CN113503922A - Detection system used in tire production process - Google Patents
Detection system used in tire production process Download PDFInfo
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- CN113503922A CN113503922A CN202110789029.2A CN202110789029A CN113503922A CN 113503922 A CN113503922 A CN 113503922A CN 202110789029 A CN202110789029 A CN 202110789029A CN 113503922 A CN113503922 A CN 113503922A
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- G—PHYSICS
- G01—MEASURING; TESTING
- G01D—MEASURING NOT SPECIALLY ADAPTED FOR A SPECIFIC VARIABLE; ARRANGEMENTS FOR MEASURING TWO OR MORE VARIABLES NOT COVERED IN A SINGLE OTHER SUBCLASS; TARIFF METERING APPARATUS; MEASURING OR TESTING NOT OTHERWISE PROVIDED FOR
- G01D21/00—Measuring or testing not otherwise provided for
- G01D21/02—Measuring two or more variables by means not covered by a single other subclass
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- G—PHYSICS
- G05—CONTROLLING; REGULATING
- G05B—CONTROL OR REGULATING SYSTEMS IN GENERAL; FUNCTIONAL ELEMENTS OF SUCH SYSTEMS; MONITORING OR TESTING ARRANGEMENTS FOR SUCH SYSTEMS OR ELEMENTS
- G05B19/00—Programme-control systems
- G05B19/02—Programme-control systems electric
- G05B19/04—Programme control other than numerical control, i.e. in sequence controllers or logic controllers
- G05B19/042—Programme control other than numerical control, i.e. in sequence controllers or logic controllers using digital processors
Abstract
The application provides a detecting system for in tire production process, detecting system includes: the device comprises a support, a shell arranged on the upper surface of the support, a main control board and a power supply board arranged in the shell, and an optical lens arranged below the shell, wherein the optical lens is connected with the shell through an interface flange; the main control board and the power panel are dispersedly provided with: the color linear sensor comprises a color linear sensor, an analog-to-digital converter, a field programmable gate array chip connected with the analog-to-digital converter, a singlechip connected with the field programmable gate array chip, a magnetic coupling isolation trigger connected with the field programmable gate array chip, a trigger interface connected with the magnetic coupling isolation trigger, an Ethernet physical layer chip connected with the singlechip, a memory, a magnetic coupling isolation transceiver and a Bluetooth module. The embodiment of the application not only saves the cost, but also improves the convenience of management and use.
Description
Technical Field
The application relates to the technical field of tire production, in particular to a detection system used in a tire production process.
Background
The tire manufacturing comprises a plurality of working sections, such as a sizing material extrusion working section, a cord fabric calendering working section, a cord fabric cutting working section, a belt molding working section or a tire molding working section, wherein the production of each working section directly influences the production quality of the next working section, so that the production quality of the working section is detected through detection equipment in each working section to ensure the normal operation of the subsequent working sections.
Currently, different inspection equipment is used for each production section. Therefore, the prior art has at least the following problems: different check out test set is used in the workshop section of difference, and it is inconvenient not only to install check out test set, and measurement personnel need know different check out test set moreover, and it is inconvenient all to use and manage, and in addition, more check out test set leads to the cost-push.
Disclosure of Invention
The application provides a detecting system for in tire production process for solve among the prior art tire detection equipment use and manage inconvenient problem.
In a first aspect, the present application provides an inspection system for use in a tire manufacturing process, the inspection system comprising: the optical lens comprises a support, a shell arranged on the upper surface of the support, a main control board arranged in the shell, a power panel arranged in the shell, and an optical lens arranged below the shell, wherein the optical lens is connected with the shell through an interface flange;
the main control board and the power panel are dispersedly provided with: the system comprises a color linear sensor, an analog-to-digital converter connected with the color linear sensor, a field programmable gate array chip connected with the analog-to-digital converter, a single chip connected with the field programmable gate array chip, a magnetic coupling isolation trigger connected with the field programmable gate array chip, the field programmable gate array chip is also connected with the color linear sensor, a trigger interface connected with the magnetic coupling isolation trigger, an Ethernet physical layer chip connected with the single chip, a memory, a magnetic coupling isolation transceiver and a Bluetooth module, an Ethernet interface connected with the Ethernet physical layer chip, a transceiver interface connected with the magnetic coupling isolation transceiver and a wireless Bluetooth interface connected with the Bluetooth module;
the optical lens focuses and maps the object image information of the material to be detected to the surface of the color linear sensor through an optical imaging principle to form an optical signal for imaging the material to be detected;
the color linear sensor receives an optical signal of the image of the material to be detected, the optical signal of the image of the material to be detected is converted into an electrical signal of the image of the material to be detected by a photoelectric conversion principle, the electrical signal of the image of the material to be detected is a voltage signal, and the voltage signal which can be directly received by the analog-to-digital converter is finally formed after the processing of the filter circuit, the amplifying circuit and the comparison circuit;
the analog-to-digital converter converts the voltage signal into a digital image signal through an analog-to-digital conversion principle, and sends the digital image signal to the field programmable gate array chip through three channels;
the field programmable gate array chip drives the color linear sensor to work through a preset first language program, and performs related double sampling processing on a digital image signal sent by the analog-to-digital converter through a sampling principle to form a line of color images; meanwhile, the field programmable gate array chip processes the color image through a preset first language program, realizes real-time high-speed detection on the material to be detected through a corresponding detection algorithm, and sends a detection result to the single chip microcomputer;
the single chip microcomputer is communicated with other external equipment through a preset second language program, and a detection result is sent to the Ethernet physical layer chip, the magnetic coupling isolation transceiver and the Bluetooth module so as to be sent through an Ethernet interface connected with the Ethernet physical layer chip, a transceiver interface connected with the magnetic coupling isolation transceiver and a wireless Bluetooth interface connected with the Bluetooth module;
the magnetic coupling isolation trigger is used for receiving an externally connected encoder signal and also can send out a synchronous trigger signal to be connected with another detection system, and the field programmable gate array chip completes synchronous detection through a preset first language program.
