CN113358070A - Automobile brake pad flatness and pin height detection system and detection method thereof - Google Patents
Automobile brake pad flatness and pin height detection system and detection method thereof Download PDFInfo
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- CN113358070A CN113358070A CN202110764698.4A CN202110764698A CN113358070A CN 113358070 A CN113358070 A CN 113358070A CN 202110764698 A CN202110764698 A CN 202110764698A CN 113358070 A CN113358070 A CN 113358070A
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- G—PHYSICS
- G01—MEASURING; TESTING
- G01B—MEASURING LENGTH, THICKNESS OR SIMILAR LINEAR DIMENSIONS; MEASURING ANGLES; MEASURING AREAS; MEASURING IRREGULARITIES OF SURFACES OR CONTOURS
- G01B11/00—Measuring arrangements characterised by the use of optical techniques
- G01B11/30—Measuring arrangements characterised by the use of optical techniques for measuring roughness or irregularity of surfaces
- G01B11/306—Measuring arrangements characterised by the use of optical techniques for measuring roughness or irregularity of surfaces for measuring evenness
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- G—PHYSICS
- G01—MEASURING; TESTING
- G01B—MEASURING LENGTH, THICKNESS OR SIMILAR LINEAR DIMENSIONS; MEASURING ANGLES; MEASURING AREAS; MEASURING IRREGULARITIES OF SURFACES OR CONTOURS
- G01B11/00—Measuring arrangements characterised by the use of optical techniques
- G01B11/02—Measuring arrangements characterised by the use of optical techniques for measuring length, width or thickness
- G01B11/06—Measuring arrangements characterised by the use of optical techniques for measuring length, width or thickness for measuring thickness ; e.g. of sheet material
- G01B11/0608—Height gauges
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- G—PHYSICS
- G01—MEASURING; TESTING
- G01B—MEASURING LENGTH, THICKNESS OR SIMILAR LINEAR DIMENSIONS; MEASURING ANGLES; MEASURING AREAS; MEASURING IRREGULARITIES OF SURFACES OR CONTOURS
- G01B5/00—Measuring arrangements characterised by the use of mechanical techniques
- G01B5/0025—Measuring of vehicle parts
- G01B5/0028—Brakes, brakeshoes, clutches
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Abstract
The application discloses car brake block roughness and pin height detecting system and detection method thereof belongs to this technical field of automated inspection technique, and its design essential lies in: the method comprises the following steps: control equipment, a camera, a bridge-type light source, a laser scanner; and the control equipment is respectively in communication connection with the camera, the bridge-type light source, the laser scanner and the rotating shaft connecting plate. The application aims to provide a system and a method for detecting the flatness of an automobile brake pad and the height of a pin, and the system and the method can realize automatic detection and report generation of the flatness of the brake pad and the height of the pin through machine vision.
Description
Technical Field
The application relates to the technical field of automatic detection, in particular to a system and a method for detecting flatness of an automobile brake pad and height of a pin.
Background
The birth of automobiles has been one hundred years old since the end of the last century. With the progress of internal combustion engine technology, electronic computers and material science, the running speed of automobiles is continuously increased, which puts higher demands on the braking system of the automobiles. The brake pad is extremely important as the final actuator of the brake system. Therefore, various countries in the world have developed a large number of national standards and industrial standards for brake pads.
The flatness of the brake pad and the pin detection are used as basic links of the brake pad detection, and the detection accuracy directly determines the complexity of subsequent detection work. At present, the effective standard of the brake pad in China is only GB5763-1998 which is enforced. The repeatability of each unit detection device is poor, and because the detection device belongs to non-standard equipment and has no standard control standard, each provincial level detection mechanism does not calibrate the monitoring device or only calibrates a detection instrument. In addition, the detection error between the detection devices reaches 15% -30% due to the fact that operators are not trained professionally and detection equipment manufacturers do not have metering permission. Causing a large number of duplicate and false detections to occur. Although the prior art, CN203148366U also researches the flatness detection of the brake pad. However, the detection precision and the detection efficiency of the prior art are low, and the actual requirements cannot be met.
Disclosure of Invention
The application aims to overcome the defects in the prior art and provides a system and a method for detecting the flatness of an automobile brake pad and the height of a pin.
The technical scheme of the application is as follows:
the utility model provides an automobile brake block roughness and pin height detecting system, includes: control equipment, a camera, a bridge-type light source, a laser scanner;
the control equipment is respectively in communication connection with the camera, the bridge-type light source, the laser scanner and the rotating shaft connecting plate;
the control equipment is used for analyzing the image transmitted by the camera, determining the specific position information of the brake pad on the detection station, and determining the flatness of the brake pad and the height of the pin;
the camera shoots the brake pad according to a control instruction sent by the control equipment;
the bridge-type light source performs polishing supplement on the brake pad according to a control instruction sent by the control equipment;
the laser scanner is used for scanning the brake pad according to a control command sent by the control equipment.
