CN112871735A - Automatic part detecting and sorting system and method - Google Patents
Automatic part detecting and sorting system and method Download PDFInfo
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- CN112871735A CN112871735A CN202110012594.8A CN202110012594A CN112871735A CN 112871735 A CN112871735 A CN 112871735A CN 202110012594 A CN202110012594 A CN 202110012594A CN 112871735 A CN112871735 A CN 112871735A
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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
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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
- 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
- B07C5/362—Separating or distributor mechanisms
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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
- B07C5/38—Collecting or arranging articles in groups
Abstract
The invention relates to an automatic part detecting and selecting system and method, relates to the technical field of air conditioners, and is used for solving the technical problem that the detection rate is difficult to control during manual detection. The automatic part detecting and sorting system comprises a detecting device, a processing device and a sorting device, wherein the detecting device is used for detecting parts, the parts detected by the detecting device can enter the processing device for processing no matter how the detection result is, and the sorting device places the corresponding parts processed by the processing device in the same batch in the corresponding area according to the signal sent by the detecting device after the processing procedure of the processing device is completed, so that the automatic detection can be realized, the system operation efficiency can be ensured, the detection rate can be ensured, and the production efficiency can be improved.
Description
Technical Field
The invention relates to the technical field of air conditioners, in particular to a system and a method for automatically detecting and selecting parts.
Background
The ink spraying pipe (segment) is produced by a copper pipe raw material manufacturer by carrying out ink jet marking treatment on the microscopic defects of the copper pipe after eddy current inspection or rotational inspection in the outgoing inspection process of the copper pipe, and is convenient for the subsequent air conditioner manufacturer to pick out and discard in time in the process of producing the heat exchanger. Essentially, ink jetting is a marking that characterizes rejects. Generally speaking, copper pipe manufacturers adopt 3 spray guns to spray ink around the copper pipe, the ink spraying area is larger than 3/4 on the circumference of the copper pipe, and the length is generally 400-600 mm. Each finished copper pipe has 1-6 ink-jet defects. At present, the ink-jet tube is generally subjected to visual special detection and picking by production personnel after copper tubes are subjected to processing procedures such as feeding, cutting, forming, blanking and the like. But on the whole, its actual relevance ratio is difficult to manage and control, in case detect the inefficacy, has the copper pipe of micro defect to flow into after-process and make the heat exchanger after, will cause the system leakage, seriously influences air conditioner product quality.
Disclosure of Invention
The invention provides an automatic part detecting and selecting system and method, which are used for solving the technical problem that the detection rate is difficult to control in manual detection.
According to a first aspect of the present invention there is provided an automatic parts inspection and picking system comprising:
a detecting device provided in a feeding direction of the parts, the detecting device being configured to simultaneously detect the parts of the same batch passing therethrough;
a processing apparatus provided downstream of the detection device, the processing apparatus being configured to process the part output from the detection device; and
the picking device is arranged at the downstream of the processing equipment, and the picking device is in signal connection with the detection device;
the detecting device sends the stored detection result of the part which is currently blanked to the picking device, and the picking device places the corresponding parts of the same batch processed by the processing equipment in the corresponding area according to the signal sent by the detecting device.
In one embodiment, the detection device comprises:
the image shooting unit is arranged above the part to be detected and used for obtaining a surface image of the part to be detected;
the image acquisition unit is electrically connected with the image shooting unit and is used for carrying out digital processing on the image obtained by the image shooting unit; and
and the image recognition and processing unit is electrically connected with the image acquisition unit and is used for comparing the data obtained by the image acquisition unit with a preset value and outputting a first signal or a second signal to the sorting device according to the comparison.
In one embodiment, the detection device further comprises a light source arranged above the part to be detected and a light reflecting element arranged below the part to be detected, and light emitted by the light source can at least cover 1/2 circumferential surfaces of the part to be detected.
In one embodiment, the time interval of each shooting of the image shooting unit is 50-100 ms; or the shooting frequency of the image shooting unit is that the part to be detected is shot once every 30-60mm of feeding.
In one embodiment, the image capture unit comprises an industrial camera having pixels of 30 or more pixels and an image horizontal or vertical resolution of 70 or more ppi.
In one embodiment, the detection device further comprises a rack, a display screen and a sliding window are respectively arranged on two opposite side surfaces of the rack, and a lifting window is arranged on one side of the rack, which is far away from the processing equipment;
the display screen is electrically connected with the image recognition and processing unit and is used for displaying the information of the online detection of the part in real time, and the information comprises: production date, machine station number, copper pipe length, processed cycle number, single-cycle qualified or unqualified detection point count, start-stop time and result signal;
and an emergency stop button is also arranged on the display screen.