Optionally, the magnetically coupled isolation transceiver comprises at least one of a magnetically coupled isolation controller local area network transceiver and a magnetically coupled isolation 485 transceiver;
the magnetic coupling isolation controller local area network transceiver is connected with a controller local area network transceiver interface;
the magnetic coupling isolation 485 transceiver is connected with a 485 transceiver interface;
the preset first language is Verilog hardware description language;
the preset second language is C language.
Optionally, the detection system further comprises a mounting bracket, the mounting bracket spans across the tire production line, the mounting bracket is used for fixing the detection device at a preset height, and the optical lens of the detection device faces the material bearing table of the production line.
Optionally, the detection system further includes a three-dimensional adjusting mechanism, and the three-dimensional adjusting mechanism is detachably connected to the detection device and is used for adjusting the position of the detection device in the X direction, the Y direction, and the Z direction.
Optionally, the three-dimensional adjustment mechanism is provided with a connector for connecting with the mounting bracket, and the three-dimensional adjustment mechanism is mounted on the mounting bracket through the connector.
Optionally, the material bearing table comprises a conveying roller way, the detection system further comprises an auxiliary light source, the auxiliary light source is installed on the installation support and located below the material bearing table, and light rays of the auxiliary light source penetrate through a roller gap of the conveying roller way and irradiate in a detection visual field of the optical lens.
Optionally, the detection device further comprises two collimation laser lamps, the two collimation laser lamps are arranged on two sides of the optical lens, and a connecting line of the two collimation laser lamps is parallel to the roll gap.
Optionally, an anti-smashing sheath is arranged on the outer side of the optical lens, and the anti-smashing sheath is used for preventing the optical lens from being damaged.
Optionally, a heat sink is further provided on the housing.
Optionally, the detection system further includes a display screen, and the display screen is disposed on the mounting bracket and is used for displaying data detected by the detection device in real time.
According to the detection system for the tire production process, an electric device such as a field programmable gate array chip is arranged on a main control board, different program codes can be stored in the field programmable gate array chip, and when a detection instruction is received, the program code corresponding to the detection instruction is called to execute a corresponding detection process; therefore, the programmable gate array chip is programmed to realize different detection procedures of width measurement, length measurement, center line detection, stagger angle detection, slotting detection, hole breaking detection, PE film leakage detection, steel wire leakage detection and the like on the material to be detected, namely, the same detection device can be used for realizing different detection procedures; compared with the prior art that different detection processes are finished by using different detection devices, the method and the device for detecting the temperature of the workpiece can finish different processes by using the same detection device, not only saves the cost, but also improves the convenience of management and use.
Drawings
In order to more clearly illustrate the embodiments of the present application or the technical solutions in the prior art, the drawings needed to be used in the description of the embodiments or the prior art will be briefly described below, and it is obvious that the drawings in the following description are some embodiments of the present application, and other drawings can be obtained by those skilled in the art without creative efforts.
Fig. 1 is a front view of a detection device according to an embodiment of the present application;
FIG. 2 is a side view of a detection device according to an embodiment of the present application;
fig. 3 is a top view of a detecting device according to an embodiment of the present disclosure;
fig. 4 is a connection diagram of electrical devices disposed in a main control board and a power board according to another embodiment of the present disclosure;
FIG. 5 is a front view of a three-dimensional adjustment mechanism provided in accordance with yet another embodiment of the present application;
FIG. 6 is a side view of a three-dimensional adjustment mechanism provided in accordance with yet another embodiment of the present application;
FIG. 7 is a top view of a three-dimensional adjustment mechanism provided in accordance with yet another embodiment of the present application;
FIG. 8 is a schematic structural diagram of a detection system according to yet another embodiment of the present application;
fig. 9 is a schematic view of a usage scenario of a detection apparatus according to another embodiment of the present application;
fig. 10 is a schematic view of a usage scenario of a detection apparatus according to another embodiment of the present application;
fig. 11 is a schematic view of a usage scenario of a detection apparatus according to another embodiment of the present application;
in the figure: the device comprises a support 1, a shell 2, an upper shell 21, a lower shell 22, a main control board 3, a power panel 4, an optical lens 5, an interface flange 6, a collimation laser lamp 7, an anti-smashing jacket 8, a cooling fin 9, an aircraft head adapter plate 10, an ultraviolet filter 11, a limiting frame 13, a fixing plate 14, a fine adjustment bracket 15, an X-direction adjusting jackscrew 16, an optical axis 17, a Y-direction adjusting jackscrew 18, a separating fixing ring 19, a mounting base plate 20, a mounting left side plate 25, a Z-direction adjusting jackscrew 26, a fine adjustment knob 23, a mounting right side plate 24, a detection device 100, a three-dimensional adjusting mechanism 200, a mounting bracket 300, a color linear sensor 301, an analog-to-digital converter 302, a programmable gate array chip 303, a single chip microcomputer 304, a magnetic coupling isolation trigger 305, a tire production line 400, a chip 401, a memory 402, a magnetic coupling isolation transceiver 403, a Bluetooth module 404, an Ethernet interface 405, a transceiver interface 406, Wireless bluetooth interface 407, trigger interface 408, material plummer 500, auxiliary light source 600, display screen 700, first display screen 701, second display screen 702, terminal box 800, magnetic coupling isolation CAN transceiver 4031, magnetic coupling isolation 485 transceiver 4032, controller area network transceiver interface 4061, 485 transceiver interface 4062.