Further, still include: the camera stand column and the base support are fixed with the detection platform;
the camera is fixed on the camera upright post, and the lens is downward and is vertically placed with the detection station;
the bridge-type light source is of an annular structure, the middle part of the bridge-type light source is hollow, and the upper part of the hollow middle part corresponds to the camera, namely the camera observes the brake pad on the detection station through the hollow middle part of the bridge-type light source; the bridge-type light source is positioned under the camera, the light of the detection position is monitored through the photoresistor array, the bridge-type light source is adjusted to supplement the light of the brake pad to be detected, and the contrast and the precision of the camera during image acquisition are ensured; the upper part of the bridge-type light source is fixed on the camera column, namely: the camera upright post, the camera and the bridge type light source form 1 whole;
the laser of the laser scanner adopts 850 nm infrared waves, the emission angle is more than 120 degrees, and the output power is less than 2 watts;
the laser scanner is fixed at the other end of the connecting plate; a rotating shaft of the rotating shaft connecting plate is rotatably connected with the end part of the cantilever plate; a motor is fixedly arranged on the lower surface of the cantilever plate, and an output shaft of the motor is provided with a gear which is meshed with the rotating shaft so as to drive the rotating shaft to rotate and further drive the rotating shaft to rotate so as to drive the laser scanner to rotate;
when the rotating shaft connecting plate rotates by taking the rotating shaft as a center, the laser scanner is driven to project the brake pad line by line, and meanwhile, the camera collects a projected laser line picture in real time.
Furthermore, a driving component of the rotating shaft connecting shaft consists of a motor control module with encoder feedback, the minimum rotating angle of the rotating shaft is 360 degrees/1024, and the laser scanner can be ensured to complete the omnibearing projection of the brake pad.
Further, the control apparatus includes: the system comprises a data analysis processing module, a scanner rotation control module, a communication module and a display; the data analysis processing module, the scanner rotation control module, the communication module and the display are in communication connection with each other;
the data analysis processing module is used for analyzing the image transmitted by the camera, determining the specific position information of the brake pad on the detection station and determining the flatness of the brake pad and the height of the pin;
the scanner rotation control module 1 adopts an embedded processor, is used for controlling the rotation of a rotating shaft connecting plate, and controls the rotating shaft of the rotating shaft connecting plate to rotate so as to drive the laser scanner to project the brake pads line by line according to the given brake pad central position of the data analysis processing module;
the communication module is used for communication processing among the data analysis processing module, the camera, the bridge-type light source and the scanner rotation control module.
The utility model provides an automobile brake block roughness and pin height detecting system, includes: the device comprises a control device, a camera, a bridge-type light source, a laser scanner and an auxiliary actuating mechanism;
the control equipment is respectively in communication connection with the camera, the bridge-type light source, the laser scanner, the rotating shaft connecting plate and the auxiliary actuating mechanism;
the control equipment is used for analyzing the image transmitted by the camera, determining the specific position information of the brake pad on the detection station, and determining the flatness of the brake pad and the height of the pin;
the camera shoots the brake pad according to a control instruction sent by the control equipment;
the bridge-type light source performs polishing supplement on the brake pad according to a control instruction sent by the control equipment;
the laser scanner is used for scanning the brake pad according to a control command sent by the control equipment;
wherein, supplementary actuating mechanism includes: the conveying belt is controlled by the electric control system and arranged on the detection platform;
further comprising: the camera stand column and the base support are fixed with the detection platform;
the camera is fixed on the camera upright post, and the lens is downward and is vertically placed with the detection station;
the bridge-type light source is of an annular structure, the middle part of the bridge-type light source is hollow, and the upper part of the hollow middle part corresponds to the camera, namely the camera observes the brake pad on the detection station through the hollow middle part of the bridge-type light source; the bridge-type light source is positioned under the camera, the light of the detection position is monitored through the photoresistor array, the bridge-type light source is adjusted to supplement the light of the brake pad to be detected, and the contrast and the precision of the camera during image acquisition are ensured; the upper part of the bridge-type light source is fixed on the camera column, namely: the camera upright post, the camera and the bridge type light source form 1 whole;
the laser of the laser scanner adopts 850 nm infrared waves, the emission angle is more than 120 degrees, and the output power is less than 2 watts;
the laser scanner is fixed at the other end of the connecting plate; a rotating shaft of the rotating shaft connecting plate is rotatably connected with the end part of the cantilever plate; a motor is fixedly arranged on the lower surface of the cantilever plate, and an output shaft of the motor is provided with a gear which is meshed with the rotating shaft so as to drive the rotating shaft to rotate and further drive the rotating shaft to rotate so as to drive the laser scanner to rotate;
when the rotating shaft connecting plate rotates by taking the rotating shaft as a center, the laser scanner is driven to project the brake pad line by line, and meanwhile, a camera collects a projected laser line picture in real time;
the driving component of the rotating shaft connecting shaft consists of a motor control module with encoder feedback, the minimum rotating angle of the rotating shaft is 360 degrees/1024, and the laser scanner can be ensured to complete the omnibearing projection on the brake pad;
the control apparatus includes: the system comprises a data analysis processing module, a scanner rotation control module, a communication module and a display; the data analysis processing module, the scanner rotation control module, the communication module and the display are in communication connection with each other;
the data analysis processing module is used for analyzing the image transmitted by the camera, determining the specific position information of the brake pad on the detection station and determining the flatness of the brake pad and the height of the pin;
the scanner rotation control module 1 adopts an embedded processor, is used for controlling the rotation of a rotating shaft connecting plate, and controls the rotating shaft of the rotating shaft connecting plate to rotate so as to drive the laser scanner to project the brake pads line by line according to the given brake pad central position of the data analysis processing module;
the communication module is used for communication processing among the data analysis processing module, the camera, the bridge-type light source, the scanner rotation control module and the auxiliary execution mechanism.
