CN112461503A - LED lamp panel visual detection device and detection method - Google Patents
LED lamp panel visual detection device and detection method Download PDFInfo
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Abstract
The invention discloses a visual detection device for an LED lamp panel, which comprises a working table top and is characterized in that: the utility model provides a portable LED lamp plate, including the slide mechanism, the last electrode that is used for to the circular telegram of LED lamp plate that sets up of table surface, table surface's top is provided with portable detection mechanism, portable detection mechanism includes slide mechanism and the actuating mechanism who is used for driving slide mechanism motion, the last camera that is used for shooing the LED lamp plate that is provided with of slide mechanism, a light beam generating device that is used for sending the light beam and shines the LED lamp plate and be used for adjusting the angle adjustment mechanism that the light beam shines the angle, this visual detection device still includes visual detection host computer, the. This detection device adopts the high resolution camera to shoot the LED lamp plate, through handling the image, can accurately discern the inferior components and parts on the LED lamp plate fast to shine the inferior components and parts through the laser beam, guide the quick inferior components and parts of quality testing personnel. Can replace manual quality inspection, and has low cost, high accuracy and high efficiency.
Description
Technical Field
The invention relates to the technical field of product quality inspection, in particular to a visual inspection device and a visual inspection method for an LED lamp panel.
Background
LEDs are known as semiconductor light emitting diodes, which are made of semiconductors as their name suggests, and have the advantages of low cost, low power consumption, high brightness, bright color, vibration resistance, long life, cold light source, and the like.
At present, the LED lamp panel is widely applied to the fields of illumination, LED large screen display, traffic lights, decoration, computers, electronic toy gifts, exchangers, telephones, advertisements, urban light and color engineering and the like.
The LED lamp panel is generally manufactured by adopting a chip mounting process, namely, a plurality of lamp beads and resistors are mounted on the panel body of the chip mounter, and the lamp beads and the resistors are generally arranged on the panel body according to an array. Because the chip mounter cannot identify the defective lamp beads, the situation that the defective lamp beads are pasted on the plate body is inevitable; meanwhile, due to certain errors of the chip mounter, the situation of deviation of the mounting position of the lamp bead or the resistor can also occur; or paste the back again because soldering tin is not firm, the disappearance that drops of components and parts appears, and the product quality of LED lamp plate can all be influenced to above-mentioned condition. Therefore, the quality of the LED lamp panel needs to be checked before leaving the factory, and the detected items include: whether the lamp bead can normally give out light, whether have lamp bead disappearance, whether have resistance disappearance to and whether the position skew of lamp bead, resistance exceeds standard.
At present, some manufacturers still adopt a manual quality inspection mode, namely electrifying the LED lamp panel, finding out defective lamp beads by manually observing the on-off condition of the lamp beads, or directly observing the LED lamp panel, finding out places with obvious component loss or deviation exceeding the standard, and then performing manual remediation,
because the integration level of LED lamp plate is higher and higher, lean on human eye to observe many components and parts that these small and intensive arranged of volume, the problem of missed measure false detection appears very easily, causes the problem that the defective products are many to the product that dispatches from the factory. In addition, the manual method has the problems of low efficiency and high cost.
Disclosure of Invention
Aiming at the defects in the prior art, the invention aims to provide the LED lamp panel visual detection device and the detection method, which can automatically detect the LED lamp panel, accurately identify the defective component and guide a detector to quickly find the defective component.
In order to achieve the purpose, the invention provides the following technical scheme:
a visual detection device for an LED lamp panel comprises a rack, wherein a working table is arranged on the rack, the working table is used for placing the LED lamp panel, an electrode used for electrifying the LED lamp panel is arranged on the working table, a movable detection mechanism is arranged above the working table and comprises a sliding mechanism and a driving mechanism used for driving the sliding mechanism to move, a camera used for shooting the LED lamp panel, a light beam generating device used for emitting light beams to irradiate the LED lamp panel and an angle adjusting mechanism used for adjusting the light beam irradiation angle are arranged on the sliding mechanism, the visual detection device further comprises a visual detection host, a display and a lighting source used for supplementing light to the LED lamp panel, the camera is connected with the visual detection host and used for transmitting the shot images to the visual detection host, and the visual detection host is used for analyzing and processing the images, with the imperfect components and parts on the discernment LED lamp plate, the display is connected with the visual detection host computer for show the testing result.
As a preferable scheme: the sliding mechanism comprises a cross beam arranged above the working table surface and a sliding seat arranged on the cross beam, the sliding seat is L-shaped, the side surface and the top surface of the cross beam are respectively provided with a first guide rail and a second guide rail which are parallel to each other, the inner side surface and the inner top surface of the sliding seat are respectively fixed with a first sliding block and a second sliding block, the first sliding block is connected with the first guide rail in a sliding manner, and the second sliding block is connected with the second guide rail in a sliding manner.
