating; each material transferring mechanism 1 comprises a first translation module 11, a second translation module 12 which is perpendicular to the first translation module 11 and is connected with the top of the first translation module in a sliding mode, and a material bearing platform 13 which is arranged on the top of the second translation module 12 and is used for bearing materials; one end of the material bearing platform 13 is in driving connection with the second translation module 12, and a first through hole 14 is formed in the middle of the top of the other end of the material bearing platform 13; a plurality of fine molybdenum wires 15 are arranged in the first through holes 14, and the material is placed on the fine molybdenum wires 15; the visual detection mechanism 2 comprises a first visual detection module 21 and a mounting rack 22; the first visual detection module 21 is arranged close to the feeding ends of the two material transfer mechanisms 1 and is positioned below the space between the two material transfer mechanisms 1; the mounting rack 22 is arranged on one side of one of the material transfer mechanisms 1, a plurality of first lifting modules 23 are further arranged on one side of the mounting rack 22 in parallel at intervals in the length direction, and a second visual detection module 24 is arranged on each first lifting module 23; the first lifting module 23 is used for driving the second visual inspection module 24 to lift, and the second visual inspection modules 24 are used for being matched with the first visual inspection module 21 to detect the surface defects of the materials.
The first visual inspection module 21 and the second visual inspection module 24 both include a camera assembly and a light source assembly; the sorting mechanism 3 comprises a third translation module 31 which is arranged vertically to the two material transferring mechanisms 1 and is positioned above the discharge ends of the material transferring mechanisms, a second lifting module 32 which is arranged on one side of the third translation module 31 and is in sliding connection with the third translation module, and a sucker module 33 which is in driving connection with the second lifting module 32 and is used for transferring materials; general type machine vision detection equipment still include frame 6, the material moves and carries mechanism 1, vision detection mechanism 2, letter sorting mechanism 3 and tectorial membrane mechanism 4 equipartition and arrange in frame 6.
Meanwhile, referring to fig. 7, the invention further provides a product surface defect detection method, which comprises the following steps:
s1: performing area division on the material image according to functions, wherein the area division comprises a silk screen area, a camera area, an IR hole area, an earphone area and a character area;
s2: acquiring material image information, and performing incoming material detection and defect detection of each area on the material based on the image information;
s3: and classifying and summarizing the material defect detection result according to the material defect detection result of S2, and outputting the material defect detection result.
The incoming material detection in the step S2 specifically comprises the following steps:
s21: detecting whether materials are placed on the bearing platform, whether the materials are placed reversely and whether the materials are placed in an overlapped mode;
s22: detecting whether different types of materials are placed on the bearing platform and whether the materials are placed beyond the visual field;
the defect detection in S2 specifically includes the following steps:
s23: matching and positioning the material image according to the functional areas divided in the S1 based on the shape matching algorithm;
s24: intercepting partial images at the positioning positions according to the size of the functional area, and performing threshold segmentation on the functional area contained in the intercepted images;
s25: comparing the difference information with a pre-stored material standard template and storing the difference information;
s26: based on the difference information held at S25, a defective area of the image is extracted.
The working principle of the invention is as follows:
with reference to fig. 1-2, in this embodiment, the device further includes a detection platform 7, and the material transfer mechanism 1, the visual detection mechanism 2, the sorting mechanism 3, and the film coating mechanism 4 are uniformly disposed on the detection platform 7, and then are disposed in the rack 6; a qualified material discharge port and an unqualified material discharge port are respectively formed at the positions, corresponding to the two laminating mechanisms 4, of one side of the rack 6, and the ink-jet printer 5 is installed on the side of the rack 6 and is positioned above the unqualified material discharge ports; the code spraying machine 5 can spray codes on unqualified materials (such as materials which are judged to be unqualified due to the problems of dirt and the like) after film coating, so that the defects of the unqualified materials are sprayed on the film, the film can be conveniently checked by workers in time, the next-step maintenance is convenient, and the like; the front of frame 6 still is equipped with cabinet door, touch screen etc. and the operation of being convenient for, and the top of frame 6 still is equipped with the pilot lamp, and its bottom still is equipped with the truckle foot cup, is convenient for remove fixedly.
