CN219552280U - Sensor harness sheet metal part detection system based on machine vision - Google Patents

Abstract

The utility model provides a machine vision-based sensor harness sheet metal part detection system. The detection system is used for detecting whether the installation phase angle of the sheet metal part on the sensor harness assembly meets the requirement. The detection system comprises an industrial camera, an image acquisition card, a computer, a programmable logic controller and a sensor head limiting frame. The output end of the industrial camera is in communication connection with the image acquisition card, the image acquisition card is in communication connection with the computer, and the programmable logic controller is respectively in communication connection with the industrial camera, the computer and the sensor head limiting frame. The sensor wire harness sheet metal part detection system based on machine vision provided by the utility model overcomes the defects in the prior art, and the problems of high manual detection cost, low efficiency, high detection error rate and the like are solved by using an advanced machine vision detection technology to replace manual detection.

Description

Sensor harness sheet metal part detection system based on machine vision

Technical Field

The utility model belongs to the technical field of vehicle sensor detection, and particularly relates to a machine vision-based sensor harness sheet metal part detection system.

Background

In the prior art, there are typically four wheel speed sensors for each vehicle that are coupled to bearings for the wheels of the vehicle to monitor the movement of each wheel. And the wheel speed sensor, along with its wiring harness assembly, needs to be mounted on both the vehicle chassis and the suspension system. In order to install the fixed wire harness, a sheet metal part is often installed on the wire harness of the wheel speed sensor, and then the sheet metal part is fixedly connected with the chassis and the suspension through bolts.

Because the chassis and the suspension system are relatively moving, the wire harness of the wheel speed sensor is also in a state of long-term movement. If the wire harness is twisted at the time of installation, fatigue fracture and breakage of the cable core and the sheath of the wheel speed sensor are extremely liable to occur. Therefore, the wire harness of the wheel speed sensor should be as close to a natural bending state as possible when being installed, and thus, a high requirement is placed on the phase angle of the sheet metal part installed on the wire harness of the wheel speed sensor. Therefore, in the factory inspection of the wheel speed sensor harness, 100% of the inspection harness is required to check whether the phase angle of the sheet metal member is acceptable. However, there is now no reliable and accurate detection method. At present, a manual detection method is generally adopted in factories, and the head of the wheel speed sensor is held by hands, so that the wire harness is naturally hung down, and whether the wire harness assembly of the wheel speed sensor is qualified or not is judged by eyes through experience observation. Because 100% detection is required, if manual detection is adopted, the result of manual detection is often influenced by working experience, working state and differences among different workers, and the defects of low efficiency, high detection cost, increased production line ring joint, high error rate of detection, inaccuracy and the like are brought, so that the defect is extremely easy to cause.

Disclosure of Invention

The utility model aims to overcome the defects in the prior art, and provides a machine vision-based sensor harness sheet metal part detection system, so that the detection efficiency of online detection is high, the result is accurate, and the cost is low.

In order to achieve the above purpose, the utility model provides a machine vision-based sensor harness sheet metal part detection system for detecting whether the installation phase angle of a sheet metal part on a sensor harness assembly meets the requirement, wherein the detection system comprises an industrial camera, an image acquisition card, a computer, a programmable logic controller and a sensor head limiting frame; the output end of the industrial camera is in communication connection with the image acquisition card, the image acquisition card is in communication connection with the computer, and the programmable logic controller is respectively in communication connection with the industrial camera, the computer and the sensor head limiting frame.

Further, the sensor head restraint has at least one catch in which a sensor head on the sensor harness assembly can be caught and allows the entire sensor harness assembly to naturally sag.

Further, the sensor head limiting frame is provided with four clamping parts, the sensor heads on the four groups of sensor wire harness assemblies are respectively clamped in the four clamping parts, and the four groups of sensor wire harness assemblies naturally droop.

Further, the sensor head limiting frame is also provided with at least one trigger switch, and the programmable logic controller is in communication connection with the trigger switch on the sensor head limiting frame; the sensor head is clamped in the clamping part and triggers the at least one trigger switch to send out a ready signal.

Further, the programmable logic controller is provided with a signal receiving and transmitting module which is responsible for receiving the ready signal and a data processing module which is responsible for processing the received ready signal and sending out a photographing instruction.

Further, the industrial camera has a photographing element that receives and photographs the sensor harness assembly according to the photographing instruction.