As a preferable scheme: the detection fixture comprises a base fixed relative to the working table, a pressing plate arranged above the base and a top plate arranged above the pressing plate, the base and the top plate are fixedly connected through a plurality of connecting columns, the connecting columns movably penetrate through the pressing plate, a contact plate is fixed on one side of the pressing plate, and the electrodes are fixed on the contact plate; detect anchor clamps still include movable rod, handle, connecting rod and be the swing piece of broken line type, the movable rod is vertical to be passed the roof and can freely go up and down, the lower extreme and the clamp plate of movable rod are connected fixedly, the one end and the handle of swing piece are connected fixedly, the other end of swing piece rotates with the upper end of movable rod and articulates, the one end and the roof of connecting rod are articulated, the other end of connecting rod is articulated with the kink of swing piece.
As a preferable scheme: the LED lamp panel positioning device is characterized in that a positioning mechanism used for positioning the LED lamp panel is arranged on the working table surface and comprises a positioning column, and the positioning column is used for being inserted into a positioning hole in the edge of the LED lamp panel.
As a preferable scheme: the utility model discloses a table top, including table top, the storage tank, waist type hole, location post and movable block, table top is last to be fixed with the layer board, the both ends of layer board are provided with the storage tank to be provided with the movable block in the storage tank, the tank bottom of storage tank is provided with first screw hole, first waist type hole has been seted up on the movable block, first waist type hole sets up along table top's length direction, first waist type hole aligns with first screw hole, first waist type hole and first screw hole are downthehole to be worn first locking bolt, first locking bolt and first screw hole screw-thread fit, the location post is connected fixedly with the movable block.
As a preferable scheme: the movable block is provided with an insertion groove, the lower end of the positioning column is connected with an insertion block, and the insertion block is inserted into the insertion groove.
As a preferable scheme: the supporting plate is provided with a second threaded hole, the base is located on the supporting plate and provided with a second waist-shaped hole, the second waist-shaped hole is arranged along the length direction of the working table, a second locking bolt penetrates through the second waist-shaped hole and the second threaded hole, and the second locking bolt is in threaded connection with the second threaded hole.
A visual inspection method of an LED lamp panel,
for the lamp bead, the following steps are performed:
s1, with the detection station as a reference, calibrating the position of each lamp bead on the LED lamp panel to obtain the position coordinates of each lamp bead;
s2, placing the LED lamp panel at a detection station, and electrifying the LED lamp panel;
s3, shooting through a camera to obtain a complete image of the LED lamp panel;
s4, processing the complete image of the LED lamp panel, and identifying the light and dark areas in the image;
s5, comparing the position of each bright area with the position coordinates of each lamp bead one by one, and judging whether lamp beads incapable of emitting light normally exist according to the overlapping condition of the bright areas and the position coordinates of the lamp beads; judging whether the lamp beads deviate to exceed the standard or not according to the coordinate range of the bright area and the offset of the position coordinates of the lamp beads; lamp beads which can not normally emit light or deviate beyond the standard are defective lamp beads;
s6, automatically searching and irradiating the defective lamp beads through the controllable light beam generating device, and guiding detection personnel to quickly find the defective lamp beads;
for the resistance, the following steps are performed:
a. and calibrating the position of each resistor on the LED lamp panel by taking the detection station as a reference to obtain the position coordinates of the central point of each resistor.
b. The LED lamp panel is irradiated by the light source and shot by the camera, and a complete image of the LED lamp panel is obtained.
c. And processing the complete image of the LED lamp panel, and identifying a light and shade region in the image.
When the power is not supplied, the area where the resistor is located in the captured image is a dark area, and the other areas are bright areas.
d. Comparing the position of each dark area with the position coordinates of each resistor one by one, and if the position of each dark area can correspond to the position coordinates of the resistors one by one, judging that the LED lamp panel has no resistor loss; judging whether the resistor deviates to exceed the standard or not according to the coordinate range of the dark area and the offset of the position coordinate of the resistor; and the missing or offset overproof resistor is the defective resistor.
e. The defective resistor is automatically searched and irradiated through the controllable light beam generating device, and the detection personnel are guided to quickly find the defective resistor.
Preferably, the method for identifying the bright and dark areas in the image comprises the following steps: binarizing the image to change the image into a black and white mode; the black and white image is sharpened, so that the outlines of the white area and the black area are clearer, and the white area and the black area are distinguished.
