CN114392940B - Pin detection method and device for special-shaped component - Google Patents
Pin detection method and device for special-shaped component Download PDFInfo
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- CN114392940B CN114392940B CN202111505847.1A CN202111505847A CN114392940B CN 114392940 B CN114392940 B CN 114392940B CN 202111505847 A CN202111505847 A CN 202111505847A CN 114392940 B CN114392940 B CN 114392940B
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- 238000001514 detection method Methods 0.000 title claims abstract description 62
- 238000012545 processing Methods 0.000 claims abstract description 26
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- 239000000758 substrate Substances 0.000 claims description 12
- 238000005259 measurement Methods 0.000 claims description 9
- 230000000007 visual effect Effects 0.000 claims description 9
- 230000007246 mechanism Effects 0.000 claims description 6
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Classifications
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B07—SEPARATING SOLIDS FROM SOLIDS; SORTING
- B07C—POSTAL SORTING; SORTING INDIVIDUAL ARTICLES, OR BULK MATERIAL FIT TO BE SORTED PIECE-MEAL, e.g. BY PICKING
- B07C5/00—Sorting according to a characteristic or feature of the articles or material being sorted, e.g. by control effected by devices which detect or measure such characteristic or feature; Sorting by manually actuated devices, e.g. switches
- B07C5/36—Sorting apparatus characterised by the means used for distribution
- B07C5/361—Processing or control devices therefor, e.g. escort memory
- B07C5/362—Separating or distributor mechanisms
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B07—SEPARATING SOLIDS FROM SOLIDS; SORTING
- B07C—POSTAL SORTING; SORTING INDIVIDUAL ARTICLES, OR BULK MATERIAL FIT TO BE SORTED PIECE-MEAL, e.g. BY PICKING
- B07C5/00—Sorting according to a characteristic or feature of the articles or material being sorted, e.g. by control effected by devices which detect or measure such characteristic or feature; Sorting by manually actuated devices, e.g. switches
- B07C5/36—Sorting apparatus characterised by the means used for distribution
- B07C5/38—Collecting or arranging articles in groups
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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
- G01B11/002—Measuring arrangements characterised by the use of optical techniques for measuring two or more coordinates
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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
- G01B11/14—Measuring arrangements characterised by the use of optical techniques for measuring distance or clearance between spaced objects or spaced apertures
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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
- G01B11/28—Measuring arrangements characterised by the use of optical techniques for measuring areas
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- G—PHYSICS
- G01—MEASURING; TESTING
- G01N—INVESTIGATING OR ANALYSING MATERIALS BY DETERMINING THEIR CHEMICAL OR PHYSICAL PROPERTIES
- G01N21/00—Investigating or analysing materials by the use of optical means, i.e. using sub-millimetre waves, infrared, visible or ultraviolet light
- G01N21/84—Systems specially adapted for particular applications
- G01N21/88—Investigating the presence of flaws or contamination
- G01N21/8806—Specially adapted optical and illumination features
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- G—PHYSICS
- G01—MEASURING; TESTING
- G01N—INVESTIGATING OR ANALYSING MATERIALS BY DETERMINING THEIR CHEMICAL OR PHYSICAL PROPERTIES
- G01N21/00—Investigating or analysing materials by the use of optical means, i.e. using sub-millimetre waves, infrared, visible or ultraviolet light
- G01N21/84—Systems specially adapted for particular applications
- G01N21/88—Investigating the presence of flaws or contamination
- G01N21/94—Investigating contamination, e.g. dust
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- G—PHYSICS
- G01—MEASURING; TESTING
- G01N—INVESTIGATING OR ANALYSING MATERIALS BY DETERMINING THEIR CHEMICAL OR PHYSICAL PROPERTIES
- G01N21/00—Investigating or analysing materials by the use of optical means, i.e. using sub-millimetre waves, infrared, visible or ultraviolet light
- G01N21/84—Systems specially adapted for particular applications
- G01N21/88—Investigating the presence of flaws or contamination
- G01N21/95—Investigating the presence of flaws or contamination characterised by the material or shape of the object to be examined
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- G—PHYSICS
- G01—MEASURING; TESTING
- G01N—INVESTIGATING OR ANALYSING MATERIALS BY DETERMINING THEIR CHEMICAL OR PHYSICAL PROPERTIES
- G01N21/00—Investigating or analysing materials by the use of optical means, i.e. using sub-millimetre waves, infrared, visible or ultraviolet light
- G01N21/84—Systems specially adapted for particular applications
- G01N21/88—Investigating the presence of flaws or contamination
- G01N21/8806—Specially adapted optical and illumination features
- G01N2021/8841—Illumination and detection on two sides of object
Abstract
The invention discloses a stitch detection method and device of a special-shaped component, wherein the device comprises an industrial personal computer, a motion control system, an image acquisition system and a clamping system; the industrial personal computer is used for controlling the work of other systems; the clamping system is arranged on the motion control system and used for clamping and placing the device to be tested, and the motion control system is used for driving the clamping system to move within a certain range; the image acquisition system is used for acquiring the stitch area image of the device to be detected, transmitting the image information to the industrial personal computer for processing, and the industrial personal computer completes stitch detection according to the image information acquired by the image acquisition system. The invention greatly reduces the workload of staff, improves the economic benefit of enterprises, can adapt to the detection of various abnormal-shaped components, has flexible and adjustable detection precision, can be flexibly configured on an automatic production line, and is suitable for the construction of intelligent factories, unmanned production lines and the like in the future.