Detailed Description
In order to make the objects, technical solutions and advantages of the embodiments of the present application clearer, the technical solutions in the embodiments of the present application are clearly and completely described below, and it is obvious that the described embodiments are a part of the embodiments of the present application, but not all of the embodiments. All other embodiments, which can be derived by a person skilled in the art from the embodiments given herein without making any creative effort, shall fall within the protection scope of the present application.
The embodiment of the application shows a detection system used in a tire production process. The detection system comprises a detection device 100, the detection device 100 comprising, with reference to fig. 1-3: the optical lens device comprises a support 1, a shell 2 arranged on the upper surface of the support 1, a main control board 3 arranged in the shell 2, a power supply board 4 arranged in the shell 2, and an optical lens 5 arranged below the shell 2, wherein the optical lens 5 is connected with the shell 2 through an interface flange 6.
Further, referring to fig. 4, the main control board 3 and the power board 4 are dispersedly provided with: a color linear sensor 301, an analog-to-digital converter 302 connected to the color linear sensor 301, a Field Programmable Gate Array (FPGA) chip 303 connected to the analog-to-digital converter 302, a single chip microcomputer 304 connected with the field programmable gate array chip 303, a magnetic coupling isolation trigger 305 connected with the field programmable gate array chip 303, the field programmable gate array chip 303 is also connected with the color linear sensor 301, an Ethernet Physical Layer (PHY for short) chip 401 connected with the single chip 304, a memory 402, a magnetic coupling isolation transceiver 403, a Bluetooth module 404, an ethernet interface 405 connected to the ethernet physical layer chip 401, a transceiver interface 406 connected to the magnetically-coupled isolated transceiver 403, a wireless bluetooth interface 407 connected to the bluetooth module 404, and a trigger interface 408 connected to the magnetically coupled isolated trigger 305.
The optical lens 5 focuses and maps the object image information of the material to be detected to the surface of the color linear sensor 301 through an optical imaging principle, so as to form an optical signal for imaging the material to be detected.
The color linear sensor 301 receives an optical signal of the imaging of the material to be detected, converts the optical signal of the imaging of the material to be detected into an electrical signal of the imaging of the material to be detected by a photoelectric conversion principle, wherein the electrical signal of the imaging of the material to be detected is a voltage signal, and is processed by the filter circuit, the amplifying circuit and the comparison circuit to finally form a voltage signal which can be directly received by the analog-to-digital converter 302.
The analog-to-digital converter 302 converts the voltage signal into a digital image signal by an analog-to-digital conversion principle, and sends the digital image signal to the field programmable gate array chip 303 through three channels.
The field programmable gate array chip 303 drives the color linear sensor to work through a preset first language program, and performs related double sampling processing on a digital image signal sent by the analog-to-digital converter 302 through a sampling principle to form a line of color images; meanwhile, the field programmable gate array chip 303 processes the color image through a preset first language program, and realizes real-time high-speed detection of the material to be detected through a corresponding detection algorithm, and sends a detection result to the single chip microcomputer 304.
The single chip microcomputer 304 communicates with other external devices through a preset second language programming, and sends a detection result to the ethernet physical layer chip 401, the magnetic coupling isolation transceiver 403 and the bluetooth module 404, so as to send the detection result through an ethernet interface 405 connected to the ethernet physical layer chip 401, a transceiver interface 406 connected to the magnetic coupling isolation transceiver 403 and a wireless bluetooth interface 407 connected to the bluetooth module 404.
The magnetic coupling isolation trigger 305 is configured to receive an externally connected encoder signal, and also can send a synchronous trigger signal to connect with another detection system, so that the field programmable gate array chip 303 completes synchronous detection through a preset first language program.
As can be seen from the above, in the detection apparatus for producing a tire provided in the embodiment of the present application, the electrical device such as the field programmable gate array chip 303 is disposed on the main control board 3, different program codes may be stored in the field programmable gate array chip 303, and when a detection instruction is received, the program code corresponding to the detection instruction is called to execute a corresponding detection process; therefore, the programmable gate array chip 303 is programmed to realize different detection procedures of width measurement, length measurement, center line detection, stagger angle detection, slotting detection, hole breaking detection, PE film leakage detection, steel wire leakage detection and the like on the material to be detected, namely, different detection procedures can be realized by using the same detection device; compared with the prior art that different detection processes are finished by using different detection devices, the method and the device for detecting the temperature of the workpiece can finish different processes by using the same detection device, not only saves the cost, but also improves the convenience of management and use.