In one embodiment, the processing equipment is in communication with the detection device to send information of the parts processed thereon to the detection device;
the processing equipment is characterized in that a first belt line for conveying parts and a U-shaped receiving hopper arranged at the tail end of the belt line are arranged at the discharging tail end of the processing equipment, and the U-shaped receiving hopper is used for temporarily storing the parts of the same batch processed by the processing equipment.
In one embodiment, the picking device is a robot having a load capacity or a transfer mechanism connecting a blanking end of the processing facility and a component placement area.
In one embodiment, the picking device comprises a clamping mechanism, the clamping mechanism comprises arc-shaped clamping jaws for clamping parts, and the arc-shaped clamping jaws extend into the hollow part of the U-shaped receiving hopper and clamp the parts.
In one embodiment, further comprising:
the guide mechanism is arranged at the upstream of the detection device and is used for guiding the part to enter the detection device;
the material receiving work truck or the second belt line is arranged in a qualified product area positioned at the downstream of the processing equipment and is used for conveying qualified parts obtained by the sorting device; and
a scrap bin disposed in a product reject area downstream of the processing apparatus for storing rejected parts captured by the picking device.
According to a second aspect of the invention, there is provided a method of automatic inspection and sorting of parts comprising the steps of:
passing the parts through a detection device that simultaneously detects parts of the same batch that pass through the detection device;
the detection device generates a detection result and stores the detection result in a queue mode;
causing a machining device to machine the part output from the detection device;
the processing equipment conveys the processed parts to the blanking end of the processing equipment, meanwhile, the detection device sends the stored detection result of the parts which are currently blanked to the picking device, and the picking device places the corresponding parts which are located at the blanking end in the same batch in the corresponding area according to the signal sent by the detection device.
In one embodiment, the detection device generating the detection result and storing the detection result in a queue comprises the following sub-steps:
the detection device obtains a multiple relation between the distance from the detection device to the blanking tail end of the processing equipment and the length of the processed part according to the length of a machine table of the processing equipment, the distance between the detection device and the feeding position of the processing equipment and the length of the processed part;
the detection device judges whether the part currently being detected is qualified or unqualified, generates a detection result and stores the detection result in a queue mode.
In one embodiment, the processing equipment conveys the processed parts to the blanking end of the processing equipment, meanwhile, the detection device sends the stored detection result of the parts currently being blanked to the picking device, and the picking device places the corresponding parts of the same batch at the blanking end in the corresponding area according to the signal sent by the detection device comprises the following substeps:
the processing equipment conveys the processed parts to the blanking tail end of the processing equipment,
the detection device acquires a detection result of a part currently being blanked in the processing equipment according to the actual position of the part in the processing equipment and the multiple relation, and sends a first signal or a second signal to the sorting device;
the picking device places corresponding parts of the same batch at the blanking tail end in a corresponding product qualified area according to the first signal; or the picking device places corresponding parts of the same batch at the blanking end in the corresponding product unqualified area according to the second signal.
In one embodiment, passing the parts through a detection device that simultaneously detects the parts of the same batch passing therethrough comprises the sub-steps of:
enabling the parts of the same batch to enter a guide mechanism together;
the parts of the same batch output by the guide mechanism are made to pass through the detection device at the same time, and the detection device detects the parts of the same batch passing through the detection device at the same time.
Compared with the prior art, the invention has the advantages that:
(1) the parts are detected through the detection device, no matter how the detection result of the parts detected by the detection device is, the parts can enter the processing equipment to be processed, and after the processing procedure of the processing equipment is completed, the picking device places the corresponding parts in the same batch processed and completed by the processing equipment in the corresponding area according to the signal sent by the detection device, so that automatic detection can be realized, the efficiency of system operation can be ensured, the detection rate can be ensured, and the production efficiency can be improved.
(2) Different parts can be automatically identified through the picking device, so that accurate classification and placement of different parts are realized.
(3) The ink jet tube can be quickly and accurately identified through visual detection devices such as an image shooting unit.
(4) The detection result and related parameters in the appointed time period can be displayed, recorded and remotely transmitted through the display screen.
Drawings
The invention will be described in more detail hereinafter on the basis of embodiments and with reference to the accompanying drawings.
FIG. 1 is a front view of an automatic parts inspection and picking system in an embodiment of the present invention;
FIG. 2 is a top view of an automatic parts inspection and picking system in an embodiment of the present invention;
FIG. 3a is a top view of the detection device shown in FIG. 2;
FIG. 3b is a view of FIG. 3a from A;
FIG. 3c is a view of FIG. 3a from B;
FIG. 3d is a view of FIG. 3a looking from C;
FIG. 4 is a schematic perspective view of the processing tool of FIG. 2;
FIG. 5 is a flow chart of a method for automatic part detection and picking in an embodiment of the present invention.