Description
Technical Field
The invention relates to the field of image detection, in particular to a stitch detection method and device for a special-shaped component.
Background
At present, most of the surface mounting devices can only mount some electronic components meeting industry standards, the surface mounting of special-shaped components is carried out manually, the process often occupies more than half of the surface mounting workload of the whole PCB, the production speed and quality are greatly influenced, the economic benefit of products can be influenced, in addition, in the process of inserting, workers need naked eyes to test the pin quality of the inserting, and a series of problems of high intensity, long time, high error rate, high product reject ratio and the like of manual operation can be brought. In general, the detection of the pins of the special-shaped components before the insertion is a crucial step for the whole process of mounting the insertion, and the good performance of the pins of the special-shaped components is the basis of the insertion work and is the guarantee of the product quality of the PCB.
At present, a part of practical methods replace a manual stitch detection method by adopting a digital image processing mode, the methods mainly collect images from the side surfaces of the stitches and detect the relevant integrity of the stitches by an image processing technology, but the clamping device required by the mode is complex, and the image processing of the obtained two-dimensional images of the stitches is complex. Some of the detection methods also use a detection clamp to directly carry out power-on test on the pins and collect the power-on level to judge the quality of the pins, but cannot obtain the quality information of dirt of the pins and bending of the pins, so that the test stability is not high.
Disclosure of Invention
In order to overcome the defects in the prior art, the invention provides a pin detection method of a special-shaped component, which adopts a pin detection device of the special-shaped component comprising an industrial personal computer, a motion control system, an image acquisition system and a clamping system, and comprises the following steps:
s1, initializing and adjusting an industrial personal computer and an image acquisition system;
s2, selecting or resetting a stitch area template matched with the device to be tested in the industrial personal computer, and setting related parameters;
s3, conveying the device to be tested to a material taking position of the clamping system by an external feeding mechanism, controlling the clamping system to move to the material taking position by the industrial personal computer through the motion control system, clamping the device to be tested, and further enabling the clamping system to move to a photographing position after clamping is finished;
s4, the industrial personal computer controls the image acquisition system to complete photographing of the device to be tested at the photographing position, acquires the stitch area image of the device to be tested, and transmits the photographed image information to the industrial personal computer;
s5, the industrial personal computer carries out visual algorithm processing on the shot image information, compares the processed stitch area image of the device to be tested with the pre-stored stitch area template image, and judges whether the stitch area of the device to be tested is qualified or not according to a comparison result;
s6, after detection is completed, storing a judging result of whether the device is qualified into a database, and sending a motion control signal generated by the judging result to a motion control system;
s7, for qualified devices, the industrial personal computer controls the clamping system to move to the plug-in position through the motion control system to complete subsequent plug-ins, and for unqualified devices, the industrial personal computer controls the clamping system to move to the waste throwing position through the motion control system to discard the unqualified devices;
and S8, the industrial personal computer controls the motion control system to move the clamping system to a waiting position so as to wait for detection of the next device to be detected, and if the stitch area template needs to be replaced before the next device to be detected is detected, the step S1 is returned, and if the stitch area template does not need to be replaced, the step S3 is returned until detection of all the devices to be detected is completed.
In some embodiments, step S5 specifically includes:
s51, firstly smoothing and denoising the image information of the stitch region by using a mean value filtering algorithm, then carrying out gray morphology open operation processing, and then carrying out gray value linear transformation on the image information after the open operation processing;
s52, if no mark point exists in the image information, directly entering a step S53, if the mark point exists in the image information, carrying out area measurement, position deviation detection and point measurement on the mark lighting spot area, and judging whether the mark point is qualified or not according to a measurement result;
s53, selecting a preliminary stitch region from the image information by using a local dynamic threshold segmentation method;
s54, performing open operation processing on the image of the preliminary stitch region selected in the step S53 so as to break the adhesion region between the stitch edge and the element base in the image;
s55, if no qualified mark point exists in the image information, directly entering a step S56, and if the qualified mark point exists in the image information, assisting in positioning the stitch area by means of the mark point;
s56, performing region-of-interest frame selection on the preliminary stitch region, so as to accurately select the stitch region;
s57, extracting quality attribute data of the stitch region image obtained in the step S56, comparing the quality attribute data with related data of a preset stitch region template image, judging that the device to be tested is unqualified and ending the step S5 when the similarity of the quality attribute data and the related data is smaller than a preset threshold value, otherwise, entering the step S58;
s58, each stitch bright spot area in the stitch area image corresponds to one stitch, area filling is carried out on each stitch bright spot area in the stitch area image, then feature extraction is carried out on each stitch bright spot area after filling is finished, the extracted feature parameters are compared with a preset parameter threshold value, and whether the device to be tested is qualified or not is judged according to a comparison result.
