CN117259252A - Disc casting surface defect detection device based on machine vision and use method - Google Patents
Disc casting surface defect detection device based on machine vision and use method Download PDFInfo
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- CN117259252A CN117259252A CN202311483594.1A CN202311483594A CN117259252A CN 117259252 A CN117259252 A CN 117259252A CN 202311483594 A CN202311483594 A CN 202311483594A CN 117259252 A CN117259252 A CN 117259252A
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- 238000005266 casting Methods 0.000 title claims abstract description 384
- 238000001514 detection method Methods 0.000 title claims abstract description 125
- 230000007547 defect Effects 0.000 title claims abstract description 115
- 238000000034 method Methods 0.000 title claims abstract description 17
- 230000007246 mechanism Effects 0.000 claims abstract description 182
- 238000012545 processing Methods 0.000 claims abstract description 58
- 230000005540 biological transmission Effects 0.000 claims abstract description 17
- 230000007306 turnover Effects 0.000 claims abstract description 14
- 238000003860 storage Methods 0.000 claims description 36
- 210000000078 claw Anatomy 0.000 claims description 20
- 230000008569 process Effects 0.000 claims description 8
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- 230000001976 improved effect Effects 0.000 abstract description 20
- 230000002950 deficient Effects 0.000 description 13
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- 238000004519 manufacturing process Methods 0.000 description 7
- 238000012546 transfer Methods 0.000 description 7
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- 238000010521 absorption reaction Methods 0.000 description 2
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- 230000000875 corresponding effect Effects 0.000 description 1
- 230000002349 favourable effect Effects 0.000 description 1
- 230000006698 induction Effects 0.000 description 1
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- 239000002994 raw material Substances 0.000 description 1
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- 239000004576 sand Substances 0.000 description 1
- 239000007858 starting material Substances 0.000 description 1
- UONOETXJSWQNOL-UHFFFAOYSA-N tungsten carbide Chemical compound [W+]#[C-] UONOETXJSWQNOL-UHFFFAOYSA-N 0.000 description 1
- 230000000007 visual effect Effects 0.000 description 1
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
- B07C5/34—Sorting according to other particular properties
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B07—SEPARATING SOLIDS FROM SOLIDS; SORTING
- B07C—POSTAL SORTING; SORTING INDIVIDUAL ARTICLES, OR BULK MATERIAL FIT TO BE SORTED PIECE-MEAL, e.g. BY PICKING
- B07C5/00—Sorting according to a characteristic or feature of the articles or material being sorted, e.g. by control effected by devices which detect or measure such characteristic or feature; Sorting by manually actuated devices, e.g. switches
- B07C5/02—Measures preceding sorting, e.g. arranging articles in a stream orientating
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B07—SEPARATING SOLIDS FROM SOLIDS; SORTING
- B07C—POSTAL SORTING; SORTING INDIVIDUAL ARTICLES, OR BULK MATERIAL FIT TO BE SORTED PIECE-MEAL, e.g. BY PICKING
- B07C5/00—Sorting according to a characteristic or feature of the articles or material being sorted, e.g. by control effected by devices which detect or measure such characteristic or feature; Sorting by manually actuated devices, e.g. switches
- B07C5/36—Sorting apparatus characterised by the means used for distribution
- B07C5/361—Processing or control devices therefor, e.g. escort memory
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B07—SEPARATING SOLIDS FROM SOLIDS; SORTING
- B07C—POSTAL SORTING; SORTING INDIVIDUAL ARTICLES, OR BULK MATERIAL FIT TO BE SORTED PIECE-MEAL, e.g. BY PICKING
- B07C5/00—Sorting according to a characteristic or feature of the articles or material being sorted, e.g. by control effected by devices which detect or measure such characteristic or feature; Sorting by manually actuated devices, e.g. switches
- B07C5/36—Sorting apparatus characterised by the means used for distribution
- B07C5/361—Processing or control devices therefor, e.g. escort memory
- B07C5/362—Separating or distributor mechanisms
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B07—SEPARATING SOLIDS FROM SOLIDS; SORTING
- B07C—POSTAL SORTING; SORTING INDIVIDUAL ARTICLES, OR BULK MATERIAL FIT TO BE SORTED PIECE-MEAL, e.g. BY PICKING
- B07C5/00—Sorting according to a characteristic or feature of the articles or material being sorted, e.g. by control effected by devices which detect or measure such characteristic or feature; Sorting by manually actuated devices, e.g. switches
- B07C5/36—Sorting apparatus characterised by the means used for distribution
- B07C5/38—Collecting or arranging articles in groups
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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
- B07C2501/00—Sorting according to a characteristic or feature of the articles or material to be sorted
- B07C2501/0063—Using robots
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- Investigating Materials By The Use Of Optical Means Adapted For Particular Applications (AREA)
Abstract
The invention discloses a device for detecting surface defects of disc castings based on machine vision and a using method thereof, and belongs to the field of automatic detection of casting defects. The invention discloses a machine vision-based disc casting surface defect detection device, which is characterized in that: the casting lifting device comprises a controller, a casting rotating lifting mechanism, a casting sucking clamping mechanism, a casting transmission turning mechanism and a casting detection sorting mechanism, wherein the casting rotating lifting mechanism, the casting sucking clamping mechanism, the casting transmission turning mechanism and the casting detection sorting mechanism are electrically connected with the controller; the casting sucking and clamping mechanism is used for transferring castings in the casting rotating and lifting mechanism to the casting detecting and sorting mechanism for detection; the casting rotation lifting mechanism comprises a driving mechanism, and the driving mechanism is used for rotating and lifting the casting. The casting transmission turn-over mechanism is used for moving, placing and turning over so as to detect surface defects of the front surface and the back surface of the casting and sort the casting in the casting detection sorting mechanism. The invention has the main purposes of batch processing of castings, reducing the manual workload and improving the working efficiency. Meanwhile, the efficiency of moving and placing and processing the castings is improved.