Reference numerals:
1-a detection device; 11-a frame; 12-a light source; 13-an image capturing unit; 14-a lens; 15-a reflective element; 16-a display screen; 17-a sliding window; 18-an image acquisition unit; 191-an image recognition unit; 192-an image processing unit; 7-a signal transmission unit;
2-processing equipment; 21-a first belt line; a 22-U-shaped receiving hopper;
3-a sorting device;
4-a guiding mechanism; 41 upper guide rollers 41; 42-lower guide roll;
5-material receiving tooling vehicle; 6-a waste tank.
Detailed Description
The invention will be further explained with reference to the drawings.
According to a first aspect of the present invention, as shown in fig. 1 and 3, the present invention provides an automatic part detecting and picking system, which comprises a guiding mechanism 4, a detecting device 1, a processing device 2 and a picking device 3, which are sequentially arranged, wherein a part P (including a plurality of passes of parts) is guided by the guiding mechanism 4, surface detection is performed by the detecting device 1 and processing is performed by the processing device 2, and the finally processed part P is sorted and placed by the picking device 3.
The respective components of the present invention will be described in detail below.
The detecting device 1 is provided in the feeding direction of the parts P, and the detecting device 1 is used for simultaneously detecting the parts P of the same batch passing through the detecting device 1. As shown in FIG. 2, a part P of the same lot may include multiple passes. Fig. 2 shows a schematic representation of a part P with 8 passes of the same batch, the parts with 8 passes being respectively P1, P2, P3, P4, P5, P6, P7 and P8, the parts with 8 passes being arranged in sequence along a direction perpendicular to the feeding direction. The parts of 8 passes simultaneously enter the detection device 1 for detection, so that the detection efficiency is improved.
The detection device 1 simultaneously detects the parts of 8 passes and stores the detection results; when the parts of the 8 passes are blanked after being processed by the processing equipment 2, the detection device 1 sends the stored detection results corresponding to the parts of the 8 passes to the sorting device 3, and the sorting device 3 places the corresponding parts of the same batch processed by the processing equipment 2 in the corresponding area according to the corresponding signals (for example, qualified or unqualified), so that the separation of different parts is realized, and the mixing is avoided.
Therefore, the detecting device 1 of the present invention does not immediately send the detection result to the sorting device 3 after the detection is completed, but stores the detection result thereof first; the parts after the completion of the inspection are processed in the processing facility 2 regardless of whether the results thereof are good or bad. Since the number of rejected parts is, after all, a very small fraction, the machining time for a few rejected products is negligible compared to the time of waiting for a system shutdown. When the parts are discharged and output after the detected parts are processed, the detection device 1 sends the detection result of the parts currently discharged and output to the selecting device 3, and the selecting device 3 classifies and puts different parts according to the signal. This has the advantage that the production equipment does not have to be shut down for the entire process when distinguishing between different parts (e.g. pass or fail), thereby increasing the efficiency of the process.
In some specific embodiments, the part P may be an ink jet tube of an air conditioner. In addition, the part P can also be various light pipes or threaded pipe products with the pipe diameter in the range of phi 5-phi 19, such as long U pipes, straight pipes or elbow products and the like, which are suitable for manufacturing air conditioners.
The present invention will be described in detail below by taking an example in which the detected part P is an ink jet tube (copper tube) of an air conditioner. No distinction will be made between parts, ink jet tubes and copper tubes hereinafter.
As shown in fig. 3a, 3b, 3c and 3d, the detection device 1 comprises an image capturing unit 13, an image acquisition unit, an image recognition and processing unit, a light source 12 and a light reflecting element 15. Wherein the light source 12 is disposed above the part to be measured (ink jet tube), the light reflecting member 15 is disposed below the part to be measured, and the light emitted from the light source 12 can cover at least 1/2 circumferential surfaces of the part to be measured.
When the light emitted from the light source 12 is irradiated onto the part to be measured, the light is reflected by the reflecting member 15, and the image photographing unit 13 disposed above the part to be measured can photograph in real time, thereby obtaining a surface image of the part to be measured.
Further, the light emitted by the light source 12 should be white light. The reflecting element 15 can be a reflecting plate, the reflecting plate needs to cover all feeding passes of the parts to be measured, and the material is preferably white calcium plastic plate or hard board with high reflecting rate.