Alternatively, the main control board 3 and the power board 4 may be disposed in a dispersed manner, wherein a portion of the main control board 3 is disposed on the main control board 3, and another portion of the main control board 4 is disposed on the power board 4.
Optionally, the main control board 3 is provided with: the color linear sensor 301, the analog-to-digital converter 302 connected with the color linear sensor 301, the field programmable gate array chip 303 connected with the analog-to-digital converter 302, the single chip microcomputer 304 connected with the field programmable gate array chip 303, the field programmable gate array chip 303 further connected with the color linear sensor 301, the Ethernet physical layer chip 401 connected with the single chip microcomputer 304, the memory 402, and the Ethernet interface 405 connected with the Ethernet physical layer chip 401.
The power panel 4 is provided with: the bluetooth wireless communication device comprises a magnetic coupling isolation transceiver 403, a transceiver interface 406 connected with the magnetic coupling isolation transceiver 403, a bluetooth module 404, a wireless bluetooth interface 407 connected with the bluetooth module 404, a magnetic coupling isolation trigger 305, and a trigger interface 408 connected with the magnetic coupling isolation trigger 305.
Of course, the size of the main control board 3 and the power board 4 may be reset, and the embodiment of the present application is not limited herein.
Of course, the detection device can be only arranged on the main control board 3, but compared with the detection device only arranged on the main control board 3, the detection device can be dispersedly arranged on the main control board 3 and the power panel 4, and the size of the detection device can be reduced.
In addition, it should be noted that, the detection precision of the material to be detected is improved from the source in the embodiment of the application. In the prior art, when a single material is measured, a moving frame is mostly adopted to drive two correlation type electron microscope sensors or parallel light sensors to move for detection; when the width of two materials is measured, a linear array sensor is mostly adopted for detection, and the resolution of the linear array sensor can only reach 7500 lines at most; when the quantity of the detected materials is increased, only a plurality of linear array sensors can be used for detecting in parallel, and the limitation of the detection range is controlled; the main disadvantages are: the sensor has low resolution, inaccurate mechanical movement positioning, complex structure and higher cost; in the embodiment of the application, a color high-precision linear sensor chip is selected as a detection chip, and is combined with an auxiliary light source (see fig. 8) of a light-emitting diode (light-emitting diode, LED for short), so that real RGB colors can be recognized, the resolution is up to 10680 lines, a plurality of materials can be detected simultaneously, the width of 10 effective materials can be output simultaneously, the number of all the materials in a detection range is counted, and 1000 materials can be counted at most; the detection range of the method can reach 2000MM from 200MM and be within 1000MM, the detection precision can reach +/-0.2 MM and can reach +/-0.3 MM from 1000MM to 2000 MM; the detection function of multiple materials, high precision and wide range is really realized; the method provides an effective detection means for the detection field with high requirement on product width detection precision, large cord width range span and special requirement on installation position in the tire manufacturing process.
Optionally, and still referring to FIG. 4, the magnetically-coupled isolation transceiver includes at least one of a magnetically-coupled isolation Controller Area Network (CAN) transceiver 4031 and a magnetically-coupled isolation 485 transceiver 4032;
wherein, the magnetic coupling isolation controller local area network transceiver 4031 is connected with a controller local area network transceiver interface 4061;
wherein, the magnetic coupling isolation 485 transceiver 4032 is connected with a 485 transceiver interface 4062;
the preset first Language is Verilog Hardware Description Language (English full name: Hardware Description Language, English short name: HDL).
Wherein the preset second language is a C language.
Optionally, the single chip microcomputer 304 may be a 32-bit MCU micro control unit, which is also called an STM32 single chip Microcomputer (MCUs).
The Memory 402 may be a Synchronous Dynamic Random-Access Memory (SDRAM).
Optionally, the detection apparatus 100 further includes two collimated laser lamps 7, the two collimated laser lamps 7 are disposed on two sides of the optical lens 5, and a connection line of the two collimated laser lamps 7 is parallel to the roll gap.
The collimated laser light 7 is used to assist in the adjustment of the position of the detection device 100.
When the position of the detection device 100 is adjusted, the collimation laser lamp 7 can be turned on in advance, so that the laser beam lines on the left side and the right side pass through the middle of the roll gap and are just opposite to the center of the light source, namely, the detection device 100 can be adjusted, and when the detection device is normally detected, the collimation laser lamp 7 is turned off. Therefore, the collimation laser lamp 7 is used for assisting in adjustment, and debugging is more convenient.
Optionally, a smash-proof sheath 8 is disposed on the outer side of the optical lens 5, and the smash-proof sheath 8 is used for preventing the optical lens 5 from being damaged.
Optionally, a heat sink 9 is also provided on the housing 2.
Optionally, the housing 2 includes an upper housing 21 and a lower housing 22, so that when a device in the housing 2 fails, the housing 2 can be disassembled for maintenance.
Further, the detection device 100 further includes an aircraft adapter plate 10 and an UltraViolet filter 11 (hereinafter referred to as "ultra violet," for short, UV ").