Description
Technical Field
The invention relates to the technical field of automatic detection of casting defects, in particular to a device for detecting surface defects of disc castings based on machine vision and a using method thereof.
Background
Casting is one of the basic processes of the modern device manufacturing industry, and is widely applied in the industries of machinery manufacturing industry, automobile manufacturing industry, building industry and the like. However, the disc castings often have high quality requirements, and generally do not allow casting defects such as shrinkage (porosity), air holes, sand inclusion, rib cracks and the like. However, these defects are inevitably present due to problems in the raw materials or the casting process. Surface defects not only affect the appearance of the product, but also affect various properties of the product. Therefore, the surface defects of the disc casting must be inspected in time during the early stages of production. The traditional manual detection method is to identify defects on the surface of the casting by naked eyes, select unqualified castings and mark the unqualified castings. The process has the problems of high labor cost, low efficiency, poor consistency, easy omission, poor accuracy, poor traceability and the like. On the other hand, the vision system has been gradually applied to various industries because of its advantages of high speed, high accuracy, good repeatability and traceability in surface defect detection.
Chinese patent CN114088727a discloses a novel automatic turning device for detecting surface defects of castings, which comprises a pair of grabbing detection mechanisms, a vertical turning mechanism and a conveyor belt mechanism, wherein the grabbing detection mechanisms and the vertical turning mechanism are arranged up and down; the grabbing detection mechanism is used for detecting the surface defects of the casting twice, and the vertical turnover mechanism is arranged between the two detection mechanisms for turning over the casting, so that the defect detection of the casting without dead angles in all directions can be realized; the defective castings can be transferred to the defective product area through the grabbing detection mechanism, full automation in the field of casting defect detection is realized, an intelligent algorithm for identifying the defects on the surfaces of the castings is matched, automatic intelligent detection of the castings with high speed and accuracy is realized, time consumption for detecting the surfaces of the castings is greatly shortened, production efficiency of enterprises is improved, labor cost is saved, and production cost is reduced.
However, the automatic continuous conveying of the castings to the detection mechanism cannot be realized in the scheme, the castings still need to be manually placed on the conveyor belt, the treatment efficiency is low, and batch treatment of the castings is not facilitated.
Disclosure of Invention
Technical problem to be solved by the invention
The invention aims to overcome the defects in the prior art, provides a device for detecting the surface defects of disc castings based on machine vision and a use method thereof, solves the problems of large manual workload and low degree of automation caused by manually placing castings, improves the processing efficiency of the castings, and realizes batch processing of the castings. Meanwhile, the castings are located at the positions to be clamped by rotating and lifting, so that the efficiency of sucking, clamping and moving the castings by the casting sucking and clamping mechanism is improved, and the treatment efficiency of the castings is improved.
Technical proposal
In order to achieve the purpose, the technical scheme provided by the invention is that the device for detecting the surface defects of the disc castings based on machine vision and the using method thereof;
the invention discloses a machine vision-based disc casting surface defect detection device, which comprises a controller, a casting rotating and lifting mechanism, a casting sucking and clamping mechanism, a casting transmission turning mechanism and a casting detection and sorting mechanism, wherein the casting rotating and lifting mechanism, the casting sucking and clamping mechanism, the casting transmission turning mechanism and the casting detection and sorting mechanism are electrically connected with the controller; the casting sucking and clamping mechanism is used for transferring castings in the casting rotating and lifting mechanism to the casting detecting and sorting mechanism for detection; the casting rotation lifting mechanism comprises a driving mechanism, and the driving mechanism is used for rotating and lifting the casting.
As a still further improvement of the present invention, the driving mechanism includes a first driving mechanism for rotating the casting; the first driving mechanism comprises a rotary dividing plate, a driver and a casting bearing plate; the rotary dividing plate is connected with the casting bearing plate through a central shaft, and the driving mechanism is used for driving the rotary dividing plate and the casting bearing plate to rotate in a stepping mode.
As a further improvement of the invention, the driving mechanism also comprises a second driving mechanism for lifting castings, wherein the second driving mechanism comprises a casting limiter, a screw-nut pair, a carrier platform and an asynchronous motor which are arranged on a casting bearing plate; the casting limiter comprises a chassis fixedly connected with a casting bearing plate, and limiting rods uniformly distributed around the chassis and one end of which is connected with the casting bearing plate; the vertical screw nut pair is arranged in the center of the chassis and connected with the asynchronous motor, and the upper end of the screw nut pair is connected with the carrier platform for placing castings.
As a further improvement of the invention, the casting detection and sorting mechanism comprises a front defect detection module for detecting surface defects of the front surface of the casting; the front defect detection module comprises an image processing mechanism I, a front detection table for placing castings and a front defect product storage cabinet adjacent to the front detection table; the first image processing mechanism comprises a wireless signal transmitter; the back defect detection module is used for detecting surface defects of the back surface of the casting; the reverse defect detection module comprises a second image processing mechanism, a reverse detection table for placing castings and a reverse defect product storage cabinet adjacent to the reverse detection table; the second image processing mechanism comprises a wireless signal transmitter.
As a further improvement of the invention, the first image processing mechanism and the second image processing mechanism are both 3D vision processors, and cameras of the 3D vision processors are arranged on a rotation driving mechanism which is used for driving the cameras to rotate.
As a further improvement of the invention, the acceptable product containing module comprises a magnetic attraction sorter and an acceptable product storage; the magnetic sorter comprises a support rod, a rotating rod and an electromagnetic chuck II which are sequentially connected, a wireless signal receiver for receiving wireless signals sent by the image processing mechanism II after detection is arranged in the magnetic sorter, and the qualified product storage comprises a chassis II fixedly connected with the ground, and limiting rods II uniformly distributed around the chassis II and with one end connected with the ground; the second screw nut pair is arranged in the center of the second chassis and connected with the second asynchronous motor, and the upper end of the second screw nut pair is connected with the second carrier platform for placing qualified products.