In some embodiments, step S58 specifically includes:
after each stitch bright spot area is subjected to area filling, calculating the total number of stitch bright spot areas, and measuring the moment, the area and the central coordinate offset of each stitch bright spot area;
if the total number of the stitch bright spot areas is consistent with the preset number, and the measured distance, area and center coordinate offset of each stitch bright spot area are respectively in the range of the preset distance threshold, area threshold and center coordinate offset threshold, judging that the device to be tested is qualified, otherwise, judging that the device to be tested is unqualified.
In some embodiments, in step S2, it is first determined whether the pin area template data of the same type as the device to be tested is stored in the industrial personal computer, if yes, a corresponding pin area template is selected, and if not, the pin area template is reset according to the following steps:
and step S3 and step S4 are executed on the device to be tested, the processed stitch area image of the device to be tested is obtained, a worker carries out manual judgment according to the processed stitch area image of the device to be tested, if the device to be tested is judged to be qualified manually, the industrial personal computer stores related data of the device to be tested, a new stitch area template is built according to the related data, step S6 is carried out, and if the device to be tested is judged to be unqualified, step S6 is carried out directly.
The invention further provides a pin detection device of the special-shaped component, which comprises an industrial personal computer, a motion control system, an image acquisition system and a clamping system;
the industrial personal computer is respectively and electrically connected with the motion control system, the image acquisition system and the clamping system and is used for controlling the work of other systems;
the clamping system is arranged on the motion control system and is used for clamping and placing a device to be tested, and the motion control system is used for driving the clamping system to move within a certain range;
the image acquisition system is used for acquiring the pin area image of the device to be detected and transmitting the image information to the industrial personal computer for processing;
the pin detection device of the special-shaped component completes pin detection according to the pin detection method of the special-shaped component.
In some embodiments, the motion control system further comprises a base plate, the motion control system being fixedly mounted on the base plate;
the image acquisition system comprises a mounting frame, an industrial camera and a linear laser light source;
the bottom end of the mounting frame is fixed on the substrate, and the middle part of the top end of the mounting frame is used as a photographing position of the device to be tested;
the linear laser light source is fixedly arranged at the top end of the mounting frame and faces the photographing position from the side face;
the industrial camera is positioned at the bottom end of the mounting frame and faces the photographing position from the bottom surface.
In some embodiments, the image acquisition system further comprises a loading rail and an optical fiber sensor, wherein the loading rail is fixedly installed on the mounting frame or fixedly installed on the substrate through a support column; the inlet end of the feeding track is matched with an external feeding mechanism, the outlet end of the feeding track is used as a material taking position, and the optical fiber sensor is fixedly arranged on one side of the material taking position; the optical fiber sensor is used for transmitting information to the industrial personal computer when detecting that the device to be detected reaches the material taking position, and the industrial personal computer further controls the clamping system to move to the material taking position through the motion control system so as to clamp the device to be detected.
In some embodiments, the clamping system comprises a connecting plate, a descending cylinder, a clamping cylinder, and a clamping jaw; the connecting plate is connected with the tail end of the motion control system, the descending cylinder is fixed on the connecting plate, the clamping cylinder is positioned below the descending cylinder, and the clamping jaw is positioned below the clamping cylinder; the descending cylinder is used for controlling the clamping cylinder below and the clamping jaw to move up and down integrally, and the clamping cylinder is used for controlling the clamping jaw to clamp and place the device to be tested.
In some embodiments, the image acquisition system includes two industrial cameras, two linear laser light sources, two feeding tracks and a plurality of optical fiber sensors, wherein the two linear laser light sources are respectively positioned at the left side and the right side of the photographing position, the two feeding tracks are parallel to each other, and the two industrial cameras are placed parallel to each other and respectively correspond to the outlet ends of the two feeding tracks;
the clamping system comprises two descending air cylinders, two clamping air cylinders and two clamping jaws, so that two sets of clamping pieces are formed, each set of clamping piece works respectively, and when the clamping system moves to a material taking position, the two sets of clamping pieces correspond to the positions of the two feeding tracks respectively.