Further, referring to fig. 9-11, fig. 9-11 illustrate a usage scenario of the detection apparatus 100. As shown in fig. 9, the detection apparatus 100 can be connected to the following devices and make the devices implement corresponding functions:
the detection device 100 CAN be connected with a display through CAN communication so as to display the detected data through the display; the detection apparatus 100 may also be connected to a computer, such as a notebook computer, via an ethernet network, for scheduling the detection apparatus 100 via the computer;
the detection device 100 can also be connected with the SPRO320 controller through RS485 communication, and is used for forwarding data such as instructions and messages of the detection device 100 through the controller;
the detection device 100 can also be connected with an industrial computer through ethernet communication, and is used for performing operations such as collecting, recording, storing or forming a report on data of the detection device through the industrial computer;
the detection device 100 can also be connected with a Manufacturing Execution System (Manufacturing Execution System, abbreviated as MES) through ethernet communication, wherein the MES is a user Manufacturing Execution System, and a customer can directly collect, record, store or form a report through the MES; or send messages such as recipe information to the detecting device 100 through the MES system;
the detection device 100 may also be connected to a touch screen controller through ethernet communication, and is configured to forward data such as an instruction and a message issued by the detection device 100 to other devices through the touch screen controller;
the detection device 100 can also be connected with the controller through RS485 communication, and is used for forwarding data such as instructions and messages sent by the detection device 100 to other devices through the controller;
the detection device 100 may also be directly connected to the encoder, so that the encoder may trigger the detection device 100 to start working, or measure the length of the material to be detected, etc.
Fig. 10 shows another usage scenario of the detection apparatus 100, the usage connection relationship is as shown in fig. 10, and the functions of the devices are as described above, which are not repeated herein.
Fig. 11 shows another usage scenario of the detection apparatus 100, where the usage connection relationship is as shown in fig. 11, and the functions of each device are as described above, which are not described herein again.
It should be noted that fig. 10 and 11 differ in that the detection device 100 in fig. 10 is used only for performing the detection operation, and the detection device 100 in fig. 11 can be used for performing both the detection operation and the control operation.
Of course, the embodiments of the present application only take the usage scenarios shown in fig. 9 to 11 as examples, and do not limit the usage scenarios of the detection apparatus 100.
In addition, the detection device 100 provided by the embodiment of the application can also optimize the detection setting function. In the prior art, for a similar detection device, abnormal detection can be caused when foreign matters, scrap iron, dust and the like fall on a light source in the detection process, and when the detection device is fixed and the edge of a detection sector surface irradiates on a frame shield, the shield needs to be cut; in this way, the detection setting function is added, the minimum detection width can be set, and when foreign matters and scrap iron exist on the light source, the widths of the foreign matters and the scrap iron can be shielded, so that normal detection can be carried out; the automatic exposure adjusting device has the advantages that the automatic exposure adjusting function is added, the brightness of the light source becomes dark along with the increase of the service life of the device, dust is attached to the light source, the pixel peak value is gradually reduced, when the light source is reduced to a limit, the automatic exposure adjusting device can be automatically switched to a low-level driving clock mode, so that the exposure is increased, when the manual adjusting aperture is large, the automatic exposure adjusting device can be automatically switched to a high-level driving clock mode, so that the exposure is reduced, and normal detection is carried out; this application has still increased the shielded function of detection range, and when detecting the sector edge and shining on the frame guard shield, only need through software setting shield fall the guard shield shelter part the scope can, avoid cutting the operation of frame guard shield.
In addition, the detection device 100 provided by the embodiment of the application can realize multiple detection functions. In the prior art, only a single detection function can be realized for the similar detection devices, and in the field of comprehensive detection, a plurality of different detection devices need to be configured for simultaneous detection, so that the use cost of equipment is greatly increased; according to the method, different detection modes can be set according to different detection environments, for example, an extrusion line workshop section, and the method can realize the detection of the width of the tire tread, the tire side and the apex and the detection of the width and the central line of the inner liner; the method comprises the following steps of cutting off a section, wherein the method can realize cord width detection, cord splicing stagger angle detection, cord splicing slotting detection, cord hole detection, cord Polyethylene (PE) film foreign matter detection, cord steel wire leakage detection and the like; the calendering section can realize cord width detection, cord density detection and the like; the belt ply cutting method and the belt ply cutting device can realize belt ply width detection, belt ply cutting angle detection and belt ply cutting length detection; the detection functions are realized through an FPGA algorithm, the multiple detection functions are operated in parallel, the detection rates are not affected, and the cost of putting a factory into equipment for use is greatly saved.
The width measurement detection is to perform backlight irradiation on a material to be detected according to a detection range, project an image of the material to be detected onto a target surface of a detection chip through an optical lens, and calculate the positions and the number of effective pixels of the image shielded on the target surface of the detection chip; and (4) converting the position value and the width value of the actual material through calibration calculation.
The central line detection is that the central convex line of an object to be detected is subjected to side highlight irradiation according to the detection range, an image of the object to be detected is projected onto the target surface of the detection chip through the optical lens, the position of a bright spot pixel shielded on the target surface of the detection chip by the image is calculated, and the position value of the central line of the inner liner is calculated through calibration calculation.
The stagger angle detection is characterized in that backlight irradiation is carried out on a material to be detected in a detection range, an image of the material to be detected is projected onto a target surface of a detection chip through an optical lens, real-time statistics is carried out on the edge position shielded by the image by combining a longitudinally-installed encoder, the average width of a sudden change position is calculated, and the width value of the cord fabric splicing stagger angle is calculated through check calculation.