Because the spraying range of the ink jet tube can at least cover the surface of the copper tube 3/4 as required in the spraying process of the ink jet tube, the part to be detected does not need to rotate when passing through the detection device 1 along the feeding direction, because the coating on the qualified ink jet tube covers the surface of the copper tube 3/4, and the light emitted by the light source 12 can at least cover the 1/2 circumferential surface of the part to be detected, the image shot by the image shooting unit 13 can be completely used for judging whether the batch part to be detected is qualified (i.e. whether the ink jet tube has an ink jet mark).
The image capturing unit 13 may simultaneously process the parts to be inspected in a plurality of passes arranged side by side (for example, the parts to be inspected in 8 passes shown in fig. 2), thereby improving the inspection efficiency.
The image acquisition unit 18 is electrically connected with the image shooting unit 13, and the image shooting unit 13 sends the shot image to the image acquisition unit 18 for digital processing, so as to obtain data such as gray value and brightness value of the image. The image acquisition unit 18 sends this data to an image recognition and processing unit which compares the data obtained by the image acquisition unit with preset values and outputs a first signal (OK) or a second signal (NG) to the sorting device 3 on the basis thereof.
The first signal is a signal representing that the part to be detected is qualified, and the second signal is a signal representing that the part to be detected is unqualified. The image recognition and processing unit outputs the first signal (OK) or the second signal (NG) to the sorting device 3 via the signal transmission unit. Therefore, if the image recognition and processing unit outputs a first signal to the sorting device 3 through the signal transmission unit, it indicates that the surface of the copper pipe detected this time does not contain the ink jet mark; on the contrary, if the image recognition and processing unit outputs the second signal to the sorting device 3 through the signal transmission unit, it indicates that the surface of the copper tube detected this time contains the ink jet mark.
Specifically, the image recognition and processing unit includes an image recognition unit 191 and an image processing unit 192. The image recognition unit 191 compares the preprocessed image with the image of the surface of the qualified copper pipe, and extracts an area with large color difference and gray scale difference between the preprocessed image and the image of the qualified copper pipe, and the abnormal area image with a small area is probably generated on the surface of the copper pipe due to oxidation, oil stain and slight indentation. Therefore, it is generally necessary to determine the area size of the region with large color difference and gray level difference, and when the area size of the region is larger than a certain preset area preset value, the determined region is determined to be an abnormal region in the surface image of the component to be measured. And if the abnormal area does not exist in the surface image, judging that the part to be detected has no ink jet mark, and generating a qualified detection result of the part to be detected.
Then, the image processing unit 192 compares the image of the abnormal area in the surface image of the to-be-detected part with the image of the inkjet mark, and if the color difference between the two images is small, it can be determined that the inkjet mark exists on the surface of the to-be-detected part, and the to-be-detected part has a quality hidden trouble, and then an unqualified detection result of the to-be-detected part is generated. If the difference between the two images is large, the image of the abnormal area is considered to be caused by putty, indentation and the like, and a qualified detection result of the part to be detected is generated.
Generally, the grey scale value of the ink-jet copper pipe is lower after the image is formed; and abnormal images caused by small indentations can be filtered out through the image preprocessing step.
Preferably, the time interval of each shooting by the image shooting unit 13 is 50-100 ms; or the shooting frequency of the image shooting unit 13 is shooting once for each feeding 30-60mm of the part to be detected, so that the ink-jet section of each copper pipe can be timely and effectively identified.
Preferably, the image capturing unit 13 comprises an industrial camera having pixels of 30 ten thousand or more pixels and an image of 70ppi or more in horizontal or vertical resolution. The focal point of the lens 14 of the industrial camera is set to the distance from the image capturing unit 13 to the part to be measured.
The detection device 1 further comprises a rack 11, and a display screen 16 and a sliding window 17 are respectively arranged on two opposite side faces of the rack 11. One side of the frame 11, which is far away from the processing equipment 2, is provided with a vertical sliding window, so that an operator can conveniently replace copper pipe coiling materials, maintain the equipment, maintain and repair the equipment, eliminate the problem of material blockage and the like.
The display screen 16 may be a manual touch screen, which can visually display the related content of the copper pipe online detection in real time. The display screen 16 is electrically connected with the image recognition and processing unit and is used for displaying the information of the online detection of the part in real time, and the information comprises: production date, machine station number, copper pipe length, number of processed cycles, counting of qualified or unqualified detection points in a single cycle, start-stop time and result signals.
In addition, the industrial personal computer can also enable the display screen 16 to have terminal functions of querying historical data of a specified time period, remote data transmission and the like.
The rack 11 is further provided with an industrial personal computer which is connected with the display screen 16 to control the display of the display screen 16.