Preferably, the method for determining the coordinate offset comprises the following steps: firstly, determining the central coordinates of a target area, namely finding out the points with the maximum and minimum X-axis coordinates and the points with the maximum and minimum Y-axis coordinates in the target area, connecting the points with the minimum X-axis coordinates with the points with the maximum X-axis coordinates, connecting the points with the minimum Y-axis coordinates with the points with the maximum Y-axis coordinates, taking the intersection point of the two connecting lines as the central point of the target area, calculating the coordinates of the central point, and then calculating the offset vector of the central point coordinates and the calibration coordinates of the target area.
Compared with the prior art, the invention has the advantages that: this detection device adopts the high resolution camera to shoot the LED lamp plate, through carrying out analysis and discernment to the image of shooing, can accurately discern the inferior components and parts on the LED lamp plate fast to shine inferior components and parts through the laser beam, automatic guide quality testing personnel find the inferior components and parts fast. The detection device can replace manual quality inspection, and is low in cost; the accuracy is high, and the condition of missing detection and error detection cannot occur; can continuously work and has high efficiency.
Drawings
FIG. 1 is a schematic view of the overall structure of the detecting device;
FIG. 2 is an enlarged view of portion A of FIG. 1;
FIG. 3 is an enlarged view of portion B of FIG. 1;
FIG. 4 is a schematic view of the connection of the oscillating member to the movable rod;
FIG. 5 is an enlarged view of the portion C of FIG. 1;
FIG. 6 is a schematic cross-sectional view of the lamp panel positioning mechanism;
FIG. 7 is a schematic view of a connection structure of a base and a pallet;
FIG. 8 is a schematic view of the internal structure of the detecting device;
FIG. 9 is a schematic structural view of a mobile detection mechanism;
fig. 10 is an enlarged view of a portion D in fig. 9.
1, a frame; 2. a work table; 3. a control box; 4. detecting the clamp; 401. a base; 402. connecting columns; 403. pressing a plate; 404. a top plate; 405. a movable rod; 406. a connecting rod; 407. a swinging member; 408. a handle; 409. a contact plate; 410. an electrode; 5. an LED lamp panel; 6. a support pillar; 7. a cross beam; 8. a sliding seat; 9. a first guide rail; 10. a first slider; 11. a second guide rail; 12. a second slider; 13. a drive motor; 14. a synchronous belt; 15. a rotating electric machine; 16. a laser pen; 17. a first camera; 18. a second camera; 19. a connecting frame; 20. a first light source; 21. a second light source; 22. a cover body; 23. a support plate; 24. a containing groove; 25. a movable block; 26. a positioning column; 27. positioning holes; 28. a first threaded hole; 29. a first kidney-shaped hole; 30. a first locking bolt; 31. inserting grooves; 32. an insertion block; 33. a second threaded hole; 34. a second kidney-shaped hole; 35. a second locking bolt.
Detailed Description
The first embodiment is as follows:
referring to fig. 1, 2, 8, 9 and 10, the LED lamp panel visual detection device comprises a rack 1, wherein a working table surface 2 is arranged on the rack 1, the working table surface 2 is used for placing an LED lamp panel 5, a detection clamp 4 is arranged on the working table surface 2, the detection clamp 4 is of a lifting structure, the detection clamp 4 is provided with a movable electrode 410, and the electrode 410 is used for being in contact with a conductive contact on the lamp panel.
A lamp bead array is integrated on the LED lamp panel 5, and after the LED lamp panel 5 is placed on the working table surface 2, the length direction of the working table surface 2 is set to be the row arrangement direction of the lamp beads, namely the lamp beads are arranged in multiple rows along the length direction of the working table surface 2; the width direction of the working table surface 2 is the row arrangement direction of the lamp beads, namely the lamp beads are arranged in a plurality of rows along the width direction of the working table surface 2.
A cross beam 7 is arranged above the working table top 2 along the length direction of the table top, two ends of the cross beam 7 are fixedly connected with the working table top 2 through support columns 6, and a movable detection mechanism is arranged on the cross beam 7.
Referring to fig. 2 and 8, the movable detection mechanism includes a sliding seat 8 in an "L" shape, a first guide rail 9 and a second guide rail 11 are respectively arranged on the side surface and the top surface of the cross beam 7, the first guide rail 9 and the second guide rail 11 are both arranged along the length direction of the cross beam 7 (the length direction of the cross beam 7 is the length direction of the working table 2), a first slider 10 and a second slider 12 are respectively fixed on the inner side surface and the inner top surface of the sliding seat 8, the first slider 10 is connected with the first guide rail 9 in a sliding manner, and the second slider 12 is connected with the second guide rail 11 in a sliding manner, so that the sliding seat 8 can freely slide back and forth along the cross beam 7; the movable detection mechanism further comprises a first camera 17 and a second camera 18 which are fixedly arranged on the sliding seat 8, and lenses of the first camera 17 and the second camera 18 are downward and used for shooting the LED lamp panel 5 on the working table surface 2; the movable detection mechanism further comprises a laser pen 16 and a rotating motor 15, the rotating motor 15 is fixedly connected with the sliding seat 8, an output shaft of the rotating motor 15 is parallel to the cross beam 7, the laser pen 16 is fixedly connected with an output shaft of the rotating motor 15, and the axial direction of the laser pen 16 is perpendicular to the axial direction of the rotating motor 15; a synchronous belt 14 is arranged on the cross beam 7 along the length direction of the cross beam, a driving motor 13 is arranged at one end of the cross beam 7, an output shaft of the driving motor 13 is in transmission connection with the synchronous belt 14, and the driving motor 13 can drive the synchronous belt 14 to move after being started. In this embodiment, the synchronous belt 14 is disposed on the top surface of the beam 7, and the second slider 12 is fixedly connected to the synchronous belt 14; in other embodiments, the timing belt 14 may be provided on the side surface of the beam 7, and the first slider 10 may be connected and fixed to the timing belt 14.