As a further improvement of the invention, the casting transmission turn-over mechanism comprises a moving part which reciprocates between the front defect detection module and the back defect detection module, and a clamp which is rotationally connected with the moving platform, wherein the moving part and the clamp are internally provided with the wireless signal receiver for receiving wireless signals sent by the first image processing mechanism and the second image processing mechanism after detection.
As a further improvement of the invention, the casting transmission turning mechanism also comprises a moving platform, one side of the moving platform is provided with a moving chute, and the moving part is provided with a bulge which slides in a clearance with the moving chute; the other side of the moving platform is provided with a gear track, the tail end of the clamp penetrates through the moving part, and a gear meshed with the gear track is arranged for overturning the rotary casting of the clamp.
As a further improvement of the invention, the casting sucking and clamping mechanism comprises a fixed bracket which spans the casting transmission turn-over mechanism and the casting detection sorting mechanism, a rail is arranged on a cross rod of the fixed bracket, two ends of a connecting rod are arranged in the rail, an inductor is connected with the connecting rod in a penetrating way, and a mechanical claw of an electromagnetic chuck is arranged at the connecting center of the inductor.
The application method of the disc casting surface defect detection device based on machine vision is characterized by comprising the following steps of:
s1, firstly placing a casting in a limiter, after a device is powered on, driving a rotary index plate to rotate in a stepping manner by a driver, and driving a casting bearing plate to rotate, wherein in the stepping rotation process, an asynchronous motor drives a screw rod of a screw rod nut pair to ascend, so that the casting is positioned at a position to be clamped;
s2, after the specific position of the casting is identified and confirmed by an inductor in the casting absorbing and clamping mechanism, an electromagnetic chuck in the center of the mechanical claw stretches out to absorb the casting, and the mechanical claw is used for clamping the casting; after the casting is sucked and clamped by the casting sucking and clamping mechanism, the driver drives the rotary index plate and the casting bearing plate to rotate in a stepping way, and an asynchronous motor in the other casting limiter drives a screw rod of the screw rod nut pair to ascend, so that the next casting is positioned at a position to be clamped;
s3, transferring the casting to a front detection table in a front defect detection module by the mechanical claw, and detecting the front surface defect of the casting by the image processing mechanism; if the surface defect exists on the front surface of the casting, the image processing mechanism I sends a wireless signal, the clamp clamps the casting after receiving the signal, the moving part moves the front surface defect product storage cabinet after receiving the signal, and the clamp releases the casting to enable the casting to fall into the front surface defect product storage cabinet; if no surface defect exists on the front surface of the casting, the image processing mechanism sends a wireless signal, the clamp clamps the casting after receiving the signal, and the moving part moves to the reverse surface detection table after receiving the signal;
s4, stopping moving the clamp at the position of the back detection table of the moving part, turning over the casting by the clamp in the moving process, loosening the casting, and placing the casting on the back detection table so as to enable the second image processing mechanism to detect the defects of the back surface of the casting; if the surface defect exists on the back surface of the casting, the second image processing mechanism sends a wireless signal, the clamp clamps the casting after receiving the signal, the moving part moves to the front of the storage cabinet of the defect product on the back surface after receiving the signal, the clamp loosens the casting to enable the casting to fall into the storage cabinet of the defect product on the back surface, and the moving part returns to the front surface to be detected, so that the next casting is clamped; if no surface defect exists on the back surface of the casting, the second image processing mechanism sends a wireless signal, and the electromagnetic sorter receives the wireless signal and then moves the casting to a qualified product storage;
s5, repeating the steps S1 to S4 to finish the detection of the castings in the casting limiter; after all castings in the casting limiter are detected, the asynchronous motor drives the screw rod of the screw-nut pair to descend, and the castings are placed after the descending is completed so as to detect the next batch of castings.
Advantageous effects
Compared with the prior art, the technical scheme provided by the invention has the following beneficial effects:
(1) The driving mechanism in the casting rotating and lifting mechanism can rotate and lift the casting, so that the casting is conveniently sucked and clamped by the casting sucking and clamping mechanism, and the transferring efficiency of the casting is improved; the driver drives the casting bearing plate carrying the casting to rotate step by step through the rotary index plate, and the casting on the carrier table is supplied to the casting sucking and clamping mechanism. The asynchronous motor makes the foundry goods on the carrier platform rise through the lead screw that drives the lead screw nut pair, and the foundry goods of being convenient for is absorbed and is held the position that the foundry goods was located to the accurate induction of inductor in the mechanism to be located the gripper center and have flexible electromagnetic chuck of function and can accurately absorb the foundry goods, both avoided electromagnetic chuck to absorb the not firm problem that drops at the shrink in-process foundry goods of electromagnetic chuck absorption that the position of foundry goods was caused, also shortened electromagnetic chuck telescopic displacement's distance, improved the efficiency of absorption and transfer foundry goods, the treatment effeciency of foundry goods has also obtained promoting. Furthermore, the indexing and time of one step in step rotation can be realized by using different rotary indexing plates or parameters and the like of a controller related to the rotary indexing plates or a starter in an adjusting device, so as to adapt to the transfer time and the detection time of different castings, and avoid that the waiting time of a casting rotary lifting mechanism is too long or a mechanical claw is ready, and the casting rotary lifting mechanism is still in rotary lifting; so that each mechanism in the device operates more compactly and the working efficiency of the device is improved.
(2) The upper end of the screw-nut pair is connected with the carrier platform, and a plurality of castings can be stored for detection at one time by matching with the rod piece in the casting limiter, so that batch processing of the castings is facilitated, the workload of manually and repeatedly placing the castings is reduced, the automation degree is higher, and the processing efficiency of the castings is higher.