Further, the data analysis processing module calibrates the position of the pin, and adopts a template matching method, which comprises the following steps:
A. determining the size transformation ratio of the template picture and the picture to be detected according to the fixed distance between the camera and the brake pad, and determining the standard sample picture as the template picture for detecting the product after carrying out ratio transformation on the standard sample picture;
B. the central position and the rotation angle of the brake pad to be detected at the detection position are quickly determined by rotating and translating the template picture and comparing the template picture with the picture to be detected for real-time errors;
C. and performing fast regression operation through a support vector machine algorithm to quickly calibrate the position of the pin.
Further, the data analysis processing module determines the flatness of the brake pad and adopts a least square method to fit and scan a laser line, and the steps are as follows:
A. determining an effective scanning area of the laser according to the position and the rotation angle given by the brake pad position calibration algorithm;
B. fitting an ideal laser line according to the coordinates of the laser points, and solving the sum of the longitudinal coordinate differences of each row of ideal laser lines and the actual laser lines;
C. dividing the laser line into L sections, solving the sum difn [ L ] of the difference on the L section, and making the L sections black in different degrees according to difn [ L ], wherein the black part is the unevenness on the scanning line;
D. and finally, processing the unevenness value of each line according to the weight, and comparing the processing result with a set unevenness standard to judge whether the product is qualified.
A detection method of an automobile brake pad flatness and pin height detection system comprises the following steps:
A. placing the brake pad on a detection station of a detection platform;
B. the method comprises the steps that a camera carries out photographing monitoring on a detection station in real time, when the brake pad is recognized to enter the detection station, control equipment controls a bridge-type light source to polish and supplement the brake pad, and then a photographing instruction is sent to the camera to obtain a picture;
the picture is transmitted to a data analysis processing module of the control equipment by a camera, the picture is processed by the data analysis processing module, and the position of the brake pad in the detection station is calculated;
the data analysis processing module transmits the position information of the brake pad in the detection station to the scanner rotation control module;
after the scanner rotation control module obtains the position information of the brake pad, the scanner rotation control module controls the rotating shaft connecting plate to drive the laser scanner to perform laser scanning on the brake pad; in the process, the camera collects images in real time in the scanning process and transmits the images to the data analysis processing module;
and the data analysis processing module obtains the flatness parameter and the pin height parameter through calculation, displays the detection result through a display and generates a detection report at the same time.
A detection method of an automobile brake pad flatness and pin height detection system comprises the following steps:
A. placing a brake pad to be tested on a conveyor belt of an auxiliary actuating mechanism, and conveying the brake pad to a detection position by the conveyor belt, wherein the detection position is positioned right below a camera and a laser projector;
B. the camera is real-time to the monitoring station of shooing, and when discerning the brake block and getting into the detection station, controlgear sends the instruction to supplementary actuating mechanism: the conveyor belt stops moving;
then, the control equipment controls the bridge-type light source to polish and supplement the brake pad, and then sends a photographing instruction to the camera to obtain a picture;
then, the picture is transmitted to a data analysis processing module of the control equipment by a camera, the picture is processed by the data analysis processing module, and the position of the brake pad in the detection station is calculated;
then, the data analysis processing module transmits the position information of the brake pad in the detection station to the scanner rotation control module;
then, after the scanner rotation control module obtains the position information of the brake pad, the scanner rotation control module controls the rotating shaft connecting plate to drive the laser scanner to perform laser scanning on the brake pad; in the process, the camera collects images in real time in the scanning process and transmits the images to the data analysis processing module;
then, the data analysis processing module obtains a flatness parameter and a pin height parameter through calculation, a detection result is displayed through a display, and a detection report is generated at the same time;
C. and the auxiliary executing mechanism receives the detection result and then processes the detection result, if the detection result is qualified, the next detection process is carried out, if the detection result is unqualified, the brake pad is removed to an unqualified area, and meanwhile, the auxiliary executing mechanism transmits the next brake pad to be detected to enter a detection station.
The beneficial effect of this application lies in:
first, a first invention of the present application is: the hardware design architecture of the whole detection system is provided. Specifically, it is embodied in "comprising: control device, camera, bridge light source, laser scanner, auxiliary actuator ", and the mutual design of camera, bridge light source, laser scanner, auxiliary actuator, and the modular design of" control device ".