The method comprises the steps of detecting whether the spliced curtain cloth is slit or broken according to the fact that the object to be detected is subjected to backlight irradiation within a detection range, projecting an image of the object to be detected onto a target surface of a detection chip through an optical lens, carrying out image splicing on images scanned for a plurality of times continuously in front and at back, and judging whether bright lines or bright spot mutation exists in the spliced images.
The detection method comprises the steps of detecting a PE film leakage and a steel wire leakage, strengthening the front side of a material to be detected, projecting an image of the material to be detected onto a target surface of a detection chip through an optical lens, carrying out image splicing on images scanned for a plurality of times continuously from front to back, identifying the color of a bright line or a bright spot in a spliced image, and detecting whether the PE film or the steel wire leakage exists on spliced curtain cloth.
Wherein, angle detection, length measurement detect: performing backlight irradiation on a material to be detected, projecting an image of the material to be detected onto a target surface of a detection chip through an optical lens, performing real-time statistics on the edge position shielded by the image by combining a longitudinally-installed encoder, fitting a linear equation of edge position change by a linear fitting method, and calculating the bevel angle of a belted layer; the counting of the encoder is counted in the process from the shielding of the appointed point of the image to the non-shielding, and the cutting length of the belt ply can be calculated by combining the calculation of the motion deviation angle.
In addition, the detection device 100 provided in the embodiment of the present application can also realize both the detection function and the control function. In the prior art, the similar detection device is only used as a detection device, detected data or states are sent to a controller through a data interface, and then the controller is communicated with other equipment to realize a control function; for example, the Controller receives the formula information of a Programmable Logic Controller (PLC), and the Controller controls the display to display data, alarm and the like; the controller is used as an intermediate communication medium and is connected through a cable, so that the response speed of the whole system can be influenced; according to the method, a high-performance single chip microcomputer chip is selected as a control core chip, a control system and a detection system are combined together, the method can be directly connected with an MES (manufacturing execution system) of a user through an Ethernet, and the formula information transmitted by the MES can be acquired; the system is connected with a display, and the display is controlled to give an alarm and display data according to the obtained formula; the system is connected with a production line PLC, and the stop state of the production line is triggered and controlled through a level; of course, the system can also be directly used as a detection device and accessed into a statistical system, and the statistical system finishes data acquisition, storage, recording and report forming.
In addition, the Bluetooth module is arranged to support wireless Bluetooth communication, the mode and the parameters of the detection device 100 can be remotely set through a mobile phone application program, the detection device can be directly operated through the mobile phone application program in some areas with narrow installation space and inconvenient operation, and when equipment is damaged, a maintenance worker can obtain relevant technical parameters of the detection device 100 and information such as delivery date, serial number, batch, model and the like of the detection device 100 only by connecting the detection device 100 through the mobile phone application program; when a new detection device 100 is replaced, only the technical parameters to be backed up need to be led into the new detection device 100, so that the tedious work required by replacing the detection device 100 is greatly facilitated, and time and labor are saved.
In addition, in the prior art, the lens distortion factor affects the precision of all optical detection devices, and the measurement precision of the detection devices can be reduced if the lens distortion is not well processed; the application provides a method for eliminating distortion by self-learning curve fitting to eliminate the influence of lens distortion on detection precision; the method uses several high-precision stripe rulers, and the light and dark stripe intervals are respectively 0.5MM, 1MM, 2MM and 5 MM; acquiring image bright and dark images of different stripe scales, and performing self-learning fitting through an FPGA algorithm to finally learn an optimal fitting curve, wherein the abscissa of the fitting curve is the pixel position value of the bright and dark stripe images; the ordinate of the fitting curve is the position value of the actual distance of the light and dark stripes, when the edge pixel position value of the object to be measured is output, the actual distance value corresponding to the fitting curve is the actual position value in the detection range of the current material, and therefore the actual width value of the material to be measured can be measured; according to different detection ranges, self-learning is carried out before delivery, every 50MM is divided into a grade from 200MM to 2000MM, fitting verification of the method is carried out, fitted data are stored in a ferroelectric memory, after each time of power-on, a fitting data table is selected according to the corresponding grade, and an actual width value corresponding to the current grade is calculated, so that the measurement error caused by lens distortion is well solved.
Optionally, referring to fig. 5-7, the detecting system further includes a three-dimensional adjusting mechanism 200, wherein the three-dimensional adjusting mechanism 200 is detachably connected to the detecting device 100 for adjusting the position of the detecting device 100 in the X-direction, the Y-direction and the Z-direction.
As shown in fig. 5 to 7, the three-dimensional adjustment mechanism 200 includes: the device comprises a limiting frame 13, a fixing plate 14, a fine adjustment bracket 15, an X-direction adjusting jackscrew 16, an optical axis 17, a Y-direction adjusting jackscrew 18, a separated fixing ring 19, a mounting bottom plate 20, a mounting left side plate 25, a Z-direction adjusting jackscrew 26, a fine adjustment knob 23 and a mounting right side plate 24.
In use, the detection device 100 is fixed to the three-dimensional adjustment mechanism 200 by the fixing plate 14, and when the position of the detection device 100 needs to be adjusted, a screw in a corresponding direction may be screwed.
The three-dimensional adjusting mechanism that this application embodiment provided can assist the light swift debugging equipment of staff and use equipment. When the equipment is installed, errors on a mechanical structure are inevitably generated; the three-dimensional adjusting mechanism can compensate mechanical deviation from the X/Y/Z directions, and finally the material bearing table 500, the material to be detected and the light source are on the same vertical plane, so that linear detection is realized, and the detection precision is improved.