The display screen 16 is also provided with an emergency stop button. When each coil of copper pipe is used up, an operator presses an emergency stop button before preparing to connect the next coil of material, so as to avoid false detection and invalid signal output caused by a detection program in the material changing process.
As described above, the inspection apparatus 1 of the present invention does not immediately send the inspection result to the sorting apparatus 3 after the inspection is completed, but stores the inspection result first. Because the detection device 1 is arranged at the upstream of the processing equipment 2, the detection device 1 and the blanking output of the processing equipment 2 have a sequential relation in spatial position, and the copper pipe section detected at a certain moment is not an actual discharging finished product. For example, the current time is tj, the part in the jth batch is detected in the detecting device 1, and the part that is being discharged after the machining of the machining equipment 2 is completed is the part in the ith batch, that is, the part in the ith batch is the part that has been detected in the detecting device 1 at the time ti before the current time tj (where t, i and j are all positive integers).
Therefore, the invention proposes that the signals generated by the detection device 1 are stored in a queue mode, and after the batch of parts are subjected to detection, feeding and processing, the detection result signals corresponding to the parts are transmitted to the sorting device 3 when the batch of parts is ready for discharging, so that the correct action commands corresponding to the signals can be effectively executed.
Based on the principle, the length of the machine table of the processing equipment 2 and the length from a detection point of the detection device 1 to the feeding position of the processing equipment 2 are used as fixed parameters to be input; the length of the machined part is used as an adjustable parameter and is input and confirmed by an operator before the machine is rotated every time. By programming these parameters, it can be calculated that the distance from the above-mentioned detection point to the blanking output of the processing device 2 contains several processed parts. Namely the multiple relation between the distance from the detection point to the discharging output and the length of the processed parts, thereby accurately judging whether the parts of each batch contain the ink jet marks and whether the first signal command (OK) or the second signal command (NG) is executed during discharging.
It should be noted that, because the detecting device 1 detects the parts in multiple passes at the same time during the detection, the detecting device 1 outputs a second signal as long as one of the parts is detected as being unqualified; in other words, as long as one of the parts of the same batch is rejected, the parts of this batch are all judged to be rejected, so that the picking device 3 places all the parts of this batch in the rejected area according to the command. Since a batch of parts may have 8 or less parts, even if the batch of parts is placed in a defective area, the operator may subsequently pick out the one part having the inkjet mark in the defective area and manually place the other parts not having the inkjet mark in the defective area. Therefore, the detection device 1, the processing equipment 2 or the sorting device 3 can continuously work, and the working efficiency is improved. And the operator selects an unqualified part from 8 or less parts, which is obviously very convenient and fast, and the operation of the whole production line is not influenced.
As shown in fig. 2 and 5, a machining device 2 is provided downstream of the inspection apparatus 1, and the machining device 2 is used to machine the part output from the inspection apparatus. The processing device 2 is in communication connection with the detection device 1, and the processing device 2 sends all information of parts processed by the processing device to the detection device 1 for recording, in other words, the detection device 1 can obtain and record information of all process states, processing start and stop times and the like of the parts processed on the processing device 2, so that the detection device 1 can accurately obtain information of the parts which are blanked at the current moment and transmit a detection result of the parts which are blanked at the current moment to the sorting device 3.
As shown in fig. 4, the blanking end of the processing equipment 2 is provided with a first belt line 21 for conveying parts and a U-shaped receiving hopper provided at the end of the belt line for temporarily storing the parts of the same batch processed by the processing equipment 2.
As described above, a part of the same batch can be considered as a component, all parts in the component are qualified, and the component can be judged as qualified; and if only one part in the assembly is unqualified, the assembly is judged to be unqualified. Therefore, the parts of multiple passes are all output at one time at the blanking output of the processing equipment 2.
As shown in fig. 1 and 3, a picking device 3 is arranged downstream of the processing device 2, and the picking device 3 is in signal connection with the detection device 1. The picking device 3 places the corresponding parts of the same batch processed by the processing equipment 2 in the corresponding area according to the signal sent by the detection device 1.
Alternatively, the picking device 3 is a robot having a load capacity (for example, a load of 3 to 5Kg) or a transfer mechanism that connects the blanking end of the processing facility 2 and the parts placement area. Furthermore, the clamping mechanism is required to be arranged on each of the two parts, the clamping mechanism comprises an arc-shaped clamping jaw for grabbing the part, and the arc-shaped clamping jaw extends into the hollow part of the U-shaped receiving hopper and clamps the part. The arc-shaped clamping jaw can be made of rubber, elastic plastic and other materials with certain elasticity, so that clamping and proper placement actions can be carried out on the premise that mechanical or external stress damage is not caused to a processed copper pipe product.