Secondly, the second invention point corresponds to the first invention point, and provides a detection method of the detection system, which comprises the following steps:
A. placing a brake pad to be tested on a conveyor belt of an auxiliary actuating mechanism, and conveying the brake pad to a detection position by the conveyor belt, wherein the detection position is positioned right below a camera and a laser projector;
B. the camera is real-time to the monitoring station of shooing, and when discerning the brake block and getting into the detection station, controlgear sends the instruction to supplementary actuating mechanism: the conveyor belt stops moving;
then, the control equipment controls the bridge-type light source to polish and supplement the brake pad, and then sends a photographing instruction to the camera to obtain a picture;
then, the picture is transmitted to a data analysis processing module of the control equipment by a camera, the picture is processed by the data analysis processing module, and the position of the brake pad in the detection station is calculated;
then, the data analysis processing module transmits the position information of the brake pad in the detection station to the scanner rotation control module;
then, after the scanner rotation control module obtains the position information of the brake pad, the scanner rotation control module controls the rotating shaft connecting plate to drive the laser scanner to perform laser scanning on the brake pad; in the process, the camera collects images in real time in the scanning process and transmits the images to the data analysis processing module;
then, the data analysis processing module obtains a flatness parameter and a pin height parameter through calculation, a detection result is displayed through a display, and a detection report is generated at the same time;
C. and the auxiliary executing mechanism receives the detection result and then processes the detection result, if the detection result is qualified, the next detection process is carried out, if the detection result is unqualified, the brake pad is removed to an unqualified area, and meanwhile, the auxiliary executing mechanism transmits the next brake pad to be detected to enter a detection station.
Third, the third invention of the present application is: the method for calibrating the pin position by the data analysis processing module comprises the following steps of:
A. determining the size transformation ratio of the template picture and the picture to be detected according to the fixed distance between the camera and the brake pad, and determining the standard sample picture as the template picture for detecting the product after carrying out ratio transformation on the standard sample picture;
B. the central position and the rotation angle of the brake pad to be detected at the detection position are quickly determined by rotating and translating the template picture and comparing the template picture with the picture to be detected for real-time errors;
C. and performing fast regression operation through a support vector machine algorithm to quickly calibrate the position of the pin.
Fourth, a fourth invention of the present application is: the method for determining the flatness of the brake pad by the data analysis processing module comprises the following steps of:
A. determining an effective scanning area of the laser according to the position and the rotation angle given by the brake pad position calibration algorithm;
B. fitting an ideal laser line according to the coordinates of the laser points, and solving the sum of the longitudinal coordinate differences of each row of ideal laser lines and the actual laser lines;
C. dividing the laser line into L sections, solving the sum difn [ L ] of the difference on the L section, and making the L sections black in different degrees according to difn [ L ], wherein the black part is the unevenness on the scanning line;
D. and finally, processing the unevenness value of each line according to the weight, and comparing the processing result with a set unevenness standard to judge whether the product is qualified.
Drawings
The present application will be described in further detail with reference to the following examples, which are not intended to limit the scope of the present application.
Fig. 1 is a structural design diagram of a camera, a bridge type light source, a laser scanner, a spindle connecting plate, and a detection platform of example 1.
FIG. 2 is a schematic diagram of the system for detecting flatness and pin height of an automobile brake pad according to embodiment 1.
FIG. 3 is a schematic diagram of the system for detecting flatness and pin height of an automobile brake pad according to embodiment 2.
The reference numerals in fig. 1-3 are illustrated as follows:
the system comprises a control device 101, a camera 102, a bridge-type light source 103, a laser scanner 104, a rotating shaft connecting plate 105, a detection platform 106, a camera upright 107, a base support 108 and an auxiliary actuating mechanism 109;
the system comprises a data analysis processing module 1011, a scanner rotation control module 1012, a communication module 1013 and a display 1014.
Detailed Description
The first embodiment is as follows: the utility model provides an automobile brake block roughness and pin height detecting system, includes: a control device 101, a camera 102, a bridge-type light source 103, a laser scanner 104, a spindle connection plate 105. The control device 101 is in communication connection with the camera 102, the bridge-type light source 103, the laser scanner 104, and the spindle connection board 105, respectively.
Further comprising: the detection platform 106, the camera upright 107 and the base support 108 are fixed with the detection platform 106.
The camera 102 is used for shooting a brake pad to obtain an image; the camera is fixed on a camera upright post, the lens is downward and is vertically placed with a detection station (a brake pad to be detected is placed on the detection station), and the brake pad is shot according to a control instruction sent by the control equipment 101. In the first embodiment, the camera 102 is an MER-500-14U3M/C-L industrial camera, and is responsible for surface defect detection of the brake pad to be detected, position determination of the brake pad in a station to be detected and pin position determination. The camera combines a new CMOS technology with a USB3.0 interface, is clear in shooting and accurate in measurement, has the resolution of 2592 x 1944, the frame rate of 14fps at the maximum resolution, is diversified in image acquisition mode, can be used under various operating systems such as Windows and the like, and can ensure repeated measurable performance of the same index under different use scenes.
The bridge-type light source 103 is used for polishing and supplementing the brake pad; the bridge-type light source 103 is an annular structure, the middle part of the bridge-type light source is hollow, and the upper part of the hollow area in the middle part corresponds to the camera 102, namely, the camera 102 observes the brake pad on the detection station through the hollow area in the middle part of the bridge-type light source 103. The bridge-type light source 203 is located under the camera, light rays of the detection position are monitored through the photoresistor array, the bridge-type light source is adjusted to supplement light rays of the brake pad to be detected, and contrast and precision of the camera during image acquisition are guaranteed. The upper part of the bridge-type light source is fixed on the camera column, namely: the camera upright post, the camera and the bridge type light source form 1 whole.