After the driving motor 13 is started, the synchronous belt 14 is driven to move, the synchronous belt 14 drives the second sliding block 12 to start sliding, so that the sliding seat 8 and the whole movable detection mechanism synchronously move along with the sliding seat, and the first camera 17 and the second camera 18 can shoot different parts on the LED lamp panel 5; and rotating electrical machines 15 can drive laser pen 16 and swing in a certain angle, can shine the lamp pearl of different lines in the same row on LED lamp plate 5 after laser pen 16 swings.
The detection device further comprises a visual detection host, a display and a control box 3, wherein the first camera 17, the second camera 18 and the display are all connected with the visual detection host, a motor driving module and a laser pen 16 control module are integrated in the control box 3, and the visual detection host is connected with the motor driving module and the laser pen 16 control module. The motor driving module can adopt a PLC controller, the control module of the laser pen 16 can be a relay module in the PLC controller, and the on-off of the power supply of the laser pen 16 can be controlled by controlling the on-off of the power supply of the laser pen 16 through the relay module. In other embodiments, the motor drive module and the laser pointer 16 control module may be other modules or devices, not to be enumerated here!
Referring to fig. 3 and 4, the detection fixture 4 includes a base 401 fixed to the work table 2, a pressing plate 403 disposed above the base 401, and a top plate 404 disposed above the pressing plate 403, the base 401 and the top plate 404 are connected and fixed by a plurality of connecting posts 402, the connecting posts 402 movably penetrate through the pressing plate 403, so that the pressing plate 403 can move up and down, a contact plate 409 is fixed to one side of the pressing plate 403, a plurality of electrodes 410 for contacting with conductive contacts on the LED lamp panel 5 are disposed on the contact plate 409, and the plurality of electrodes 410 are arranged in a row; the detection clamp 4 further comprises a movable rod 405, a handle 408, a connecting rod 406 and a swinging piece 407 in a folding line type, wherein the movable rod 405 vertically penetrates through the top plate 404 and can freely lift, the lower end of the movable rod 405 is fixedly connected with the pressing plate 403, one end of the swinging piece 407 is fixedly connected with the handle 408, the other end of the swinging piece 407 is rotatably hinged with the upper end of the movable rod 405, one end of the connecting rod 406 is hinged with the top plate 404, and the other end of the connecting rod 406 is hinged with a bending part of the swinging piece 407. The structure is that when the handle 408 is swung downwards, the movable rod 405 can be lifted upwards, so that the pressure plate 403 is driven to ascend, and the contact plate 409 and the electrode 410 ascend synchronously; when the handle 408 is swung upward, the movable rod 405 is lowered to drive the pressing plate 403 to descend, so that the contact plate 409 and the electrode 410 are lifted synchronously. After the LED lamp panel 5 is placed on the working table surface 2, the handle 408 is swung downwards, so that the electrode 410 (the electrode 410 is connected with the test power supply) is lowered to be in contact with the conductive contact on the LED lamp panel 5, and the on-off of the lamp beads can be controlled by controlling the on-off of the test power supply.