In some embodiments, a hub and a placement box are also included; the industrial personal computer is directly connected with the hub through a data line, the hub is respectively connected with the image acquisition system and the motion control system through a data line, and the motion control system is directly connected with the clamping system through a data line; the placement box is fixedly arranged above the substrate.
Compared with the prior art, the invention has the beneficial effects that:
compared with the traditional manual detection mode and other mechanical detection modes, the stitch detection method and device for the special-shaped components provided by the invention greatly lighten the workload of workers, improve the economic benefit of enterprises, adapt to the detection of various special-shaped components, have flexible and adjustable detection precision, adapt to different application scenes, and can be flexibly configured on an automatic production line to be matched with the construction of future intelligent factories, unmanned production lines and the like.
Drawings
FIG. 1 is a flow chart of a method for detecting pins of a special-shaped component according to the present invention;
FIG. 2 is a flowchart showing the steps of step S5 in FIG. 1;
FIG. 3 is a schematic diagram of a pin area after photographing and image processing in an embodiment;
fig. 4 is a schematic diagram of a pin detection device of a special-shaped component provided by the invention;
FIG. 5 is an enlarged view of the image acquisition system of FIG. 4;
FIG. 6 is an enlarged view of the clamping system of FIG. 4;
fig. 7 is a top view of a part of a structure of a pin detection device of a special-shaped component provided by the invention.
Reference numerals illustrate: 1. an industrial personal computer; 2. a hub; 3. a motion control system; 4. an image acquisition system; 5. a clamping system; 6. placing a box; 7. a substrate; 3.1, a first shaft; 3.2, a second shaft; 3.3, a third shaft; 4.1, a feeding track; 4.2, an optical fiber sensor; 4.3, industrial cameras; 4.4, mounting rack; 4.5, a linear laser source; 5.1, connecting the plates; 5.2, a downlink cylinder; 5.3, clamping the air cylinder; and 5.4, clamping jaws.
Detailed Description
In order to make the technical means, the creation characteristics, the achievement of the purpose and the effect of the present invention easy to understand, the following further describes how the present invention is implemented with reference to the accompanying drawings and the detailed description.
Referring to fig. 1, another aspect of the present invention provides a method for detecting pins of a special-shaped component, which includes an industrial personal computer 1, a motion control system 3, an image acquisition system 4, and a clamping system 5, and includes the following steps:
s1, initializing and adjusting the industrial personal computer 1 and the image acquisition system 4;
s2, selecting or resetting a stitch area template matched with the device to be tested in the industrial personal computer 1, and setting related parameters;
s3, conveying the device to be tested to a material taking position of the clamping system 5 by an external feeding mechanism, controlling the clamping system 5 to move to the material taking position and clamping the device to be tested by the industrial personal computer 1 through the motion control system 3, and further enabling the clamping system 5 to move to a photographing position after clamping is finished;
s4, the industrial personal computer 1 controls the image acquisition system 4 to complete photographing of the device to be tested at the photographing position, acquires a stitch area image of the device to be tested, and transmits the photographed image information to the industrial personal computer 1;
s5, the industrial personal computer 1 carries out visual algorithm processing on the shot image information, compares the processed stitch region image of the device to be tested with the pre-stored stitch region template image, and judges whether the stitch region of the device to be tested is qualified or not according to a comparison result;
s6, after detection is completed, storing a judging result of whether the device is qualified into a database, and sending a motion control signal generated by the judging result to the motion control system 3;
s7, for qualified devices, the industrial personal computer 1 controls the clamping system 5 to move to a plug-in position through the motion control system 3 to complete subsequent plug-ins, and for unqualified devices, the industrial personal computer 1 controls the clamping system 5 to move to a waste throwing position through the motion control system 3 to discard the unqualified devices;
s8, the industrial personal computer 1 controls the motion control system 3 to move the clamping system 5 to a waiting position so as to wait for detection of a next device to be detected, and before the next device to be detected is detected, if the stitch area template needs to be replaced, the step S1 is returned, and if the stitch area template does not need to be replaced, the step S3 is returned until detection of all the devices to be detected is completed.