Wherein the laser scanner 104 is used for scanning the brake pad. The laser adopts 850 nm infrared wave, the emission angle is more than 120 degrees, the output power is less than 2 watts, and brake pads of different models and sizes can be ensured to be within the laser radiation angle.
When the rotating shaft connecting plate 105 rotates by taking the rotating shaft as a center, the laser scanner is driven to project the brake pad line by line, and meanwhile, the camera collects a projected laser line picture in real time. The driving component of the rotating shaft connecting shaft consists of a motor control module with encoder feedback, the minimum rotating angle of the rotating shaft is 360 degrees/1024, and the laser scanner can be ensured to complete the omnibearing projection of the brake pad.
The base bracket 108 is provided with a cantilever plate, the rotating shaft connecting plate 105 comprises a connecting plate and a rotating shaft fixed at one end of the connecting plate, and the laser scanner 104 is fixed at the other end of the connecting plate; the rotating shaft of the rotating shaft connecting plate 105 is rotatably connected with the end of the cantilever plate (a bearing is arranged on the cantilever, the rotating shaft can only horizontally rotate in the bearing, and the gravity of the rotating shaft is transmitted to the bearing) (the driving component of the rotating shaft connecting plate 105 is not shown in fig. 1); a motor is fixedly arranged on the lower surface of the cantilever plate, and an output shaft of the motor is provided with a gear which is meshed with the rotating shaft so as to drive the rotating shaft to rotate, and then the rotating shaft 105 is driven to rotate, so that the laser scanner 104 is driven to rotate.
The control apparatus 101 includes: a data analysis processing module 1011, a scanner rotation control module 1012, a communication module 1013 and a display; the data analysis processing module 1011, the scanner rotation control module 1012, the communication module 1013 and the display are connected with each other in a communication manner.
The data analysis processing module 1011 is configured to analyze the image transmitted from the camera 102, determine specific position information of the brake pad on the detection station, and determine the flatness of the brake pad and the height of the pin. The data analysis processing module 1011 adopts a least square method to fit and scan laser lines to determine the flatness of the brake pad, adopts a template matching method to quickly calibrate the position of the pin, adopts a laser deviation and height correlation algorithm to determine the height of the pin, and calls a cross-platform multimedia development kit library function to realize video and image display and the like; and aiming at special application occasions such as unnatural illumination, detection table jitter and the like, the robustness of an image processing mode is improved by adapting the invariant moment algorithm.
The scanner rotation control module 1012 adopts an embedded processor, which is used to control the rotation of the rotating shaft connecting plate, and according to the given brake pad center position of the data analysis processing module 1011, the rotating shaft of the rotating shaft connecting plate is controlled to rotate so as to drive the laser scanner to project the brake pad line by line. In the first embodiment, a modularized design is adopted by using the Freescale MCIMX27, and the modularized design is used for controlling the laser lighting detection angle of a laser scanner to scan the brake pad line by line; the control system can control the rotating shaft connecting plate according to the coordinate position of the brake pad to be detected, adjusts the laser scanner and the rotating shaft connecting plate to realize the whole surface detection of the brake pad, ensures that the data analysis processing module 1011 establishes the plane data of the brake pad flatness and the pin height, and calculates the flatness and the pin height parameters of the brake pad through the detection algorithm.
The communication module 1013 is used for communication processing among the data analysis processing module 1011, the camera 102, the bridge light source 103, and the scanner rotation control module 1012.
The working method of the detection system comprises the following steps:
A. placing the brake pad on a detection station of the detection platform 106;
B. the method comprises the steps that a camera 102 conducts real-time photographing monitoring on a detection station, when the fact that a brake pad enters the detection station is recognized, a control device 101 controls a bridge-type light source 103 to conduct polishing supplement on the brake pad, and then a photographing instruction is sent to the camera 102 to obtain a picture;
the picture is transmitted to a data analysis processing module 1011 of the control equipment 101 by the camera 102, the picture is processed by the data analysis processing module 1011, and the position of the brake pad in the detection station is calculated;
the data analysis processing module 1011 transmits the position information of the brake pad in the detection station to the scanner rotation control module 1012 (i.e. an embedded processor);
after the scanner rotation control module 1012 obtains the position information of the brake pad, the rotation shaft connecting plate is controlled to drive the laser scanner to perform laser scanning on the brake pad; in the process, the camera collects images in real time in the scanning process and transmits the images to the data analysis processing module 1011;
the data analysis processing module 1011 obtains the flatness parameter and the pin height parameter through calculation, displays the detection result through a display, and simultaneously generates a detection report.
Example two: on the basis of the first embodiment, the following steps are added: and the auxiliary actuator 109 is in communication connection with the control device 101. The auxiliary actuator 109 includes: and the conveying belt controlled by the electronic control system is arranged on the detection platform 106.