When the picking device 3 receives the signal sent by the detection device 1, the arc-shaped clamping jaw extends into the hollow part of the U-shaped receiving hopper and extends into the clamping part, and the part is placed into the corresponding area according to the corresponding signal.
The guide mechanism 4 is used to guide the parts into the inspection device 1. As shown in fig. 1, the guide mechanism 4 includes an upper guide roller 41 and a lower guide roller 42, and the component passes between the upper guide roller 41 and the lower guide roller 42. The number of the guide mechanisms 4 may be set as needed, and as in the example shown in fig. 1, 2 guide mechanisms 4 are provided.
In addition, the automatic part detecting and sorting system further comprises a material receiving truck 5 (or a second belt line) and a waste material tank 6, wherein the material receiving truck 5 (or the second belt line) is arranged in a product qualified area located at the downstream of the processing equipment 2 and is used for conveying qualified parts obtained by the sorting device 3, and the qualified products are conveniently and effectively conveyed to a next procedure in time. A scrap box 6 is provided in the area of product reject downstream of the processing apparatus 2 for storing rejected parts picked up by the picking device 3. The capacity of the waste chute 6 is ensured to be capable of containing about 20 parts, manual selection is carried out by manpower after the waste chute is filled with the parts, real unqualified products are scrapped, and the qualified products are placed into the material receiving trolley 5.
In addition, the detection device 1 can be further provided with an alarm device, and the alarm device is electrically connected with the image recognition and processing unit and used for sending an alarm signal when the image recognition and processing unit judges that the ink jet mark exists on the surface of the part to be detected. The alarm device can be an acoustic alarm device or a light alarm device and is used for reminding a user.
According to a second aspect of the present invention, as shown in fig. 5, the present invention provides an automatic parts inspecting and sorting method, which preferably uses the automatic parts inspecting and sorting system described above for inspecting and sorting, and particularly, the automatic parts inspecting and sorting method of the present invention includes the following steps.
In the first step, the parts P (P1, P2, … … Pn) in a plurality of passes are sequentially introduced into the guide mechanism 4 in the feeding direction and guided.
In the second step, the parts P in the plurality of passes output from the guide mechanism 4 are simultaneously introduced into the inspection apparatus 1, and the inspection apparatus 1 simultaneously inspects the parts P in the plurality of passes in the same batch.
Specifically, the image capturing unit 13 simultaneously captures images of the parts to be measured in a plurality of passes arranged side by side (for example, the parts to be measured in 8 passes shown in fig. 2). The image shooting unit 13 sends the shot image to the image acquisition unit for digital processing, so as to obtain data such as gray value and brightness value of the image. The image acquisition unit sends the data to the image recognition and processing unit,
and thirdly, detecting the result by the detection device 1 and storing the detection result in a queue mode.
Specifically, the image recognition and processing unit compares the preprocessed image with the image of the surface of the qualified copper pipe, and extracts an area with large color difference and gray scale difference between the preprocessed image and the image of the qualified copper pipe, and the abnormal area image with a small area is probably generated on the surface of the copper pipe due to oxidation, oil stain and slight indentation. Therefore, it is generally necessary to determine the area size of the region with large color difference and gray level difference, and when the area size of the region is larger than a certain preset area preset value, the determined region is determined to be an abnormal region in the surface image of the component to be measured. And if the abnormal area does not exist in the surface image, judging that the part to be detected has no ink jet mark, and generating a qualified signal of the part to be detected.
Then, the image recognition and processing unit compares the image of the abnormal area in the surface image of the part to be detected with the image of the inkjet mark, if the color difference between the images is small, the inkjet mark is present on the surface of the part to be detected, the part to be detected has hidden quality trouble, and the unqualified detection result of the part to be detected is generated. If the difference between the two images is large, the image of the abnormal area is considered to be caused by putty, indentation and the like, and a qualified detection result of the part to be detected is generated.
Further, since the current part detected by the detecting device 1 is not the part currently being output by the processing equipment 2, the detecting device 1 needs to store the current detection result signal thereof, and obtain the multiple relationship between the distance from the detecting device 1 to the blanking end of the processing equipment 2 and the length of the processed part according to the length of the machine table of the processing equipment 2, the distance between the detecting device 1 and the feeding position of the processing equipment 2, and the length of the processed part.
For example, the distance D between the detection device 1 and the blanking end of the processing equipment 2 is 9 times the length L of the processed part, i.e., D is 9L, in other words, the distance D between the detection device 1 and the blanking end of the processing equipment 2 includes 9 processed parts.