Optionally, referring to fig. 8, the detection system further includes a mounting bracket 300, the mounting bracket 300 spans across the tire production line 400, in fig. 8, the tire production line 400 is a transportation roller way, the mounting bracket 300 is used to fix the detection device 100 at a preset height, and the optical lens 5 of the detection device 100 faces the material carrying table 500 of the production line, in fig. 8, the material carrying table 500 is also a transportation roller way.
Alternatively, the three-dimensional adjustment mechanism 200 is provided with a connector for connection with the mounting bracket 300, and the three-dimensional adjustment mechanism 200 is mounted on the mounting bracket 300 through the connector.
During installation, the three-dimensional adjusting mechanism 200 may be fixed on the mounting bracket 300 through a connecting member, and then the detecting device 100 may be fixed on the three-dimensional adjusting mechanism 200, so that the detecting device 100 may be fixed on the mounting bracket, and the position of the detecting device 100 relative to the material bearing platform 500 and the material to be detected may be adjusted through the three-dimensional adjusting mechanism 200.
Optionally, referring to fig. 8, the material carrying table 500 includes a transportation roller way, the detection system further includes an auxiliary light source 600, the auxiliary light source 600 is installed on the installation support 300 and located below the material carrying table 500, and light of the auxiliary light source 600 penetrates through a gap between rollers of the transportation roller way and irradiates the detection field of the optical lens 5.
The auxiliary light source 600 may be an LED light source.
Optionally, the detection system further includes a display screen 700, and the display screen 700 is disposed on the mounting bracket 300 and is used for displaying data detected by the detection device 100 in real time.
Optionally, the display screen 700 includes a first display screen 701 and a second display screen 702, and the two display screens may be used one or simultaneously as needed.
Further, the detection system further comprises a junction box 800. The junction box 800 is used to connect the detection system to other devices.
By connecting the inspection system with other devices through one terminal block 800, the terminal block 800 improves convenience of use as compared to disposing the device terminals included in the inspection system at different positions.
Further, according to different detection methods and detection environments, the method can comprise the following working processes:
the first working process can be width measurement detection, cord density detection and the like. In order to realize the working process, the detection device 100 of the present application needs to be connected with the mounting bracket 300, cross over the tire production line 400, and be installed at the central position of the tire production line 400; the auxiliary light source 600 is connected with the mounting bracket 300, and the light of the auxiliary light source 600 irradiates in the detection visual field of the optical lens 5 through the conveying roll gap; the detection device 100 is connected with an industrial controller, receives formula information transmitted by the industrial controller, and transmits detection data and detection states to the industrial controller for display; the industrial controller is connected with the factory PLC to control whether the tire production line 400 needs to be stopped or not; the industrial controller is connected with the display screen 700, and the data of actual measurement are directly displayed on the display screen 700, so that the field workers can watch the data conveniently, after the formula information is received, the actual measurement data and the formula information are compared, an alarm lamp on the display screen 700 is controlled to perform sound-light alarm, and the industrial controller comprises the SPRO320 controller, the touch screen controller, the controller and the like.
The second working process can be used for realizing stagger angle detection, slotting detection, hole breaking detection, PE paper foreign matter detection, fixed length detection, angle detection and steel wire leakage detection. In order to realize the working process, the detection device 100 of the present application needs to be connected with the mounting bracket 300, cross over the tire production line 400, and be installed at the central position of the tire production line 400; the auxiliary light source 600 is connected with the mounting bracket 300, and the light of the auxiliary light source 600 irradiates in the detection visual field of the optical lens 5 through the conveying roll gap; the auxiliary light source 600 is connected with the mounting bracket 300, the front surface of the auxiliary light source 600 irradiates the surface of the material to be detected, and the reflection brightness of the foreign matters is increased; the detection device 100 is connected with an encoder, judges the starting and stopping states of the tire production line 400, and acquires longitudinal data through a pulse counting principle; this application detection device 100 is connected with the PC, according to the technological requirement of mill, the formula information of receipt PC transmission, can also carry out data storage, form the report form with the detected data, detected state transmission for the PC, this application detection device 100 is connected with display screen 700, can show actual measurement's data on display screen 700 directly perceivedly, make things convenient for the field work personnel to watch, after receiving formula information, compare measured data and formula information, the alarm lamp on the control display screen 700 carries out audible and visual alarm.
The third working process can be cord center line detection. In order to realize the working process, the detection device 100 of the present application needs to be connected with the mounting bracket 300, cross over the tire production line 400, and be installed at the central position of the tire production line 400; the auxiliary light source 600 is connected with the mounting bracket 300, the side surface of the auxiliary light source 600 irradiates the surface of the material to be detected, and the central convex line of the surface of the material to be detected is lightened; this application detection device 100 links to each other with adhesive tape laminating controller, and the marginal position value and the central point value that detect through this application detection device 100 and wait to detect the material feed back to adhesive tape laminating controller, walk the location by adhesive tape laminating controller control brushless integral type motor and carry out the film laminating.