With further reference to fig. 2, step S5 preferably specifically includes:
s51, firstly smoothing and denoising the image information of the stitch region by using a mean value filtering algorithm, then carrying out gray morphology open operation processing, and then carrying out gray value linear transformation on the image information after the open operation processing;
s52, if no mark point exists in the image information, directly entering a step S53, if the mark point (mark point) exists in the image information, carrying out area measurement, position deviation detection and point measurement on the mark spot area, and judging whether the mark point is qualified or not according to a measurement result;
s53, selecting a preliminary stitch region from the image information by using a local dynamic threshold segmentation method;
s54, performing open operation processing on the image of the preliminary stitch region selected in the step S53 so as to break the adhesion region between the stitch edge and the element base in the image;
s55, if no qualified mark point exists in the image information, directly entering a step S56, and if the qualified mark point exists in the image information, assisting in positioning the stitch area by means of the mark point;
s56, performing region of interest (ROI) frame selection on the preliminary stitch region so as to accurately select the stitch region;
s57, extracting quality attribute data of the stitch region image obtained in the step S56, comparing the quality attribute data with related data of a preset stitch region template image, judging that the device to be tested is unqualified and ending the step S5 when the similarity of the quality attribute data and the related data is smaller than a preset threshold value, otherwise, entering the step S58;
s58, each stitch bright spot area in the stitch area image corresponds to one stitch, area filling is carried out on each stitch bright spot area in the stitch area image, then feature extraction is carried out on each stitch bright spot area after filling is finished, the extracted feature parameters are compared with a preset parameter threshold value, and whether the device to be tested is qualified or not is judged according to a comparison result.
Preferably, step S58 specifically includes:
after each stitch bright spot area is subjected to area filling, calculating the total number of stitch bright spot areas, and measuring the moment, the area and the central coordinate offset of each stitch bright spot area;
if the total number of the stitch bright spot areas is consistent with the preset number, and the measured distance, area and center coordinate offset of each stitch bright spot area are respectively in the range of the preset distance threshold, area threshold and center coordinate offset threshold, judging that the device to be tested is qualified, otherwise, judging that the device to be tested is unqualified.
Referring to fig. 3, a schematic diagram of a stitch area after photographing and image processing in an embodiment is shown. It can be seen that the figure has a plurality of bright spots on the left side, which are similar to rectangles, and two large circular bright spots on the right side, wherein the two circular bright spots on the right side are the mark bright spots, the plurality of bright spots on the left side are the stitch bright spots, and each stitch bright spot corresponds to one stitch of the device.
Further, in step S2, it is first determined whether the pin area template data of the same type as the device to be tested is stored in the industrial personal computer 1, if yes, a corresponding pin area template is selected, and if not, the pin area template is reset according to the following steps:
and step S3 and step S4 are executed on the device to be tested, the processed stitch area image of the device to be tested is obtained, a worker carries out manual judgment according to the processed stitch area image of the device to be tested, if the device to be tested is judged to be qualified manually, the industrial personal computer 1 stores related data of the device to be tested, a new stitch area template is built accordingly, step S6 is carried out, and if the device to be tested is judged to be unqualified, step S6 is carried out directly.
It will be appreciated that when resetting the stitch region template, the processing steps of the stitch region image are similar to the processing manners in steps S51-S56, and finally, the region of interest (ROI) is also adopted for framing, so as to obtain an accurate stitch region image for manual judgment by a worker, and if the device to be tested is qualified, the stitch region image data and related parameters are saved, so as to be used as a new stitch region template.
Referring to fig. 4-7, the invention further provides a pin detection device for special-shaped components, which comprises an industrial personal computer 1, a motion control system 3, an image acquisition system 4 and a clamping system 5; the industrial personal computer 1 is respectively and electrically connected with the motion control system 3, the image acquisition system 4 and the clamping system 5, and the industrial personal computer 1 is used for controlling the work of other systems; the clamping system 5 is arranged on the motion control system 3, the clamping system 5 is used for clamping and placing a device to be tested, and the motion control system 3 is used for driving the clamping system 5 to move within a certain range; the image acquisition system 4 is used for acquiring the pin area image of the device to be detected, transmitting the image information to the industrial personal computer 1 for processing, and the pin detection device of the special-shaped component completes pin detection according to the pin detection method of the special-shaped component.
Further, the pin detection device of the special-shaped component further comprises a substrate 7, and the motion control system 3 is fixedly arranged on the substrate 7; the image acquisition system 4 comprises a mounting frame 4.4, an industrial camera 4.3 and a linear laser light source 4.5; the bottom end of the mounting frame 4.4 is fixed on the base plate 7, and the middle part of the top end of the mounting frame 4.4 is used as a photographing position of the device to be tested; the linear laser light source 4.5 is fixedly arranged at the top end of the mounting frame 4.4 and faces the photographing position from the side face; the industrial camera 4.3 is located at the bottom end of the mounting frame 4.4 and is facing the photographing position from the bottom surface.
Preferably, the substrate 7 is provided with an opening at the position where the industrial camera 4.3 is arranged, and the industrial camera 4.3 is fixedly arranged inside the opening and is positioned below the plane of the substrate 7; the linear laser light source 4.5 is for emitting a red linear laser light. The invention adopts red linear laser as a light source to shine, so that the industrial camera 4.3 can acquire clear and bright images of pin areas of components.