(3) The electromagnetic sorter in the casting detection sorting system is provided with a wireless signal receiver which is used for receiving a signal sent by a wireless signal transmitter in the second image processing mechanism so as to transfer qualified castings on the reverse side detection table to a qualified product storage; the sorting operation of the moving part and the clamp is reduced, the productivity of the moving part and the clamp is liberated, so that the clamp and the moving part continue to turn back, the clamping and turning-over work of the next casting is executed, and the detection efficiency of the casting is improved.
(4) The front detection module and the back detection module of the casting detection sorting mechanism comprise an image processing mechanism, a detection table and a defective product storage cabinet, and are used for respectively detecting whether surface defects exist on the front side and the back side of a casting. The image processing mechanism performs image acquisition and analysis rating on the surface of the casting, if surface defects are detected, a detection result is sent in a wireless signal mode through the wireless signal transmitter, after the wireless signal receivers of the moving part and the clamp receive signals, the clamp clamps the casting, the moving part moves to the front of the defective product storage cabinet, the clamp releases the casting, and the casting falls into the defective product storage cabinet. And the qualified castings are sorted to a qualified product storage by an electromagnetic sorter. The detection of the surface defects of the castings and the sorting of the castings are completed by the mutual matching of different parts, so that the efficiency of detecting and sorting the castings is improved.
(5) The image processing mechanisms are all 3D visual processors, the cameras can rotate by 360 degrees, the pixels of the cameras are higher, the collected surface images of the casting are more comprehensive and clearer, and compared with the traditional manual detection, the accuracy and consistency of the detection are greatly improved.
Drawings
FIG. 1 is a schematic structural diagram of a device for detecting surface defects of disc castings based on machine vision;
FIG. 2 is a schematic diagram of a front view structure of a device for detecting surface defects of disc castings based on machine vision in the present application;
FIG. 3 is a schematic side view of a device for detecting surface defects of disc castings based on machine vision;
FIG. 4 is a schematic top view of a device for detecting surface defects of disc castings based on machine vision;
fig. 5 is a schematic structural diagram of a belt driver in a machine vision-based disc casting surface defect detection device.
Reference numerals in the schematic drawings illustrate:
100. a casting rotation lifting mechanism; 110. a casting bearing plate; 120. a casting limiter; 1201. a chassis; 1202. a limit rod; 130. a screw-nut pair; 140. rotating the dividing plate; 150. a driver; 1501. a rotating lever; 1502. a column; 160. a carrier stage; 170. a load-bearing base; 180. an asynchronous motor; 190. a central shaft;
200. a casting sucking and clamping mechanism; 210. an electromagnetic chuck; 220. a mechanical claw; 230. an inductor; 240. a connecting rod; 250. a guide rail; 260. a fixed bracket;
300. a casting transmission turn-over mechanism; 310. a moving member; 320. a clamp; 330. a gear track; 340. moving the chute; 350. a gear; 360. a mobile platform;
400. a casting detection processing mechanism; 410. a front detection table; 4201. an image processing mechanism I; 4202. an image processing mechanism II; 430. a front defect product storage cabinet; 440. a reverse side detection table; 450. a storage cabinet for defective products on the back; 460. a magnetic suction separator; 4601. a support rod; 4602. a rotating rod; 4603. an electromagnetic chuck II; 470. a qualified product storage; 4701. a chassis II; 4702. a second limiting rod; 4703. a screw-nut pair II; 4704. a carrier stage II; 4705. and an asynchronous motor II.
Detailed Description
For a further understanding of the present invention, the present invention will be described in detail with reference to the drawings and examples.
The structures, proportions, sizes, etc. shown in the drawings are shown only in connection with the present disclosure, and are not intended to limit the scope of the invention, since any modification, variation in proportions, or adjustment of the size, etc. of the structures, proportions, etc. should be considered as falling within the spirit and scope of the invention, without affecting the effect or achievement of the objective. Also, the terms "upper", "lower", "left", "right", "middle", and the like are used herein for descriptive purposes only and are not intended to limit the scope of the invention for modification or adjustment of the relative relationships thereof, as they are also considered within the scope of the invention without substantial modification to the technical context.
The invention is further described below with reference to examples.
Examples
Referring to fig. 1 to 5, a device for detecting surface defects of disc castings based on machine vision according to the present embodiment includes a controller, a casting rotating and lifting mechanism 100, a casting sucking and clamping mechanism 200, a casting driving and turning mechanism 300, and a casting detecting and sorting mechanism 400 electrically connected to the controller; the casting sucking and clamping mechanism 200 is used for transferring castings in the casting rotating and lifting mechanism 100 to the casting detecting and sorting mechanism 400 for detection. The casting can be a conventional disc casting, an elliptic casting and a cube casting, and the thickness of the casting can be a flake casting or a thicker casting. The casting rotation and lift mechanism 100 includes a drive mechanism for rotation and lift of the casting.