The working principle of the detection device is as follows: taking fig. 1 as an example, in the initial state, the movable detection mechanism is located at the leftmost end of the beam 7. The LED lamp panel 5 is placed on the working table surface 2, the detection clamp 4 is operated after the placement position of the LED lamp panel 5 is adjusted, the electrode 410 is made to be in contact with a conductive contact on the LED lamp panel 5, the test power supply is started again to enable the lamp beads to be on, then the movable detection mechanism moves rightwards for a certain distance and then pauses, at the moment, the first camera 17 and the second camera 18 shoot images of the current section of the LED lamp panel 5, the image data are transmitted to the visual detection host, then the movable detection mechanism moves rightwards again to the next pause position, the first camera 17 and the second camera 18 shoot images of the next section, and the transmission of the image data to the visual detection host … … is repeated until the whole LED lamp panel 5 is shot. Finally, the images of all the sections are spliced into a complete image by the vision detection host, the image is processed, a white point area of the image is identified, coordinates of the white point area and coordinates of all lamp beads on the LED lamp panel 5 are compared one by one, lamp beads capable of emitting light normally can be identified, lamp beads incapable of emitting light (namely defective lamp beads) can be checked, then the movable detection mechanism is controlled to move to the position above the defective lamp beads according to the coordinates of the defective lamp beads, the laser pen 16 is located right above a column to which the defective lamp beads belong, then the vision detection host controls the rotating motor 15 to rotate, the laser pen 16 swings to be aligned with the defective lamp beads, the laser pen 16 is controlled to emit laser beams, the laser beams can just irradiate the defective lamp beads, and quality inspection personnel can quickly and accurately find the defective lamp beads through the guidance of the laser beams.
It should be noted that in the present embodiment, the shooting visual field ranges of the first camera 17 and the second camera 18 on the work table 2 are seamlessly connected. That is, the picture edge captured by the first camera 17 and the picture edge captured by the second camera 18 can be seamlessly spliced. Compared with the mode of adopting a single group of cameras, the mode of adopting two groups of cameras to shoot and splice the pictures cooperatively is adopted in the embodiment, the range of the shot pictures is larger at each time, the sliding distance of the movable detection mechanism is longer at each time, the sliding times are reduced, the shooting of the whole LED lamp panel 5 can be completed more quickly, and the visual detection efficiency is obviously improved.
Because the seat 8 that slides is "L" shape, and the upper portion and the lateral part of the seat 8 that slides all through sliding connection structure and crossbeam 7 swing joint, so make the seat 8 that slides can steadily slide, can not take place to rock or shake, the image of avoiding shooing splices the occasionally error, guarantees the accuracy of visual detection and guide.
In order to ensure that the electrodes 410 can be accurately butted against the conductive contacts on the LED lamp panel 5, the LED lamp panel 5 needs to be positioned after being placed on the work table 2. Referring to fig. 1 and 5, in the present embodiment, a positioning column 26 protruding upward is disposed on the working platform 2, and the positioning column 26 is used for being inserted into a positioning hole 27 at the edge of the LED lamp panel 5. Place back on table surface 2 with LED lamp plate 5, finely tune the position of LED lamp plate 5, make reference column 26 insert in locating hole 27 to can realize the accurate location to LED lamp plate 5.
Considering that the LED lamp panels 5 of different types and models have different sizes, the positions of the positioning holes 27 are different. In order to realize the positioning of the LED lamp panels 5 with different sizes, the positioning column 26 needs to be designed into a structure with an adjustable position. Referring to fig. 5 and 6, in this embodiment, a supporting plate 23 is further fixed on the working table 2, and the supporting plate 23 is used for supporting the LED lamp panel 5. The two ends of the supporting plate 23 are provided with accommodating grooves 24, the accommodating grooves 24 are internally provided with movable blocks 25, the bottoms of the accommodating grooves 24 are provided with first threaded holes 28, the movable blocks 25 are provided with first waist-shaped holes 29, the first waist-shaped holes 29 are arranged along the length direction of the working table surface 2, the first waist-shaped holes 29 are aligned with the first threaded holes 28, first locking bolts 30 penetrate through the first waist-shaped holes 29 and the first threaded holes 28, the first locking bolts 30 are in threaded fit with the first threaded holes 28, and the positioning columns 26 are fixedly connected with the movable blocks 25. When the first locking bolt 30 is screwed down, the movable block 25 can be locked, and after the first locking bolt 30 is unscrewed, the position of the movable block 25 can be adjusted, so that the position of the positioning column 26 can be finely adjusted, and the positioning column 26 can be adjusted along with the position of the positioning hole 27.
Referring to fig. 6, in the present embodiment, the positioning column 26 is a detachable structure, specifically: an insertion groove 31 is formed in the movable block 25, an insertion block 32 is connected to the lower end of the positioning column 26, and the insertion block 32 is inserted into the insertion groove 31. The positioning post 26 can be removed by holding it and lifting it upward. So that the positioning posts 26 with different diameters can be replaced according to the diameters of the positioning holes 27.
Referring to fig. 7, in order to adapt to the change in size of the LED lamp panel 5, the position of the detection fixture 4 is designed to be an adjustable structure in this embodiment, specifically: the supporting plate 23 is provided with a second threaded hole 33, the base 401 is positioned on the supporting plate 23, the base 401 is provided with a second waist-shaped hole 34, the second waist-shaped hole 34 is arranged along the length direction of the working table top 2, a second locking bolt 35 penetrates through the second waist-shaped hole 34 and the second threaded hole 33, and the second locking bolt 35 is in threaded connection with the second threaded hole 33. The base 401 can be locked by tightening the second locking bolt 35, and the position of the base 401, that is, the position of the detection jig 4 can be adjusted by loosening the second locking bolt 35.