Material moves and carries mechanism 1: as shown in fig. 4-5, the two material transfer mechanisms 1 are arranged in parallel at intervals along the length direction of the detection platform 7, the two material transfer mechanisms 1 have the same structure and are used for alternately transferring the materials to the detection area of the visual detection mechanism 2 for detection, and through the mutual cooperation of the two material transfer mechanisms, the materials can be continuously transferred, so that the detection efficiency is improved; when feeding, the material can be placed on the fine molybdenum wire 15 by an external manipulator or a manual mode, and the limitation is not made; the first translation module 11 of the material transfer mechanism 1 comprises a first linear motor assembly, the second translation module 12 comprises a first mounting seat which is arranged perpendicular to the first linear motor assembly and is in sliding connection with the top of the first linear motor assembly, a first screw rod assembly arranged in the first mounting seat along the length direction of the first mounting seat, a first motor in driving connection with the first screw rod assembly, and a first sliding seat which is movably arranged on the top of the first mounting seat and is in driving connection with the first screw rod assembly; one end of the material bearing platform 13 is fixedly connected with the top of the first sliding seat, and a first through hole 14 is formed in the middle of the top of the other end; in this embodiment, two tightening screws are respectively and correspondingly arranged on two sides of the top of the material bearing platform 13, where the first through hole 14 is formed, each fine molybdenum wire 15 is arranged between the two tightening screws in a direction perpendicular to the length direction of the first through hole 14, and the tightening screws can adjust the tightness of the fine molybdenum wires 15; the material is directly placed on the fine molybdenum wire 15, and the diameter of the fine molybdenum wire 15 is smaller, and under the condition that the material is stably supported, the contact part between the fine molybdenum wire 15 and the bottom of the material can be ignored, so that the detection blind area can be avoided (the fine molybdenum wire 15 is a transparent body, has a smaller diameter, can not shield a light source, can avoid the secondary pollution caused by the contact of the material and a traditional support jig), the comprehensive detection of the material is realized, and the omission is avoided.
Visual inspection mechanism 2: as shown in fig. 3, a first installation through hole is further formed in the middle of the detection platform 7 along the length direction of the detection platform, and the first installation through hole is located between the two material transfer mechanisms 1; the first visual detection module 21 is arranged close to the feeding ends of the two material transfer mechanisms 1 and is installed in the first installation through hole; the first visual detection module 21 is located below the two material transfer mechanisms 1 and is mainly used for detecting a character area located at the bottom of the material (in the embodiment, the material is a glass cover plate); the number of the first lifting modules 23 and the number of the second visual detection modules 24 are 3, and the first lifting modules and the second visual detection modules are arranged on one side of the mounting frame 22 in parallel at intervals in the length direction of the detection platform 7 (a protective cover 8 is also arranged on one side of the mounting frame 22, so that the second visual detection modules 24 can be wrapped, the damage caused by the impact of foreign objects is avoided, and the safety is improved); in this embodiment, the first lifting module 23 includes a first sliding module disposed on one side of the mounting frame 22 along the vertical direction, a second sliding seat slidably connected to the first sliding module, a second lead screw assembly inserted into the second sliding seat along the vertical direction and drivingly connected to the second sliding seat, and a hand wheel drivingly connected to the second lead screw assembly; the second visual detection module 24 is arranged on one side of the second sliding seat, and the second sliding seat is driven by a second lead screw assembly through a rotary hand wheel to drive the second visual detection module 24 to lift so as to focus a camera assembly of the second visual detection module 24; as shown in fig. 3, the second visual inspection module 24 located at the leftmost side is used for inspecting the white piece area (the middle part of the glass cover plate) of the material, and the other two second visual inspection modules 24 are used for inspecting the end part and the tail part of the material; through the mutual matching of the plurality of visual detection modules, the comprehensive detection of the materials can be realized;
sorting mechanism 3 and laminating mechanism 4: the third translation module 31 of the sorting mechanism 3 comprises two mounting brackets, a mounting beam and a second linear motor assembly; the two mounting brackets are respectively arranged at the two outer sides of the two material transferring mechanisms 1, and the mounting cross beam is arranged between the two mounting brackets; the second linear motor assembly is arranged on one side of the mounting cross beam, the second lifting module 32 comprises a first sliding plate in sliding connection with the second linear motor assembly, a lifting cylinder arranged on the first sliding plate, and a sucker module 33 is in driving connection with the lifting cylinder; the double-shaft motion of the sucker module 33 can be realized through the mutual matching of the second linear motor assembly and the lifting cylinder, so that the material can be conveniently sucked and released; each material moves and carries discharge end one side of mechanism 1 and all arranges a tectorial membrane mechanism 4, and tectorial membrane mechanism 4 can carry out the tectorial membrane to the material after the detection, and is simple and convenient.