Finally, it should be noted that all the contents not described in the technical solutions of the present application can be implemented by using the prior art. In addition, the above embodiments are only used for illustrating the technical solutions of the present application, and not for limiting the same; although the present application has been described in detail with reference to the foregoing embodiments, it will be understood by those skilled in the art; the technical solutions described in the foregoing embodiments may still be modified, or some or all of the technical features may be equivalently replaced; and the modifications or the substitutions do not make the essence of the corresponding technical solutions depart from the scope of the technical solutions of the embodiments of the present application.
Claims (10)
1. A testing system for use in a tire manufacturing process, said testing system comprising: the optical lens comprises a support, a shell arranged on the upper surface of the support, a main control board arranged in the shell, a power panel arranged in the shell, and an optical lens arranged below the shell, wherein the optical lens is connected with the shell through an interface flange;
the main control board reaches the dispersion is provided with on the power strip: the color linear sensor, an analog-to-digital converter connected with the color linear sensor, a field programmable gate array chip connected with the analog-to-digital converter, a single chip connected with the field programmable gate array chip, a magnetic coupling isolation trigger connected with the field programmable gate array chip, the field programmable gate array chip is also connected with the color linear sensor, a trigger interface connected with the magnetic coupling isolation trigger, an Ethernet physical layer chip, a memory, a magnetic coupling isolation transceiver and a Bluetooth module connected with the single chip, an Ethernet interface connected with the Ethernet physical layer chip, a transceiver interface connected with the magnetic coupling isolation transceiver and a wireless Bluetooth interface connected with the Bluetooth module;
the optical lens focuses and maps the object image information of the material to be detected to the surface of the color linear sensor through an optical imaging principle to form an optical signal for imaging the material to be detected;
the color linear sensor receives the optical signal imaged by the material to be detected, converts the optical signal imaged by the material to be detected into an electrical signal imaged by the material to be detected according to a photoelectric conversion principle, wherein the electrical signal imaged by the material to be detected is a voltage signal, and is processed by a filter circuit, an amplifying circuit and a comparison circuit to finally form a voltage signal which can be directly received by the analog-to-digital converter;
the analog-to-digital converter converts the voltage signal into a digital image signal through an analog-to-digital conversion principle, and sends the digital image signal to the field programmable gate array chip through three channels;
the field programmable gate array chip drives the color linear sensor to work through a preset first language program, and performs related double sampling processing on the digital image signal sent by the analog-to-digital converter through a sampling principle to form a line of color images; meanwhile, the field programmable gate array chip processes the color image through the preset first language programming, realizes real-time high-speed detection on the material to be detected through a corresponding detection algorithm, and sends a detection result to the single chip microcomputer;
the single chip microcomputer is communicated with other external equipment through a preset second language program, and the detection result is sent to the Ethernet physical layer chip, the magnetic coupling isolation transceiver and the Bluetooth module so as to be sent through an Ethernet interface connected with the Ethernet physical layer chip, a transceiver interface connected with the magnetic coupling isolation transceiver and a wireless Bluetooth interface connected with the Bluetooth module;
the magnetic coupling isolation trigger is used for receiving an externally connected encoder signal and also can send a synchronous trigger signal to be connected with another detection system, and the field programmable gate array chip completes synchronous detection through the preset first language programming.
2. The detection system of claim 1, wherein the magnetically-coupled isolation transceiver comprises at least one of a magnetically-coupled isolation controller area network transceiver and a magnetically-coupled isolation 485 transceiver;
the magnetic coupling isolation controller local area network transceiver is connected with a controller local area network transceiver interface;
the magnetic coupling isolation 485 transceiver is connected with a 485 transceiver interface;
the preset first language is a Verilog hardware description language;
the preset second language is C language.
3. The inspection system of claim 1, further comprising a mounting bracket spanning a tire production line, the mounting bracket configured to secure the inspection device at a predetermined height, and wherein the optical lens of the inspection device faces a material support platform of the production line.
4. The inspection system of claim 3, further comprising a three-dimensional adjustment mechanism removably coupled to the inspection device for adjusting the position of the inspection device in the X, Y, and Z directions.
5. The detection system according to claim 4, wherein the three-dimensional adjustment mechanism is provided with a connection for connection with the mounting bracket, the three-dimensional adjustment mechanism being mounted on the mounting bracket via the connection.
6. The detection system according to claim 3, wherein the material bearing table comprises a transport roller way, the detection system further comprises an auxiliary light source, the auxiliary light source is mounted on the mounting bracket and located below the material bearing table, and light rays of the auxiliary light source penetrate through a roller gap of the transport roller way and irradiate in a detection view of the optical lens.
7. The detection system according to claim 6, wherein the detection device further comprises two collimated laser lamps, the two collimated laser lamps are arranged on two sides of the optical lens, and a connecting line of the two collimated laser lamps is parallel to the roll gap.
8. The detection system according to claim 1, wherein an anti-smash sheath is arranged on the outer side of the optical lens, and the anti-smash sheath is used for preventing the optical lens from being damaged.
9. The detection system of claim 1, further comprising a heat sink disposed on the housing.
10. The detection system according to claim 3, further comprising a display screen disposed on the mounting bracket for displaying data detected by the detection device in real time.
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| CN202110789029.2A CN113503922A (en) | 2021-07-13 | 2021-07-13 | Detection system used in tire production process |
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| CN202110789029.2A CN113503922A (en) | 2021-07-13 | 2021-07-13 | Detection system used in tire production process |
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