In order to enable the visual detection device to be used for detecting the position offset of the lamp bead and some non-luminous components (such as resistors), an illumination light source is further arranged above the working table surface 2 in the embodiment. Referring to fig. 8, the illumination light source in this embodiment includes a first light source 20 and a second light source 21 arranged along the length direction of the table top and having a bar shape, and the first light source 20 and the second light source 21 are respectively located at the front side and the rear side of the movable detection mechanism. The strip-shaped lighting source can irradiate each part of the component carrier plate on the working table surface 2, and the camera can shoot clear images.
As shown in fig. 8, in this embodiment, the first light source 20 and the second light source 21 are both inclined toward the mobile detection mechanism, so that the irradiation areas between the first light source 20 and the second light source 21 are overlapped, and thus, light can be intensively irradiated onto the LED lamp panel 5 or other component carrier plates, so that a camera can shoot a clearer and brighter image, which is beneficial to subsequent image processing and recognition.
Example two:
a visual detection device and a detection method for an LED lamp panel comprise the following steps:
and (3) detection of the lamp beads:
and S1, calibrating the position of each lamp bead on the LED lamp panel by taking the detection station as a reference, and acquiring the position coordinates of each lamp bead.
For the LED lamp panel of a certain model and size, the position of each lamp bead on the panel body can be determined, when the LED is placed on a working table and positioned, the position coordinates of each lamp bead are determined relative to the reference point on the working table, the X-axis distance and the Y-axis distance between each lamp bead and the reference point are measured and calculated by selecting the reference point on the working table, and the position coordinates of each lamp bead (the coordinates of the central point of the lamp bead) can be obtained.
S2, placing the LED lamp panel at the detection station, and electrifying the LED lamp panel.
The LED lamp plate is fixed a position on the detection station, and through operation detection fixture, with LED circular telegram, normal lamp pearl can light after the circular telegram, and inferior lamp pearl then can not light or luminance is very low.
And S3, shooting through a camera to obtain a complete image of the LED lamp panel.
For the LED lamp panel with a larger size, a sectional shooting mode is required, namely, a mobile camera shoots images of all sections of the LED lamp panel, and finally the images of all the sections are spliced into a complete image; and to the LED lamp plate that the size is less, then can obtain complete image through once shooing.
And S4, processing the complete image of the LED lamp panel, and identifying the light and dark areas in the image.
Because the lamp pearl on the LED lamp plate is arranged according to the array, consequently the region that luminous lamp pearl place can be brighter in the image, and the blank region between the lamp pearl of going out and lamp pearl is darker, also is light and shade alternate in the image of shooing, has the white spot array in the image promptly. Therefore, the lamp beads can be identified to be incapable of emitting light normally through image processing.
The image processing steps are as follows: binarizing the image to change the image into a black-and-white mode, wherein a light-emitting area is changed into a pure white area, and a non-light-emitting area is changed into a pure black area; the image is sharpened, so that the outline of the white area is clearer, and the white area and the black area can be distinguished more accurately.
S5, comparing the position of each bright area with the position coordinates of each lamp bead one by one, and judging whether lamp beads incapable of emitting light normally exist according to the overlapping condition of the bright areas and the position coordinates of the lamp beads; judging whether the lamp beads deviate to exceed the standard or not according to the coordinate range of the bright area and the offset of the position coordinates of the lamp beads; the lamp beads which can not normally emit light or deviate from the standard exceeding are the defective lamp beads.
The actual size of the LED lamp panel corresponds to the image size, so that the actual positions of the LED lamp panels in all areas in the image can be corresponded. And calculating the X-axis distance range and the Y-axis distance range between each white area and the reference point, comparing the coordinate range of each white area with the coordinates of the lamp beads one by one, and if the coordinates of the lamp beads fall into the white areas, indicating that the white areas are just the areas illuminated by the lamp beads, and the lamp beads can normally emit light, and accordingly, judging whether the lamp beads can normally emit light one by one. If the positions of the bright areas can correspond to the position coordinates of the lamp beads one by one, the lamp beads of the LED lamp panel are judged to be capable of normally emitting light; otherwise, judging that the LED lamp panel has a lamp bead which cannot normally emit light or a lamp bead missing lamp bead, and finding out the lamp bead which is not covered by the bright area, namely the position coordinate of the lamp bead which cannot emit light or the missing lamp bead;
meanwhile, the offset of the central coordinate of the white area and the position coordinate of the lamp bead is calculated, if the offset (offset vector) exceeds a threshold value, the position offset of the lamp bead exceeds the standard, and the lamp bead needs to be found out. The method for determining the center coordinates of the white area comprises the following steps: finding out the point with the maximum and minimum X-axis coordinates and the point with the maximum and minimum Y-axis coordinates in the white area, connecting the point with the minimum X-axis coordinates with the point with the maximum X-axis coordinates, connecting the point with the minimum Y-axis coordinates with the point with the maximum Y-axis coordinates, taking the intersection point of the two connecting lines as the center point of the white area, and calculating the coordinates of the center point.