The first driving mechanism of the casting rotation lifting mechanism 100 comprises a casting bearing plate 110 for bearing castings, a rotation dividing plate 140 and a driver 150. As an embodiment of the example, the cast bearing plate 110 is in a cross shape, and the rotary indexing plate 140 is a 90 ° rotary indexing plate 140. A 90-degree rotary index plate 140 is connected below the casting bearing plate 110, and the 90-degree rotary index plate 140 is fixedly connected with the ground through a bearing base 170. The bearing base 170, the 90-degree rotary index plate 140 and the casting bearing plate 110 are connected through a central shaft 190, and the bearing base 170 is fixedly connected to the lower end of the central shaft 190. The 90-degree rotary indexing plate 140 and the casting load bearing plate 110 are rotatably connected to a central shaft 190 and rotatable about the central shaft 190. As an implementation of an embodiment, the driver 150 is a belt driver 150, and the belt driver 150 drives the 90 ° rotation index plate 140 to rotate stepwise. The driving wheel of the belt driver 150 is connected with the driven wheel through a belt, the driven wheel is connected with a rotating rod 1501, the other end of the rotating rod 1501 is fixedly connected with a stand column 1502, and the stand column 1502 can be placed in a groove of the 90-degree rotating index plate 140. After the belt driver 150 is started, the rotating rod 1501 rotates clockwise along with the driven wheel, the upright 1502 at one end of the rotating rod 1501 moves into the groove of the 90 ° rotating index plate 140, and as the rotation proceeds, the rotating rod 1501 toggles the 90 ° rotating index plate 140 to rotate anticlockwise through the upright 1502, after the completion of one step rotation, the upright 1502 leaves one groove, and enters the next groove after one rotation, and the next step rotation is performed, so that the casting on the casting bearing plate 110 is rotated to a specified position, and the casting sucking and clamping mechanism 200 sucks and clamps the casting. The outer surface of the 90-degree rotary indexing disc 140, the surfaces of the rotary rods 1501 and the upright posts 1502 are coated with tungsten carbide coatings, and the wear-resistant rubber rings attached to the belt driver 150 have excellent wear resistance, so that the service life of the device is prolonged.
The casting limiter 120 is installed at each tail end of the casting bearing plate 110, the casting limiter 120 comprises a chassis 1201 and a limiting rod 1202, the driving mechanism II comprises a vertical screw nut pair 130 arranged in the center of the chassis 1201, the upper end of the screw nut pair 130 is connected with a carrier table 160, and the screw nut pair 130 is connected with an asynchronous motor 170 to drive a screw of the screw nut pair 130 to ascend or descend, so that the casting on the carrier table 160 is ascended or descended. The casting limiter 120 is large in inner space, can accommodate stacking of a plurality of castings, is favorable for realizing batch treatment of the castings, reduces the workload of manually repeatedly placing the castings, and is higher in automation degree and treatment efficiency of the castings. After all the castings on the casting load bearing plate 110 are inspected, the carrier stage 160 is lowered along with the screw rods of the screw-nut pairs 130, and the castings can be stacked again on the carrier stage 160 for the next batch of castings to be transferred, inspected and sorted.
In the step-by-step rotation process of the casting bearing plate 110, the asynchronous motor 170 also enables the casting on the carrier platform 160 to rise through the screw rod of the screw-nut pair 130, so that the inductor 230 in the casting sucking clamping mechanism 300 can accurately sense the position of the casting, the electromagnetic chuck 210 positioned in the center of the mechanical claw 220 and having a telescopic function can accurately suck the casting, the problem that the casting falls due to unstable suction of the electromagnetic chuck 210 caused by incorrect suction of the electromagnetic chuck 210 in the position of the casting is avoided, the telescopic displacement distance of the electromagnetic chuck 210 is shortened, the efficiency of sucking and transferring the casting is improved, and the processing efficiency of the casting is also improved.
The casting sucking and clamping mechanism 200 comprises a fixed support 260 which spans over the casting transmission turning mechanism 300 and the casting detection and sorting mechanism 400, a rail 250 is arranged on a cross rod of the fixed support 260, and two ends of a connecting rod 240 are arranged in the rail 250 and can move in a translation way in the rail 250. Further, the connecting rod 240 made of alloy material can be adopted to improve the strength of the connecting rod 240. The inductor 230 is connected with the connecting rod 240 in a penetrating way and can move on the connecting rod 240 in a translation way, the lower end of the inductor 230 is connected with the mechanical claw 220, the center of the mechanical claw 220 is provided with the electromagnetic chuck 210, and the electromagnetic chuck 210 can perform telescopic movement through the telescopic mechanism so as to suck and clamp castings; the gripper 220 is electrically connected to the sensor 230. The inductor 230 is built with an infrared sensing system for accurately locating the position of the casting to be sucked. After the casting is rotated and lifted by the casting rotation lifting mechanism 100, the position of the casting can be sensed and confirmed by the sensor 230, and the mechanical claw 220 is driven to adjust the position by the respective movements of the sensor 230 and the connecting rod 240. After moving above the casting, the fingers of the gripper 220 open and the electromagnetic chuck 210 extends through the telescoping mechanism to draw the casting. After the casting is sucked, the casting is retracted to the mechanical claw 220 through the retraction mechanism, and the claw of the mechanical claw 220 is closed to assist in clamping the casting, so that the casting is prevented from being damaged due to falling from the electromagnetic chuck 210 due to vibration and the like in the transferring process. The mechanical claw 220 moves above the front detection table 410 through the respective movement of the sensor 230 and the connecting rod 240, and then the mechanical claw is opened, the electromagnetic chuck 210 performs length expansion adjustment, and after power failure and demagnetization, the casting is stably placed on the front detection table 410 so as to detect the front of the casting. The gripper 220 is again moved to the position of the casting sensed by the sensor 230 by the respective movements of the sensor 230 and the link 240.