The inspection apparatus 1 determines whether the part currently being inspected is qualified or unqualified, and generates an inspection result and stores the inspection result in a queue manner.
And a fourth step of causing the machining device 2 to machine the part output from the detection apparatus 1. The processing device 2 may be an existing processing device for an ink jet tube of an air conditioner, and the processing procedure may be set as required, which is not described in detail herein.
Fifthly, the processing equipment 2 conveys the processed parts to the blanking tail end, meanwhile, the detection device 1 sends the stored detection results of the parts which are currently blanked to the sorting device 3, and the sorting device 3 places the corresponding parts which are positioned at the blanking tail end in the same batch in the corresponding area according to the signals.
Specifically, first, the machining device 2 conveys the machined part to the blanking end thereof.
Next, the detecting device 1 obtains a detection result of the part currently being blanked in the processing device 2 according to the actual position of the part in the processing device 2 and the multiple relation, and sends a first signal or a second signal to the sorting device 3.
For example, the image recognition and processing unit outputs a first signal (OK) to the sorting device 3 according to the processing result, that is, the surface of the copper pipe detected this time does not contain the inkjet mark, and all the parts of 8 passes of the batch are qualified. Or the image recognition and processing unit outputs a second signal (NG) to the sorting device 3 according to the processing result, namely, the surface of the copper pipe detected this time contains the ink jet mark.
It should be noted that although the second signal (NG) is output, it does not indicate that all of the 8-pass parts of the lot are rejected, because as long as one of the 8-pass parts of the lot is judged to be rejected, all of the 8-pass parts of the entire lot are marked as rejected, wherein the part that is actually rejected is picked by the subsequent manual picking process.
Thirdly, the picking device 3 places corresponding parts of the same batch at the tail end of the blanking in the corresponding qualified product area according to the first signal; or the picking device 3 places the corresponding parts of the same batch at the blanking end in the corresponding product unqualified area according to the second signal.
Therefore, the sorting device 3 can separate qualified batches and unqualified batches of parts and respectively store the parts, so that mixed use and misuse are avoided; compared with the existing manual identification and picking method, the system of the invention is more convenient and quicker to detect and pick and has controllable detection effect.
While the invention has been described with reference to a preferred embodiment, various modifications may be made and equivalents may be substituted for elements thereof without departing from the scope of the invention. In particular, the technical features mentioned in the embodiments can be combined in any way as long as there is no structural conflict. It is intended that the invention not be limited to the particular embodiments disclosed, but that the invention will include all embodiments falling within the scope of the appended claims.
Claims (14)
1. An automatic parts inspection and sorting system, comprising:
a detecting device provided in a feeding direction of the parts, the detecting device being configured to simultaneously detect the parts of the same batch passing therethrough;
a processing apparatus provided downstream of the detection device, the processing apparatus being configured to process the part output from the detection device; and
the picking device is arranged at the downstream of the processing equipment, and the picking device is in signal connection with the detection device;
the detecting device sends the stored detection result of the part which is currently blanked to the picking device, and the picking device places the corresponding parts of the same batch processed by the processing equipment in the corresponding area according to the signal sent by the detecting device.
2. The automatic parts detecting and picking system of claim 1, wherein the detecting means includes:
the image shooting unit is arranged above the part to be detected and used for obtaining a surface image of the part to be detected;
the image acquisition unit is electrically connected with the image shooting unit and is used for carrying out digital processing on the image obtained by the image shooting unit; and
and the image recognition and processing unit is electrically connected with the image acquisition unit and is used for comparing the data obtained by the image acquisition unit with a preset value and outputting a first signal or a second signal to the sorting device according to the comparison.
3. The automatic parts detecting and sorting system of claim 2, wherein the detecting device further comprises a light source disposed above the part to be tested and a light reflecting element disposed below the part to be tested, the light source emitting light that covers at least 1/2 circumferential surfaces of the part to be tested.
4. The automatic parts detecting and picking system according to claim 2 or 3, wherein the time interval of each shooting of the image shooting unit is 50-100 ms; or the shooting frequency of the image shooting unit is that the part to be detected is shot once every 30-60mm of feeding.
5. The automatic parts detecting and picking system of claim 2 or 3, wherein the image capturing unit comprises an industrial camera having pixels of 30 ten thousand or more pixels and an image of 70ppi or more in horizontal or vertical resolution.