S6, automatically searching and irradiating the defective lamp beads through the controllable light beam generating device, and guiding detection personnel to quickly find the defective lamp beads.
Control parameters of the driving motor and the rotating motor corresponding to each lamp bead need to be set in advance. The control parameter is about the number of turns that the driving motor needs to rotate (i.e. the stroke of the movable detection mechanism) when the laser pen moves to the row where the lamp bead is located, and the angle that the rotating motor needs to rotate when the laser pen swings to align with the lamp bead. For the inferior lamp pearl, control driving motor's the number of turns and the turned angle of rotating electrical machines through its control parameter that corresponds, make the laser pen just can shine inferior lamp pearl, guide the measurement personnel to find inferior lamp pearl.
For the detection of the resistance:
then the method comprises the following steps:
a. and calibrating the position of each resistor on the LED lamp panel by taking the detection station as a reference to obtain the position coordinates of the central point of each resistor.
b. The LED lamp panel is irradiated by the light source and shot by the camera, and a complete image of the LED lamp panel is obtained.
c. And processing the complete image of the LED lamp panel, and identifying a light and shade region in the image.
When the power is not supplied, the area where the resistor is located in the captured image is a dark area, and the other areas are bright areas.
d. Comparing the position of each dark area with the position coordinates of each resistor one by one, and if the position of each dark area can correspond to the position coordinates of the resistors one by one, judging that the LED lamp panel has no resistor loss; judging whether the resistor deviates to exceed the standard or not according to the coordinate range of the dark area and the offset of the position coordinate of the resistor; and the missing or offset overproof resistor is the defective resistor.
The determination method and offset calculation of the coordinates of the center of the dark area are described in detail below with reference to the foregoing description!
e. The defective resistor is automatically searched and irradiated through the controllable light beam generating device, and the detection personnel are guided to quickly find the defective resistor.
The above description is only a preferred embodiment of the present invention, and the protection scope of the present invention is not limited to the above embodiments, and all technical solutions belonging to the idea of the present invention belong to the protection scope of the present invention. It should be noted that modifications and embellishments within the scope of the invention may occur to those skilled in the art without departing from the principle of the invention, and are considered to be within the scope of the invention.
Claims (10)
1. The utility model provides a LED lamp plate visual detection device, includes the frame, is provided with table surface in the frame, and table surface is used for placing LED lamp plate, characterized by: the working table is provided with an electrode for electrifying the LED lamp panel, a movable detection mechanism is arranged above the working table, the mobile detection mechanism comprises a sliding mechanism and a driving mechanism for driving the sliding mechanism to move, the sliding mechanism is provided with a camera for shooting the LED lamp panel, a light beam generating device for emitting light beams to irradiate the LED lamp panel and an angle adjusting mechanism for adjusting the irradiation angle of the light beams, the visual detection device also comprises a visual detection host, a display and an illumination light source for supplementing light to the LED lamp panel, the camera is connected with the visual detection host, used for transmitting the shot image to a visual detection host, the visual detection host is used for analyzing and processing the image, with the imperfect components and parts on the discernment LED lamp plate, the display is connected with the visual detection host computer for show the testing result.
2. The visual inspection device of the LED lamp panel of claim 1, wherein: the sliding mechanism comprises a cross beam arranged above the working table surface and a sliding seat arranged on the cross beam, the sliding seat is L-shaped, the side surface and the top surface of the cross beam are respectively provided with a first guide rail and a second guide rail which are parallel to each other, the inner side surface and the inner top surface of the sliding seat are respectively fixed with a first sliding block and a second sliding block, the first sliding block is connected with the first guide rail in a sliding manner, and the second sliding block is connected with the second guide rail in a sliding manner.
3. The visual inspection device of the LED lamp panel of claim 1, wherein: the detection fixture comprises a base fixed relative to the working table, a pressing plate arranged above the base and a top plate arranged above the pressing plate, the base and the top plate are fixedly connected through a plurality of connecting columns, the connecting columns movably penetrate through the pressing plate, a contact plate is fixed on one side of the pressing plate, and the electrodes are fixed on the contact plate; detect anchor clamps still include movable rod, handle, connecting rod and be the swing piece of broken line type, the movable rod is vertical to be passed the roof and can freely go up and down, the lower extreme and the clamp plate of movable rod are connected fixedly, the one end and the handle of swing piece are connected fixedly, the other end of swing piece rotates with the upper end of movable rod and articulates, the one end and the roof of connecting rod are articulated, the other end of connecting rod is articulated with the kink of swing piece.