The casting detection and sorting mechanism 400 comprises a front defect detection module for detecting surface defects of the front surface of the casting; the back defect detection module is used for detecting surface defects of the back surface of the casting; and the qualified product storage module is used for sorting and storing qualified castings. The front defect detection module includes an image processing mechanism 4201 for placing the front detection stage 410 of the casting and a front defect article storage 430 adjacent to the front detection stage 410. The front defect receiving bin 430 is adjacent to the front inspection station 410 in a direction in which the clamp 320 moves when holding the casting for flipping. The first image processing mechanism 4201 includes a camera, image processing software, an image processor, and a circuit, and can detect surface defects on the front surface of the casting on the front surface detection table 410, including collecting surface images of the front surface of the casting, analyzing and processing the collected surface image data of the front surface of the casting to identify whether surface defects exist on the front surface of the casting, and grading the surface defects; the identification of the surface defects is based on the identification of pixels, compared with the traditional manual detection, the identification object has the improvement of orders of magnitude, and the accuracy and consistency of detection are improved. In addition, the number of the castings, the acquired surface images and the defect levels are also stored to realize traceability of the front defect data of the castings. The first 4201 of the image processing mechanism can be a 3D vision processor, a camera of the 3D vision processor is mounted on a rotation driving mechanism, the rotation driving mechanism is used for driving the camera to rotate, 360-degree rotation can be achieved, images of all directions of casting samples with different specifications can be effectively collected, image collection efficiency and collection comprehensiveness are greatly improved, pixels are quite high, and most of collected high-definition images are collected. The accuracy and consistency of the detection of the surface defects of the castings are further improved. If the first image processing mechanism 4201 detects that the front surface of the casting has a surface defect, the detection result is sent out in a wireless signal form through a wireless signal transmitter, the wireless signal receivers of the moving component 310 and the clamp 320 in the casting conveying and turning mechanism receive signals and then make corresponding actions, the clamp 320 clamps the casting, the moving component 310 moves to the front of the defective product storage cabinet, the upper surface of the front defective product storage cabinet 430 is in an opening state, the clamp 320 releases the casting, and the casting falls into the front defective product storage cabinet 430.
The casting transmission turn-over mechanism 300 further comprises a moving platform 360, a moving chute 340 is arranged on one side of the moving platform 360, a protrusion which slides in a clearance with the moving chute 340 is arranged on the moving part 310, and the casting transmission turn-over mechanism is of a clearance mortise-tenon structure and can slide in the moving chute 340 smoothly, so that the casting in the clamp 320 is prevented from falling off to cause damage to the casting. The other side of the moving platform 360 is provided with a gear track 330, the tail end of the clamp 320 penetrates through the moving part 310 and is provided with a gear 350 meshed with the gear track 330, and the clamp 320 rotates along with the gear 350 at the tail end in the process that the moving part 310 moves to the reverse side detecting platform, so that the turnover of castings is realized. The gear rail 330 is slightly longer than the length from the front inspection stage 410 to the rear defective article storage 450 so that the moving member 310 moves back and forth therebetween. In addition, the moving part 310 also includes circuits, processing systems, sensors, etc., which can cope with complex production conditions and emergency situations, and can be self-adjusted to restore the optimal operation state.
If it is detected that no surface defect exists on the front surface, the first image processing mechanism 4201 also transmits the detection result in a wireless signal form through a wireless signal transmitter, after the wireless signal receivers of the moving component 310 and the clamp 320 in the casting transfer and turnover mechanism receive signals, the signals react through internal circuits, sensors and the like, the clamp 320 clamps the casting, the moving component 310 moves in front of the reverse surface detection table 440, and at this time, the clamp 320 performs turnover on the clamped casting under the action of meshing rotation of the gear 350 and the gear track 330. The jig 320 releases the casting and places the casting smoothly on the reverse side inspection stage 440.
The reverse defect detection module comprises a second image processing mechanism 4202 for placing a reverse detection stage 440 of a casting and a reverse defect article storage bin 450 adjacent to the reverse detection stage 440. The reverse defect article storage bin 450 is adjacent to the reverse inspection station 440 in the direction in which the fixture 320 moves when holding the cast for inversion. The second image processing mechanism 4202 includes a camera, image processing software, an image processor, and a circuit, and can detect a surface defect of the back surface of the casting on the back surface detecting table 440, including collecting a surface image of the back surface of the casting, analyzing and processing the collected surface image data of the back surface of the casting to identify whether the back surface of the casting has a surface defect, and grading the surface defect; the identification of the surface defects is based on the identification of pixels, compared with the traditional manual detection, the identification object has the improvement of orders of magnitude, and the accuracy and consistency of detection are improved. In addition, the number of the castings, the acquired surface images and the defect levels are also stored to realize traceability of defect data on the back side of the castings. The second 4202 of the image processing mechanism can be a 3D vision processor, the camera of the 3D vision processor is mounted on the rotation driving mechanism, the rotation driving mechanism is used for driving the camera to rotate, 360-degree rotation can be achieved, images of all directions of casting samples with different specifications can be effectively collected, image collection efficiency and collection comprehensiveness are greatly improved, pixels are quite high, and most of collected high-definition images are collected. The accuracy and consistency of the detection of the surface defects of the castings are further improved. If the second image processing mechanism 4202 detects that the surface defect exists on the back surface of the casting, the detection result is sent out in a wireless signal form through the wireless signal transmitter, after the wireless signal receivers of the moving component 310 and the clamp 320 in the casting conveying turn-over mechanism receive signals, the clamp 320 clamps the casting, the moving component 310 moves to the front of the defective product accommodating cabinet, the upper surface of the back defective product accommodating cabinet 450 is in an opening state, the clamp 320 loosens the casting, and the casting falls into the back defective product accommodating cabinet 450. The moving part 310 is returned to the front of the front inspection table again to sort and turn over the next casting.