6. The automatic part detecting and picking system according to claim 2 or 3, wherein the detecting device further comprises a rack, a display screen and a sliding window are respectively arranged on two opposite side surfaces of the rack, and a lifting window is arranged on one side of the rack away from the processing equipment;
the display screen is electrically connected with the image recognition and processing unit and is used for displaying the information of the online detection of the part in real time, and the information comprises: production date, machine station number, copper pipe length, processed cycle number, single-cycle qualified or unqualified detection point count, start-stop time and result signal;
and an emergency stop button is also arranged on the display screen.
7. The automatic parts detecting and picking system of any of claims 1-3, wherein the processing equipment is communicatively connected to the detection device to send information of parts processed thereon to the detection device;
the processing equipment is characterized in that a first belt line for conveying parts and a U-shaped receiving hopper arranged at the tail end of the belt line are arranged at the discharging tail end of the processing equipment, and the U-shaped receiving hopper is used for temporarily storing the parts of the same batch processed by the processing equipment.
8. The automatic parts detecting and picking system of claim 7, wherein the picking device is a robot with load capacity or a transfer mechanism connecting a blanking end of the processing equipment and a parts placement area.
9. The automated parts inspection and sorting system of claim 7, wherein the sorting apparatus includes a gripper mechanism, the gripper mechanism including arcuate jaws for gripping parts, the arcuate jaws extending from a hollow portion of the U-shaped hopper and gripping parts.
10. The automatic parts inspection and picking system of any of claims 1-3, further comprising:
the guide mechanism is arranged at the upstream of the detection device and is used for guiding the part to enter the detection device;
the material receiving work truck or the second belt line is arranged in a qualified product area positioned at the downstream of the processing equipment and is used for conveying qualified parts obtained by the sorting device; and
a scrap bin disposed in a product reject area downstream of the processing apparatus for storing rejected parts captured by the picking device.
11. An automatic part detecting and sorting method is characterized by comprising the following steps:
passing the parts through a detection device that simultaneously detects parts of the same batch that pass through the detection device;
the detection device generates a detection result and stores the detection result in a queue mode;
causing a machining device to machine the part output from the detection device;
the processing equipment conveys the processed parts to the blanking end of the processing equipment, meanwhile, the detection device sends the stored detection results of the parts which are currently blanked to the sorting device, and the sorting device places the corresponding parts which are located at the blanking end in the same batch in the corresponding area according to the signals sent by the detection device.
12. The method of automatically inspecting and sorting parts according to claim 11, wherein the inspecting means generating the inspection results and storing the inspection results in a queue includes the substeps of:
the detection device obtains a multiple relation between the distance from the detection device to the blanking tail end of the processing equipment and the length of the processed part according to the length of a machine table of the processing equipment, the distance between the detection device and the feeding position of the processing equipment and the length of the processed part;
the detection device judges whether the part currently being detected is qualified or unqualified, generates a detection result and stores the detection result in a queue mode.
13. The method for automatically detecting and sorting parts according to claim 12, wherein the processing equipment conveys the processed parts to the blanking end of the processing equipment, the detection device sends the stored detection result of the currently blanked parts to the sorting device, and the sorting device places the corresponding parts of the same batch at the blanking end in the corresponding area according to the signal sent by the detection device comprises the following substeps:
the processing equipment conveys the processed parts to the blanking tail end of the processing equipment,
the detection device acquires a detection result of a part currently being blanked in the processing equipment according to the actual position of the part in the processing equipment and the multiple relation, and sends a first signal or a second signal to the sorting device;
the picking device places corresponding parts of the same batch at the blanking tail end in a corresponding product qualified area according to the first signal; or the picking device places corresponding parts of the same batch at the blanking end in the corresponding product unqualified area according to the second signal.
14. Method for automatic detection and sorting of parts according to any of claims 11-13, characterized in that passing the parts through a detection device which detects simultaneously the parts of the same batch passing through it comprises the sub-steps of:
enabling the parts of the same batch to enter a guide mechanism together;
the parts of the same batch output by the guide mechanism are made to pass through the detection device at the same time, and the detection device detects the parts of the same batch passing through the detection device at the same time.
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| Publication number | Priority date | Publication date | Assignee | Title |
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| CN115512458A (en) * | 2022-09-27 | 2022-12-23 | 上汽通用五菱汽车股份有限公司 | Monitoring data analysis method, device, equipment and storage medium |
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| Publication number | Priority date | Publication date | Assignee | Title |
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| CN115512458A (en) * | 2022-09-27 | 2022-12-23 | 上汽通用五菱汽车股份有限公司 | Monitoring data analysis method, device, equipment and storage medium |
| CN115512458B (en) * | 2022-09-27 | 2023-09-15 | 上汽通用五菱汽车股份有限公司 | Monitoring data analysis method, device, equipment and storage medium |
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