The communication module 1013 is used for communication processing among the data analysis processing module 1011, the camera 102, the scanner rotation control module 1012, and the auxiliary execution mechanism 109.
The working method of the detection system of the second team of the embodiment is as follows:
A. placing the brake pad to be tested on a conveyor belt (not shown in fig. 1) of the auxiliary actuator 109, the conveyor belt conveying the brake pad to a detection position, the detection position being directly below the camera and the laser projector;
B. the camera 102 carries out photographing monitoring on the detection station in real time, and when the brake pad is recognized to enter the detection station, the control equipment 101 sends an instruction to the auxiliary execution mechanism 109: the conveyor belt stops moving;
then, the control device 101 controls the bridge-type light source 103 to polish and supplement the brake pad, and then sends a photographing instruction to the camera 102 to obtain a picture;
then, the picture is transmitted to a data analysis processing module 1011 of the control device 101 by the camera 102, and the data analysis processing module 1011 processes the picture and calculates the position of the brake pad in the detection station;
then, the data analysis processing module 1011 transmits the position information of the brake pad in the detection station to the scanner rotation control module 1012 (i.e. the embedded processor);
then, after the scanner rotation control module 1012 obtains the position information of the brake pad, the rotating shaft connecting plate is controlled to drive the laser scanner to perform laser scanning on the brake pad; in the process, the camera collects images in real time in the scanning process and transmits the images to the data analysis processing module 1011;
then, the data analysis processing module 1011 obtains the flatness parameter and the pin height parameter through calculation, displays the detection result through a display, and generates a detection report at the same time;
C. and the auxiliary executing mechanism 109 receives the detection result and then processes the detection result, if the detection result is qualified, the next detection process is carried out, if the detection result is unqualified, the brake pad is removed to an unqualified area, and meanwhile, the auxiliary executing mechanism 109 transmits the next brake pad to be detected to enter a detection station.
It should be noted that the data analysis processing module 1011, the first embodiment and the second embodiment are developed based on a Linux system, and send a control instruction through the communication processing module, so as to control the camera to perform image acquisition on the detection station, perform operations such as preprocessing, feature extraction, pattern recognition and comparison on the acquired image, determine the positions of the brake pad and the pin to be detected, and transmit coordinate parameters to the embedded processor through the communication module; and meanwhile, processing a returned picture acquired by the camera to generate a detection result.
It should be noted that, the data analysis processing module 1011 uses a template matching method to quickly calibrate the pin position, and the steps are as follows:
A. determining the size transformation ratio of the template picture and the picture to be detected according to the fixed distance between the camera and the brake pad, and determining the standard sample picture as the template picture for detecting the product after carrying out ratio transformation on the standard sample picture;
B. the central position and the rotation angle of the brake pad to be detected at the detection position are quickly determined by rotating and translating the template picture and comparing the template picture with the picture to be detected for real-time errors;
C. and performing fast regression operation through a support vector machine algorithm to quickly calibrate the position of the pin.
It should be noted that, the data analysis processing module 1011 adopts a least square method to fit and scan the laser line to determine the flatness of the brake pad, and the steps are as follows:
A. determining an effective scanning area of the laser according to the position and the rotation angle given by the brake pad position calibration algorithm;
B. fitting an ideal laser line according to the coordinates of the laser points, and solving the sum of the longitudinal coordinate differences of each row of ideal laser lines and the actual laser lines;
C. dividing the laser line into L sections, solving the sum difn [ L ] of the difference on the L section, and making the L sections black in different degrees according to difn [ L ], wherein the black part is the unevenness on the scanning line;
D. the brake pad is traversed line by line to obtain unevenness values of different sections, finally the unevenness value of each line is processed according to the weight (the weight can be adjusted according to actual needs), and the processing result is compared with the set unevenness standard, namely whether the product is qualified or not can be judged.
The detection system realizes automatic operation of the whole detection system, solves the problem of repeated precision of the brake pad flatness and pin detection device in the detection process at present, and can realize automatic detection and report generation of the brake pad flatness and the pin height through machine vision.
The above-mentioned embodiments are merely preferred embodiments of the present application, which are not intended to limit the present application in any way, and it will be understood by those skilled in the art that various changes and modifications can be made without departing from the spirit and scope of the present application.
Claims (9)
1. The utility model provides an automobile brake block roughness and pin height detecting system which characterized in that includes: control equipment, a camera, a bridge-type light source, a laser scanner;
the control equipment is respectively in communication connection with the camera, the bridge-type light source, the laser scanner and the rotating shaft connecting plate;
the control equipment is used for analyzing the image transmitted by the camera, determining the specific position information of the brake pad on the detection station, and determining the flatness of the brake pad and the height of the pin;
the camera shoots the brake pad according to a control instruction sent by the control equipment;
the bridge-type light source performs polishing supplement on the brake pad according to a control instruction sent by the control equipment;
the laser scanner is used for scanning the brake pad according to a control command sent by the control equipment.