If the second image processing mechanism 4202 detects that the back surface of the casting has no surface defect, the detection result is sent out in a wireless signal form through a wireless signal transmitter, and a wireless signal receiver arranged on the electromagnetic sorter 460 receives a signal sent by the wireless signal transmitter in the second image processing mechanism 4202, so as to transfer the qualified casting on the back surface detection table 440 to the qualified product storage 470; the operation of sorting qualified castings, namely qualified products, of the moving part 310 and the clamp 320 is subtracted, and the productivity of the moving part 310 and the clamp 320 is released, so that the clamp 320 and the moving part 310 can continuously turn back, the clamping and turning-over work of the next casting is performed, and the detection efficiency of the casting is improved. The electromagnetic sorter 460 comprises a supporting rod 4601 connected with the ground, a rotating rod 4602 with one end rotatably connected with the supporting rod 4601, and the other end of the rotating rod 4602 is connected with a second electromagnetic chuck 4603, wherein the second electromagnetic chuck 4603 is provided with a telescopic structure. After the electromagnetic sorter 460 receives the signal, the rotating rod 4602 starts to rotate to a position where the electromagnetic chuck two 4603 is located above the reverse side detection table 440, and the electromagnetic chuck two 4603 stretches out to suck up the qualified castings, and stably transfers the castings to the qualified product storage 470. The qualified product storage 470 comprises a second chassis 4701, and limiting rods 4702 connected with the ground are arranged around the second chassis 4701; the vertical screw nut pair II 4703 that the chassis center was equipped with, screw nut pair II 4703 upper end is connected with carrier platform II 4704, screw nut pair II 4703 is connected with asynchronous motor II 4705 to drive screw of screw nut pair II 4703 and rise or descend, and then the foundry goods on carrier platform II 4704 realizes rising or descending, cooperates gag lever post II 4702, can pile up and store qualified foundry goods, does not need the artifical single qualified foundry goods of repeated transportation, reduces manual work load, also can avoid the foundry goods to damage oneself and the foundry goods in the accumulator from carrier platform II 4704's whereabouts height great after electromagnetic chuck II 4603 outage demagnetization. In the casting detection and sorting mechanism 400, the detection of the surface defects of the castings and the sorting of the castings are completed by the mutual matching of different components, so that the efficiency of casting detection and sorting is improved.
In addition, the indexing and time of one step rotation during step rotation can be realized by using different rotation indexing disc 140 or parameters of the controller in the adjusting device related to the rotation indexing disc 140 or the belt driver 150, etc. so as to adapt to the transfer time and the detection time of different castings, avoid that the casting rotation lifting mechanism 100 waits too long, or the mechanical claw 220 is ready, and the castings in the casting rotation lifting mechanism 100 still rotate and lift; so that each mechanism in the device operates more compactly and the working efficiency of the device is higher.
The invention and its embodiments have been described above by way of illustration and not limitation, and the invention is illustrated in the accompanying drawings and described in the drawings in which the actual structure is not limited thereto. Therefore, if one of ordinary skill in the art is informed by this disclosure, the structural mode and the embodiments similar to the technical scheme are not creatively designed without departing from the gist of the present invention.
Claims (10)
1. Disc class foundry goods surface defect detection device based on machine vision, its characterized in that: the casting lifting device comprises a controller, a casting rotating lifting mechanism (100), a casting sucking and clamping mechanism (200), a casting transmission turning mechanism (300) and a casting detecting and sorting mechanism (400), wherein the casting rotating lifting mechanism, the casting sucking and clamping mechanism (200), the casting transmission turning mechanism (300) and the casting detecting and sorting mechanism (400) are electrically connected with the controller; the casting sucking and clamping mechanism (200) is used for transferring castings in the casting rotating and lifting mechanism (100) to the casting detecting and sorting mechanism (400) for detection; the casting rotation and lifting mechanism (100) includes a drive mechanism for rotation and lifting of the casting.
2. The machine vision-based disc casting surface defect detection device according to claim 1, wherein: the driving mechanism comprises a first driving mechanism for rotating the casting; the first driving mechanism comprises a rotary index plate (140), a driver (150) and a casting bearing plate (110); the rotary dividing plate (140) is connected with the casting bearing plate (110) through a central shaft (190), and the driving mechanism drives the rotary dividing plate (140) and the casting bearing plate (110) to rotate in a stepping mode.
3. The machine vision-based disc casting surface defect detection device according to claim 2, wherein: the driving mechanism further comprises a second driving mechanism for lifting the castings, wherein the second driving mechanism comprises a casting limiter (120), a screw-nut pair (130), a carrier platform (160) and an asynchronous motor (180) which are arranged on a casting bearing plate (110); the casting limiter (120) comprises a chassis (1201) fixedly connected with a casting bearing plate (110), limiting rods (1202) uniformly distributed around the chassis (1201) and connected with the casting bearing plate (110) at one end; the vertical screw nut pair (130) is arranged in the center of the chassis, the screw nut pair (130) is connected with the asynchronous motor (180), and the upper end of a screw of the screw nut pair (130) is connected with the carrier table (160) for placing castings.
4. The machine vision-based disc casting surface defect detection device according to claim 1, wherein: the casting detection and sorting mechanism (400) comprises a front defect detection module used for detecting surface defects of the front of castings; the front defect detection module comprises an image processing mechanism I (4201) for placing a front detection table (410) of a casting and a front defect product storage cabinet (430) adjacent to the front detection table (410); the first image processing mechanism (4201) includes a wireless signal transmitter; the back defect detection module is used for detecting surface defects of the back surface of the casting; the reverse defect detection module comprises a second image processing mechanism (4202) for placing a reverse detection table (440) of the casting and a reverse defect product storage cabinet (450) adjacent to the reverse detection table (440); the second image processing mechanism (4202) includes a wireless signal transmitter.
5. The machine vision-based disc casting surface defect detection device according to claim 4, wherein: the first image processing mechanism (4201) and the second image processing mechanism (4202) are both 3D vision processors, and cameras of the 3D vision processors are mounted on a rotation driving mechanism, and the rotation driving mechanism is used for driving the cameras to rotate.