Preferably, referring to fig. 5, the image acquisition system 4 further includes a feeding track 4.1 and an optical fiber sensor 4.2, where the feeding track 4.1 is fixedly installed on the mounting frame 4.4 or fixedly installed on the substrate 7 through a support column; the inlet end of the feeding track 4.1 is matched with an external feeding mechanism, the outlet end of the feeding track 4.1 is used as a material taking position, and the optical fiber sensor 4.2 is fixedly arranged on one side of the material taking position; the optical fiber sensor 4.2 is used for transmitting information to the industrial personal computer 1 when detecting that the device to be tested reaches the material taking position, and the industrial personal computer 1 further controls the clamping system 5 to move to the material taking position through the motion control system 3 so as to clamp the device to be tested.
Referring to fig. 6, the clamping system 5 includes a connecting plate 5.1, a descending cylinder 5.2, a gripping cylinder 5.3 and a clamping jaw 5.4; the connecting plate 5.1 is connected with the tail end of the motion control system 3, the descending cylinder 5.2 is fixed on the connecting plate 5.1, the clamping cylinder 5.3 is positioned below the descending cylinder 5.2, and the clamping jaw 5.4 is positioned below the clamping cylinder 5.3; the descending cylinder 5.2 is used for controlling the clamping cylinder 5.3 below and the clamping jaw 5.4 to move up and down integrally, and the clamping cylinder 5.3 is used for controlling the clamping jaw 5.4 to finish clamping and placing the device to be tested.
Preferably, the image acquisition system 4 comprises two industrial cameras 4.3, two linear laser light sources 4.5, two feeding tracks 4.1 and a plurality of optical fiber sensors 4.2, wherein the two linear laser light sources 4.5 are respectively positioned at the left side and the right side of the photographing position, the two feeding tracks 4.1 are parallel to each other, and the two industrial cameras 4.3 are mutually parallel and respectively correspond to the outlet ends of the two feeding tracks 4.1; the clamping system 5 comprises two downlink air cylinders 5.2, two clamping air cylinders 5.3 and two clamping jaws 5.4, so that two sets of clamping pieces are formed, each set of clamping pieces work respectively, and when the clamping system 5 moves to a material taking position, the two sets of clamping pieces correspond to the positions of the two feeding rails 4.1 respectively.
Further, the pin detection device of the special-shaped component also comprises a hub 2 and a placement box 6; the industrial personal computer 1 is directly connected with the hub 2 through a data line, the hub 2 is respectively connected with the image acquisition system 4 and the motion control system 3 through a data line, and the motion control system 3 is directly connected with the clamping system 5 through a data line; the placement box 6 is fixedly arranged above the substrate 7, and the placement box 6 is used for placing unqualified devices.
Alternatively, the motion control system 3 may be of a three-axis configuration as shown, including a first axis 3.1, a second axis 3.2 and a third axis 3.3, with the motion of the clamping system 5 being controlled between positions by the co-operation of the three axes. It can be understood that the traditional plug-in device uses the servo motors placed on three coordinate axes as the motion control units, and directly performs the operation of picking and inserting the components, if the visual detection unit is not provided, the plug-in speed of the automatic plug-in device and the yield of products can be affected once the pins of the components are broken, missing, bending deformation, dirt and the like in the process of the plug-in operation. Therefore, the invention combines the image acquisition system 4 to finish the image detection of the pins of the special-shaped components, can avoid the adverse effects and improve the inserting speed and the yield of products.
It can be understood that in the actual production process, according to different requirements of different PCB boards, the types of components to be inserted are different, so that the problems of irregular bottom shapes of different special-shaped components, small color distinction between pins and components, strong light reflectivity of the pins, incomplete pin length and the like are generated, and the difficulty of a vision processing algorithm is increased; in addition, the influence of external illumination on visual acquisition and lighting can not be completely eliminated in the actual production operation process, and the stability of a visual identification detection algorithm can be influenced, so that the problem of visual detection and lighting of pins of the mounted element becomes a main reason that the special-shaped components are difficult to realize automatic assembly.
The pin detection method and device for the special-shaped component provided by the invention use two red linear lasers as light sources, project the lasers to the pin end part of the special-shaped component from the side, acquire images from the bottom of the component by using an industrial camera to obtain the front needle point image of the pin, process and analyze the front needle point image by using a visual image algorithm, identify the breakage, the loss, the breakage and the like of the pin, detect the bending degree of the pin, the dirt of the base and the algorithm identification of plug-in pins of different types, and completely meet the requirements of the good product plug-in component required by the PCB plug-in. The problems of high working strength, long time, high error rate, high product reject ratio and the like brought by manual operation are solved, and the improvement of economic benefit is also in accordance with the transformation process of an intelligent factory workshop.
In general, the excellent polishing mode adopted by the invention can reduce the complexity and difficulty of algorithm processing, and combines various visual processing algorithms, thereby greatly improving the accuracy of stitch detection of special-shaped components, greatly reducing the workload of staff and improving the economic benefit of enterprises compared with the traditional manual detection mode and other mechanical detection modes, being applicable to detection of various special-shaped components, having flexible and adjustable detection precision and being applicable to different application scenes.