4. The visual inspection device of the LED lamp panel of claim 1, wherein: the LED lamp panel positioning device is characterized in that a positioning mechanism used for positioning the LED lamp panel is arranged on the working table surface and comprises a positioning column, and the positioning column is used for being inserted into a positioning hole in the edge of the LED lamp panel.
5. The visual inspection device of the LED lamp panel of claim 4, wherein: the utility model discloses a table top, including table top, the storage tank, waist type hole, location post and movable block, table top is last to be fixed with the layer board, the both ends of layer board are provided with the storage tank to be provided with the movable block in the storage tank, the tank bottom of storage tank is provided with first screw hole, first waist type hole has been seted up on the movable block, first waist type hole sets up along table top's length direction, first waist type hole aligns with first screw hole, first waist type hole and first screw hole are downthehole to be worn first locking bolt, first locking bolt and first screw hole screw-thread fit, the location post is connected fixedly with the movable block.
6. The visual inspection device of the LED lamp panel of claim 5, wherein: the movable block is provided with an insertion groove, the lower end of the positioning column is connected with an insertion block, and the insertion block is inserted into the insertion groove.
7. The visual inspection device of the LED lamp panel of claim 5, wherein: the supporting plate is provided with a second threaded hole, the base is located on the supporting plate and provided with a second waist-shaped hole, the second waist-shaped hole is arranged along the length direction of the working table, a second locking bolt penetrates through the second waist-shaped hole and the second threaded hole, and the second locking bolt is in threaded connection with the second threaded hole.
8. A visual detection method for an LED lamp panel is characterized by comprising the following steps:
for the lamp bead, the following steps are performed:
s1, with the detection station as a reference, calibrating the position of each lamp bead on the LED lamp panel to obtain the position coordinates of each lamp bead;
s2, placing the LED lamp panel at a detection station, and electrifying the LED lamp panel;
s3, shooting through a camera to obtain a complete image of the LED lamp panel;
s4, processing the complete image of the LED lamp panel, and identifying the light and dark areas in the image;
s5, comparing the position of each bright area with the position coordinates of each lamp bead one by one, and judging whether lamp beads incapable of emitting light normally exist according to the overlapping condition of the bright areas and the position coordinates of the lamp beads; judging whether the lamp beads deviate to exceed the standard or not according to the coordinate range of the bright area and the offset of the position coordinates of the lamp beads; lamp beads which can not normally emit light or deviate beyond the standard are defective lamp beads;
s6, automatically searching and irradiating the defective lamp beads through the controllable light beam generating device, and guiding detection personnel to quickly find the defective lamp beads;
for the resistance, the following steps are performed:
a. and calibrating the position of each resistor on the LED lamp panel by taking the detection station as a reference to obtain the position coordinates of the central point of each resistor.
b. The LED lamp panel is irradiated by the light source and shot by the camera, and a complete image of the LED lamp panel is obtained.
c. And processing the complete image of the LED lamp panel, and identifying a light and shade region in the image. When the power is not supplied, the area where the resistor is located in the captured image is a dark area, and the other areas are bright areas.
d. Comparing the position of each dark area with the position coordinates of each resistor one by one, and if the position of each dark area can correspond to the position coordinates of the resistors one by one, judging that the LED lamp panel has no resistor loss; judging whether the resistor deviates to exceed the standard or not according to the coordinate range of the dark area and the offset of the position coordinate of the resistor; and the missing or offset overproof resistor is the defective resistor.
e. The defective resistor is automatically searched and irradiated through the controllable light beam generating device, and the detection personnel are guided to quickly find the defective resistor.
9. The visual inspection method of the LED lamp panel according to claim 8, wherein the light and dark areas in the image are identified by the specific method: binarizing the image to change the image into a black and white mode; the black and white image is sharpened, so that the outlines of the white area and the black area are clearer, and the white area and the black area are distinguished.
10. The visual inspection method of the LED lamp panel according to claim 8, wherein the method of determining the coordinate offset is: firstly, determining the central coordinates of a target area, namely finding out the points with the maximum and minimum X-axis coordinates and the points with the maximum and minimum Y-axis coordinates in the target area, connecting the points with the minimum X-axis coordinates with the points with the maximum X-axis coordinates, connecting the points with the minimum Y-axis coordinates with the points with the maximum Y-axis coordinates, taking the intersection point of the two connecting lines as the central point of the target area, calculating the coordinates of the central point, and then calculating the offset vector of the central point coordinates and the calibration coordinates of the target area.
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