6. The machine vision-based disc casting surface defect detection device according to claim 4, wherein: the qualified product storage module comprises a magnetic attraction sorter (460) and a qualified product storage (470); the magnetic sorter (460) comprises a support rod (4601), a rotating rod (4602) and a second electromagnetic chuck (4603) which are sequentially connected, a wireless signal receiver for receiving wireless signals sent by the second image processing mechanism (4202) after detection is arranged in the magnetic sorter (460), and the qualified product storage (470) comprises a second chassis (4701) fixedly connected with the ground, and limiting rods (4702) which are uniformly distributed around the second chassis (4701) and are connected with the ground at one end; the vertical screw nut pair II (4703) is arranged in the center of the chassis II (4701), the screw nut pair II (4703) is connected with the asynchronous motor II (4705), and the upper end of the screw nut pair II (4703) is connected with the carrier platform II (4704) for placing qualified products.
7. The machine vision-based disc casting surface defect detection device according to claim 4, wherein: the casting transmission turn-over mechanism (300) comprises a moving part (310) which reciprocates between the front defect detection module and the back defect detection module, a clamp (320) which is rotationally connected with the moving platform (360), and wireless signal receivers which are arranged in the moving part (310) and the clamp (320) are used for receiving wireless signals sent by the first image processing mechanism (4201) and the second image processing mechanism (4202) after detection.
8. The machine vision-based disc casting surface defect detection device according to claim 7, wherein: the casting transmission turnover mechanism (300) further comprises a moving platform (360), a moving chute (340) is arranged on one side of the moving platform (360), and a protrusion which slides in a clearance way with the moving chute (340) is arranged on the moving part (310); the other side of the moving platform (360) is provided with a gear track (330), the tail end of the clamp (320) penetrates through the moving part (310), and a gear (350) meshed with the gear track (330) is arranged for overturning the rotary casting of the clamp (320).
9. The machine vision-based disc casting surface defect detection device according to any one of claims 1 to 8, wherein: the casting sucking and clamping mechanism (200) comprises a fixed support (260) which spans over the casting transmission turning mechanism (300) and the casting detection sorting mechanism (400), a guide rail is arranged on a cross rod of the fixed support (260), two ends of a connecting rod (240) are arranged in the guide rail, an inductor (230) is connected with the connecting rod (240) in a penetrating manner, and a mechanical claw (220) of the electromagnetic chuck (200) is arranged in the connecting center of the inductor (230).
10. A method of using the machine vision-based disc casting surface defect detection device as claimed in claim 9, wherein:
s1, firstly placing a casting in a limiter, after a device is powered on, driving a rotary index plate (140) to rotate in a stepping mode by a driver (150), driving a casting bearing plate (110) to rotate, and driving a screw rod of a screw-nut pair (130) to ascend by an asynchronous motor (180) in the stepping rotating process to enable the casting to be in a position to be clamped;
s2, after an inductor (230) in the casting sucking and clamping mechanism (200) recognizes and confirms the specific position of the casting, an electromagnetic chuck (210) at the center of a mechanical claw (220) stretches out to suck the casting, and the mechanical claw (220) is used for clamping the casting; after the casting is sucked and clamped by the casting sucking and clamping mechanism (200), the driver (150) drives the rotary index plate (140) and the casting bearing plate (110) to rotate in a stepping way, and an asynchronous motor (180) in the other casting limiter (120) drives a screw rod of the screw-nut pair (130) to ascend so that the next casting is positioned at a position to be clamped;
s3, transferring the casting to a front surface detection table (410) in a front surface defect detection module by the mechanical claw (220), and detecting the front surface defect of the casting by an image processing mechanism I (4201); if the surface defect exists on the front surface of the casting, the first image processing mechanism (4201) sends a wireless signal, the clamp (320) clamps the casting after receiving the signal, the moving component (310) moves the front surface defect product storage cabinet (430) after receiving the signal, and the clamp (320) loosens the casting to enable the casting to fall into the front surface defect product storage cabinet (430); if no surface defect exists on the front surface of the casting, the first image processing mechanism (4201) sends a wireless signal, the clamp (320) clamps the casting after receiving the signal, and the moving component (310) moves towards the back surface detection table (440) after receiving the signal;
s4, stopping the movement of the clamp (320) at the back surface detection table (440) of the moving part (310), finishing the turning of the casting by the engagement of the gear and the gear track during the movement of the moving part (310) by the clamp (320), loosening the casting, and placing the casting on the back surface detection table (450) so that the second image processing mechanism (4202) detects the defects of the back surface of the casting; if the surface defect on the back surface of the casting is detected, the second image processing mechanism (4202) sends a wireless signal, the clamp (320) clamps the casting after receiving the signal, the moving part (310) moves to the front of the back surface defect product accommodating cabinet (430) after receiving the signal, the clamp (320) loosens the casting to enable the casting to fall into the back surface defect product accommodating cabinet (430), and the moving part (310) returns to the front surface detecting platform (410) to clamp the next casting; if no surface defect exists on the back surface of the casting, the second image processing mechanism (4202) sends a wireless signal, and after the electromagnetic sorter (460) receives the wireless signal, the qualified casting is moved to the qualified product storage (470);
s5, repeating the steps S1 to S4 to finish the detection of the castings in the casting limiter; after all castings in the casting limiter are detected, the asynchronous motor (180) drives the screw rod of the screw-nut pair (130) to descend, and the castings are placed after the descending is completed so as to detect the next batch of castings.
Priority Applications (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| CN202311483594.1A CN117259252A (en) | 2023-11-07 | 2023-11-07 | Disc casting surface defect detection device based on machine vision and use method |
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| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| CN202311483594.1A CN117259252A (en) | 2023-11-07 | 2023-11-07 | Disc casting surface defect detection device based on machine vision and use method |
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| CN117259252A true CN117259252A (en) | 2023-12-22 |
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| Application Number | Title | Priority Date | Filing Date |
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| CN202311483594.1A Pending CN117259252A (en) | 2023-11-07 | 2023-11-07 | Disc casting surface defect detection device based on machine vision and use method |
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| CN (1) | CN117259252A (en) |
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- 2023-11-07 CN CN202311483594.1A patent/CN117259252A/en active Pending
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