Finally, it is noted that the above embodiments are only for illustrating the technical solution of the present invention and not for limiting the same, and although the present invention has been described in detail with reference to the preferred embodiments, it should be understood by those skilled in the art that modifications and equivalents may be made thereto without departing from the spirit and scope of the technical solution of the present invention, which is intended to be covered by the scope of the claims of the present invention.
Claims (9)
1. The pin detection method of the special-shaped component is characterized by adopting a pin detection device of the special-shaped component, comprising an industrial personal computer (1), a motion control system (3), an image acquisition system (4) and a clamping system (5), and comprising the following steps:
s1, initializing and adjusting an industrial personal computer (1) and an image acquisition system (4);
s2, selecting or resetting a stitch area template matched with the device to be tested in the industrial personal computer (1), and setting related parameters;
s3, conveying the device to be tested to a material taking position of a clamping system (5) by a feeding mechanism, controlling the clamping system (5) to move to the material taking position and clamping the device to be tested by an industrial personal computer (1) through a motion control system (3), and further enabling the clamping system (5) to move to a photographing position after clamping is finished;
s4, the industrial personal computer (1) controls the image acquisition system (4) to complete photographing of the device to be tested in the photographing position, acquires a stitch area image of the device to be tested, and transmits the photographed image information to the industrial personal computer (1);
s5, the industrial personal computer (1) carries out visual algorithm processing on the shot image information, compares the processed stitch region image of the device to be tested with the pre-stored stitch region template image, and judges whether the stitch region of the device to be tested is qualified or not according to a comparison result;
s6, after detection is completed, storing a judging result of whether the device is qualified into a database, and sending a motion control signal generated by the judging result to a motion control system (3);
s7, for qualified devices, the industrial personal computer (1) controls the clamping system (5) to move to a plug-in position through the motion control system (3) to finish subsequent plug-ins, and for unqualified devices, the industrial personal computer (1) controls the clamping system (5) to move to a waste throwing position through the motion control system (3) to discard the unqualified devices;
s8, the industrial personal computer (1) controls the motion control system (3) to move the clamping system (5) to a waiting position so as to wait for detection of a next device to be detected, if the stitch area template needs to be replaced before the next device to be detected is detected, the step S1 is returned, and if the stitch area template does not need to be replaced, the step S3 is returned until detection of all the devices to be detected is completed;
the step S5 specifically comprises the following steps:
s51, firstly smoothing and denoising the image information of the stitch region by using a mean value filtering algorithm, then carrying out gray morphology open operation processing, and then carrying out gray value linear transformation on the image information after the open operation processing;
s52, if no mark point exists in the image information, directly entering a step S53, if the mark point exists in the image information, carrying out area measurement, position deviation detection and point measurement on the mark lighting spot area, and judging whether the mark point is qualified or not according to a measurement result;
s53, selecting a preliminary stitch region from the image information by using a local dynamic threshold segmentation method;
s54, performing open operation processing on the image of the preliminary stitch region selected in the step S53 so as to break the adhesion region between the stitch edge and the element base in the image;
s55, if no qualified mark point exists in the image information, directly entering a step S56, and if the qualified mark point exists in the image information, assisting in positioning the stitch area by means of the mark point;
s56, performing region-of-interest frame selection on the preliminary stitch region, so as to accurately select the stitch region;
s57, extracting quality attribute data of the stitch region image obtained in the step S56, comparing the quality attribute data with related data of a preset stitch region template image, judging that the device to be tested is unqualified and ending the step S5 when the similarity of the quality attribute data and the related data is smaller than a preset threshold value, otherwise, entering the step S58;
s58, each stitch bright spot area in the stitch area image corresponds to one stitch, area filling is carried out on each stitch bright spot area in the stitch area image, then feature extraction is carried out on each stitch bright spot area after filling is finished, the extracted feature parameters are compared with a preset parameter threshold value, and whether the device to be tested is qualified or not is judged according to a comparison result.
2. The method for inspecting pins of a special-shaped component according to claim 1, wherein step S58 specifically comprises:
after each stitch bright spot area is subjected to area filling, calculating the total number of stitch bright spot areas, and measuring the moment, the area and the central coordinate offset of each stitch bright spot area;
if the total number of the stitch bright spot areas is consistent with the preset number, and the measured distance, area and center coordinate offset of each stitch bright spot area are respectively in the range of the preset distance threshold, area threshold and center coordinate offset threshold, judging that the device to be tested is qualified, otherwise, judging that the device to be tested is unqualified.