2. The system of claim 1, further comprising: the camera stand column and the base support are fixed with the detection platform;
the camera is fixed on the camera upright post, and the lens is downward and is vertically placed with the detection station;
the bridge-type light source is of an annular structure, the middle part of the bridge-type light source is hollow, and the upper part of the hollow middle part corresponds to the camera, namely the camera observes the brake pad on the detection station through the hollow middle part of the bridge-type light source; the bridge-type light source is positioned under the camera, the light of the detection position is monitored through the photoresistor array, the bridge-type light source is adjusted to supplement the light of the brake pad to be detected, and the contrast and the precision of the camera during image acquisition are ensured; the upper part of the bridge-type light source is fixed on the camera column, namely: the camera upright post, the camera and the bridge type light source form 1 whole;
the laser of the laser scanner adopts 850 nm infrared waves, the emission angle is more than 120 degrees, and the output power is less than 2 watts;
the laser scanner is fixed at the other end of the connecting plate; a rotating shaft of the rotating shaft connecting plate is rotatably connected with the end part of the cantilever plate; a motor is fixedly arranged on the lower surface of the cantilever plate, and an output shaft of the motor is provided with a gear which is meshed with the rotating shaft so as to drive the rotating shaft to rotate and further drive the rotating shaft to rotate so as to drive the laser scanner to rotate;
when the rotating shaft connecting plate rotates by taking the rotating shaft as a center, the laser scanner is driven to project the brake pad line by line, and meanwhile, the camera collects a projected laser line picture in real time.
3. The system for detecting the flatness and the pin height of the automobile brake pad as claimed in claim 2, wherein the driving member of the rotating shaft connecting shaft is composed of a motor control module with encoder feedback, and the minimum rotation angle of the rotating shaft is 360 °/1024, which can ensure that the laser scanner can complete the all-directional projection of the brake pad.
4. The system of claim 2, wherein the control device comprises: the system comprises a data analysis processing module, a scanner rotation control module, a communication module and a display; the data analysis processing module, the scanner rotation control module, the communication module and the display are in communication connection with each other;
the data analysis processing module is used for analyzing the image transmitted by the camera, determining the specific position information of the brake pad on the detection station and determining the flatness of the brake pad and the height of the pin;
the scanner rotation control module 1 adopts an embedded processor, is used for controlling the rotation of a rotating shaft connecting plate, and controls the rotating shaft of the rotating shaft connecting plate to rotate so as to drive the laser scanner to project the brake pads line by line according to the given brake pad central position of the data analysis processing module;
the communication module is used for communication processing among the data analysis processing module, the camera, the bridge-type light source and the scanner rotation control module.
5. The utility model provides an automobile brake block roughness and pin height detecting system, includes: the device comprises a control device, a camera, a bridge-type light source, a laser scanner and an auxiliary actuating mechanism;
the control equipment is respectively in communication connection with the camera, the bridge-type light source, the laser scanner, the rotating shaft connecting plate and the auxiliary actuating mechanism;
the control equipment is used for analyzing the image transmitted by the camera, determining the specific position information of the brake pad on the detection station, and determining the flatness of the brake pad and the height of the pin;
the camera shoots the brake pad according to a control instruction sent by the control equipment;
the bridge-type light source performs polishing supplement on the brake pad according to a control instruction sent by the control equipment;
the laser scanner is used for scanning the brake pad according to a control command sent by the control equipment;
wherein, supplementary actuating mechanism includes: the conveying belt is controlled by the electric control system and arranged on the detection platform;
further comprising: the camera stand column and the base support are fixed with the detection platform;
the camera is fixed on the camera upright post, and the lens is downward and is vertically placed with the detection station;
the bridge-type light source is of an annular structure, the middle part of the bridge-type light source is hollow, and the upper part of the hollow middle part corresponds to the camera, namely the camera observes the brake pad on the detection station through the hollow middle part of the bridge-type light source; the bridge-type light source is positioned under the camera, the light of the detection position is monitored through the photoresistor array, the bridge-type light source is adjusted to supplement the light of the brake pad to be detected, and the contrast and the precision of the camera during image acquisition are ensured; the upper part of the bridge-type light source is fixed on the camera column, namely: the camera upright post, the camera and the bridge type light source form 1 whole;
the laser of the laser scanner adopts 850 nm infrared waves, the emission angle is more than 120 degrees, and the output power is less than 2 watts;
the laser scanner is fixed at the other end of the connecting plate; a rotating shaft of the rotating shaft connecting plate is rotatably connected with the end part of the cantilever plate; a motor is fixedly arranged on the lower surface of the cantilever plate, and an output shaft of the motor is provided with a gear which is meshed with the rotating shaft so as to drive the rotating shaft to rotate and further drive the rotating shaft to rotate so as to drive the laser scanner to rotate;
when the rotating shaft connecting plate rotates by taking the rotating shaft as a center, the laser scanner is driven to project the brake pad line by line, and meanwhile, a camera collects a projected laser line picture in real time;
the driving component of the rotating shaft connecting shaft consists of a motor control module with encoder feedback, the minimum rotating angle of the rotating shaft is 360 degrees/1024, and the laser scanner can be ensured to complete the omnibearing projection on the brake pad;
the control apparatus includes: the system comprises a data analysis processing module, a scanner rotation control module, a communication module and a display; the data analysis processing module, the scanner rotation control module, the communication module and the display are in communication connection with each other;
the data analysis processing module is used for analyzing the image transmitted by the camera, determining the specific position information of the brake pad on the detection station and determining the flatness of the brake pad and the height of the pin;
the scanner rotation control module 1 adopts an embedded processor, is used for controlling the rotation of a rotating shaft connecting plate, and controls the rotating shaft of the rotating shaft connecting plate to rotate so as to drive the laser scanner to project the brake pads line by line according to the given brake pad central position of the data analysis processing module;
the communication module is used for communication processing among the data analysis processing module, the camera, the bridge-type light source, the scanner rotation control module and the auxiliary execution mechanism.