In addition, the invention also provides a product surface defect detection method, which can realize the rapid and comprehensive detection of the defects of the glass cover plate, and comprises the steps of LOGO defect detection of silk-screen characters of the glass cover plate, key light transmission detection, screen camera/earphone hole position detection, proximity sensor light transmission hole detection, silk-screen area detection (including 2.5D/3D arc edges), missing printing, white points, black points, sawteeth, deviation, cracks, edge breakage, corner breakage, micro scratch detection, concave-convex points, silk-screen defects, heterochromatic colors, water ripples and other defects detection, the detection efficiency is high, the detection range is wide, and specifically:
firstly, dividing the glass cover plate according to functional areas of the glass cover plate, wherein the functional areas comprise a silk screen area, a camera area, an IR hole area, an earphone area and a character area, when the cover plate is placed on the fine molybdenum wire 15 and is driven to move by the material transfer mechanism 1, the first visual detection module 21 and the three second visual detection modules 24 are sequentially triggered, then different areas of the cover plate are photographed, images are transmitted to a parallel processor in equipment, and each image is respectively processed in parallel; the detection of the cover plate comprises incoming material detection and defect detection, wherein the incoming material detection mainly distinguishes the situations of material discharging, material reverse discharging, material overlapping placement, material placement beyond the visual field, material mixing (placing other materials of different types) and the like, and particularly,
1) no material, reverse placement and overlapping: the situation is different from a normal situation greatly, wherein the silk screen part can be obviously divided through a gray threshold, and whether materials exist or not, whether the materials are placed reversely or not and whether the materials are overlapped can be judged only by setting the area of a specified type of mobile phone glass cover plate;
2) non-target model (mix): subsequent positioning of the mobile phone glass cover plate is carried out by using a shape matching algorithm, and the mobile phone glass cover plate is not matched, namely the models are not right;
3) out of view: the mobile phone glass cover plate exceeds the visual field or is in contact with the edge of the image, and intersection is obtained by utilizing the extracted silk-screen area and the edge of the image for judgment.
When the material defect is detected, the shape matching algorithm can be used for positioning the functional area of the input image information, segmenting the functional area by using a threshold value, accurately extracting the segmented image, enhancing the image contrast and extracting the defect, and the multi-layer perceptron classifier is used for classifying the defect, specifically,
dividing the cover plate into a silk screen area, a camera area, an IR hole area, an earphone area and a character area according to the functional area, matching and positioning the functional areas after the first visual detection module 21 and the three second visual detection modules 24 acquire image information, extracting the areas after the functional areas are positioned, comparing the areas with a standard template stored in advance, if the areas are different, indicating that the functional areas have defects, storing the difference information and extracting the defects, and if the defects are serious, such as dirt, and the like, directly outputting a defect detection result; if the defect characteristics are smaller, clustering and connecting the defects, compensating the defect discontinuity caused by extraction, further separating and classifying the defects, comparing the defects with a standard template, and outputting a judgment result. By the method, each mechanism can be in a full-load state with high utilization rate, the working efficiency is high, the method is applicable to defect detection of different types of glass cover plates, and the working efficiency and the universality are high.
The present invention is not limited to the above preferred embodiments, and any modifications, equivalent substitutions and improvements made within the spirit and principle of the present invention should be included in the protection scope of the present invention.