3. The method for inspecting pins of a special-shaped component according to claim 2, wherein in step S2, it is firstly determined whether the pin area template data of the same type as the component to be inspected is stored in the industrial personal computer (1), if yes, a corresponding pin area template is selected, and if not, the pin area template is reset according to the following steps:
after the step S3 and the step S4 are executed on the device to be tested, the worker performs manual judgment according to the processed pin area image of the device to be tested, if the device to be tested is judged to be qualified manually, the industrial personal computer (1) stores relevant data of the device to be tested, a new pin area template is built accordingly, the step S6 is performed, and if the device to be tested is judged to be unqualified, the step S6 is performed directly.
4. The stitch detection device of the special-shaped component is characterized by comprising an industrial personal computer (1), a motion control system (3), an image acquisition system (4) and a clamping system (5);
the industrial personal computer (1) is respectively and electrically connected with the motion control system (3), the image acquisition system (4) and the clamping system (5), and the industrial personal computer (1) is used for controlling the work of other systems;
the clamping system (5) is arranged on the motion control system (3), the clamping system (5) is used for clamping and placing a device to be tested, and the motion control system (3) is used for driving the clamping system (5) to move within a certain range;
the image acquisition system (4) is used for acquiring the pin area image of the device to be detected and transmitting the image information to the industrial personal computer (1) for processing;
the pin detection device of the special-shaped component completes pin detection according to the pin detection method of the special-shaped component of any one of claims 1-3.
5. The pin inspection device of a profiled element according to claim 4, further comprising a base plate (7), the motion control system (3) being fixedly mounted on the base plate (7);
the image acquisition system (4) comprises a mounting frame (4.4), an industrial camera (4.3) and a linear laser light source (4.5);
the bottom end of the mounting frame (4.4) is fixed on the substrate (7), and the middle part of the top end of the mounting frame (4.4) is used as a photographing position of a device to be tested;
the linear laser light source (4.5) is fixedly arranged at the top end of the mounting frame (4.4) and faces the photographing position from the side face;
the industrial camera (4.3) is positioned at the bottom end of the mounting frame (4.4) and faces the photographing position from the bottom surface.
6. The pin detection device of the special-shaped component according to claim 5, wherein the image acquisition system (4) further comprises a feeding track (4.1) and an optical fiber sensor (4.2), and the feeding track (4.1) is fixedly installed on the mounting frame (4.4) or fixedly installed on the substrate (7) through a support column; the inlet end of the feeding track (4.1) is matched with an external feeding mechanism, the outlet end of the feeding track (4.1) is used as a material taking position, and the optical fiber sensor (4.2) is fixedly arranged on one side of the material taking position; the optical fiber sensor (4.2) is used for transmitting information to the industrial personal computer (1) when detecting that the device to be detected reaches the material taking position, and the industrial personal computer (1) further controls the clamping system (5) to move to the material taking position through the motion control system (3) so as to complete clamping of the device to be detected.
7. The pin detection device of the special-shaped component according to claim 6, wherein the clamping system (5) comprises a connecting plate (5.1), a descending cylinder (5.2), a clamping cylinder (5.3) and clamping jaws (5.4); the connecting plate (5.1) is connected with the tail end of the motion control system (3), the descending cylinder (5.2) is fixed on the connecting plate (5.1), the clamping cylinder (5.3) is positioned below the descending cylinder (5.2), and the clamping jaw (5.4) is positioned below the clamping cylinder (5.3); the descending cylinder (5.2) is used for controlling the clamping cylinder (5.3) below and the clamping jaw (5.4) to integrally move up and down, and the clamping cylinder (5.3) is used for controlling the clamping jaw (5.4) to finish the operation of clamping and placing a device to be tested.
8. The stitch detection device for the special-shaped component according to claim 7, wherein the image acquisition system (4) comprises two industrial cameras (4.3), two linear laser sources (4.5), two feeding tracks (4.1) and a plurality of optical fiber sensors (4.2), the two linear laser sources (4.5) are respectively positioned at the left side and the right side of the photographing position, the two feeding tracks (4.1) are parallel, the two industrial cameras (4.3) are mutually parallel, and the two industrial cameras (4.3) respectively correspond to the outlet ends of the two feeding tracks (4.1);
the clamping system (5) comprises two descending air cylinders (5.2), two clamping air cylinders (5.3) and two clamping jaws (5.4) so as to form two sets of clamping pieces, each set of clamping pieces respectively work, and when the clamping system (5) moves to a material taking position, the two sets of clamping pieces respectively correspond to the positions of the two feeding rails (4.1).
9. The pin inspection device of the special-shaped component according to claim 5, further comprising a hub (2) and a placement box (6); the industrial personal computer (1) is directly connected with the hub (2) through a data line, the hub (2) is respectively connected with the image acquisition system (4) and the motion control system (3) through the data line, and the motion control system (3) is directly connected with the clamping system (5) through the data line; the placement box (6) is fixedly arranged above the base plate (7).
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