6. The system for detecting the flatness of the automobile brake pad and the height of the pin according to claim 4 or 5, wherein the data analysis processing module calibrates the position of the pin, and a template matching method is adopted, and the method comprises the following steps:
A. determining the size transformation ratio of the template picture and the picture to be detected according to the fixed distance between the camera and the brake pad, and determining the standard sample picture as the template picture for detecting the product after carrying out ratio transformation on the standard sample picture;
B. the central position and the rotation angle of the brake pad to be detected at the detection position are quickly determined by rotating and translating the template picture and comparing the template picture with the picture to be detected for real-time errors;
C. and performing fast regression operation through a support vector machine algorithm to quickly calibrate the position of the pin.
7. The system for detecting the flatness of the automobile brake pad and the height of the pin according to claim 4 or 5, wherein the data analysis processing module determines the flatness of the brake pad and scans a laser line by fitting a least square method, and the method comprises the following steps:
A. determining an effective scanning area of the laser according to the position and the rotation angle given by the brake pad position calibration algorithm;
B. fitting an ideal laser line according to the coordinates of the laser points, and solving the sum of the longitudinal coordinate differences of each row of ideal laser lines and the actual laser lines;
C. dividing the laser line into L sections, solving the sum difn [ L ] of the difference on the L section, and making the L sections black in different degrees according to difn [ L ], wherein the black part is the unevenness on the scanning line;
D. and finally, processing the unevenness value of each line according to the weight, and comparing the processing result with a set unevenness standard to judge whether the product is qualified.
8. A detection method of an automobile brake pad flatness and pin height detection system, the automobile brake pad flatness and pin height detection system being the automobile brake pad flatness and pin height detection system of claim 4, comprising the steps of:
A. placing the brake pad on a detection station of a detection platform;
B. the method comprises the steps that a camera carries out photographing monitoring on a detection station in real time, when the brake pad is recognized to enter the detection station, control equipment controls a bridge-type light source to polish and supplement the brake pad, and then a photographing instruction is sent to the camera to obtain a picture;
the picture is transmitted to a data analysis processing module of the control equipment by a camera, the picture is processed by the data analysis processing module, and the position of the brake pad in the detection station is calculated;
the data analysis processing module transmits the position information of the brake pad in the detection station to the scanner rotation control module;
after the scanner rotation control module obtains the position information of the brake pad, the scanner rotation control module controls the rotating shaft connecting plate to drive the laser scanner to perform laser scanning on the brake pad; in the process, the camera collects images in real time in the scanning process and transmits the images to the data analysis processing module;
and the data analysis processing module obtains the flatness parameter and the pin height parameter through calculation, displays the detection result through a display and generates a detection report at the same time.
9. A detection method of an automobile brake pad flatness and pin height detection system, the automobile brake pad flatness and pin height detection system being the automobile brake pad flatness and pin height detection system of claim 5, comprising the steps of:
A. placing a brake pad to be tested on a conveyor belt of an auxiliary actuating mechanism, and conveying the brake pad to a detection position by the conveyor belt, wherein the detection position is positioned right below a camera and a laser projector;
B. the camera is real-time to the monitoring station of shooing, and when discerning the brake block and getting into the detection station, controlgear sends the instruction to supplementary actuating mechanism: the conveyor belt stops moving;
then, the control equipment controls the bridge-type light source to polish and supplement the brake pad, and then sends a photographing instruction to the camera to obtain a picture;
then, the picture is transmitted to a data analysis processing module of the control equipment by a camera, the picture is processed by the data analysis processing module, and the position of the brake pad in the detection station is calculated;
then, the data analysis processing module transmits the position information of the brake pad in the detection station to the scanner rotation control module;
then, after the scanner rotation control module obtains the position information of the brake pad, the scanner rotation control module controls the rotating shaft connecting plate to drive the laser scanner to perform laser scanning on the brake pad; in the process, the camera collects images in real time in the scanning process and transmits the images to the data analysis processing module;
then, the data analysis processing module obtains a flatness parameter and a pin height parameter through calculation, a detection result is displayed through a display, and a detection report is generated at the same time;
C. and the auxiliary executing mechanism receives the detection result and then processes the detection result, if the detection result is qualified, the next detection process is carried out, if the detection result is unqualified, the brake pad is removed to an unqualified area, and meanwhile, the auxiliary executing mechanism transmits the next brake pad to be detected to enter a detection station.
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| CN118268986A (en) * | 2024-06-03 | 2024-07-02 | 江苏甬金金属科技有限公司 | Polishing device with flatness detection function for stainless steel belt surface |
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