Further, the image acquisition card is connected with the industrial camera to acquire the shot photos, the computer is provided with a transceiver module and an image processing module, the transceiver module of the computer is connected with the image acquisition card to receive the acquired photos, and the image processing module of the computer is connected with the transceiver module to analyze and process the acquired photos.

Further, the image processing module of the computer has a calculation analysis module and a comparison module: the comparison module is connected with the calculation and analysis module so as to obtain the installation phase angle of the sheet metal part on the sensor harness assembly in the photo; the transceiver module of the computer is connected with the comparison module so as to obtain a result signal whether the installation phase angle is consistent with the preset required phase angle; the programmable logic controller is connected with a transceiver module of the computer to obtain the result signal.

Further, the detection system is also provided with at least one indicator light, and the indicator light is in communication connection with the programmable logic controller so that the programmable logic controller can control the indicator light to indicate the qualified or unqualified signal according to the received qualified or unqualified signal.

Further, the detection system also has at least one sorting mechanism communicatively coupled to the programmable logic controller to enable the programmable logic controller to control the sorting mechanism to sort out the sensor harness assemblies that are either acceptable or unacceptable based on the received pass or fail signals.

Further, the communication connection is a wired communication connection or a wireless communication connection.

Compared with the prior art, the machine vision-based sensor harness sheet metal part detection system provided by the utility model overcomes the defects in the prior art, can use the advanced machine vision detection technology to replace manual detection, has the advantages of high detection efficiency, high detection result accuracy, low cost and the like compared with the traditional manual detection, can detect small-angle areas difficult to detect manually, and improves detection precision. The scheme of the utility model can be applied to any environment in a factory due to the use of components such as a programmable logic controller, an industrial camera and the like which can endure severe environments.

Drawings

FIG. 1 is a schematic diagram of a machine vision-based sensor harness sheet metal part detection system in accordance with a preferred embodiment of the present utility model;

fig. 2 is a schematic view of an on-line detection of a sensor harness sheet metal part according to a preferred embodiment of the present utility model.

Detailed Description

The present utility model will be further described with reference to the drawings and preferred embodiments.

In the following description, numerous specific details are set forth in order to provide a thorough understanding of the present utility model to those skilled in the art. It will be apparent, however, to one skilled in the art that the present utility model may be practiced without some of these specific details. Furthermore, it should be understood that the utility model is not limited to specific described embodiments. Rather, the utility model can be considered to be implemented with any combination of the following features and elements, whether or not they relate to different embodiments. Thus, the following aspects, features, embodiments and advantages are merely illustrative and should not be considered elements or limitations of the claims except where explicitly set out in a claim. In this document, terms indicating directions such as up, down, left, right, upper, lower, etc. are merely expressed for convenience of description based on the relative positions of components in the present drawings, and should not be construed as limiting the scope of protection.

FIG. 1 is a schematic diagram of a machine vision-based sensor harness sheet metal part detection system in accordance with a preferred embodiment of the present utility model; fig. 2 is a schematic view of an on-line detection of a sensor harness sheet metal part according to a preferred embodiment of the present utility model.

As shown in fig. 1 and 2, in the present embodiment, a machine vision-based sensor harness sheet metal part detection system is provided for detecting whether the installation phase angle of a sheet metal part 11 on a sensor harness assembly 10 meets the requirement. The machine vision-based sensor harness sheet metal part detection system comprises an industrial camera 1, an image acquisition card 2, a computer 3, a programmable logic controller 4 and a sensor head limiting frame 5.

The output end of the industrial camera 1 is in communication connection with the image acquisition card 2, the image acquisition card 2 is in communication connection with the computer 1, and the programmable logic controller 4 is in communication connection with the industrial camera 1, the computer 3 and the sensor head limiting frame 5 respectively. Preferably, the communication connection may be a wired communication connection, such as a cable, or a wireless communication connection, such as bluetooth, wiFi, cellular communication, or other means.

Further, the sensor head restraint 5 has at least one catch 51. The sensor head 12 on the sensor harness assembly 10 may be retained in the retaining portion 51 and allow the entire sensor harness assembly 10 to naturally sag. As shown in fig. 2, the sensor head restraint 5 has four holding portions 51, and the sensor heads 12 on the four groups of sensor harness assemblies 10 are held in these holding portions 51, respectively, and cause the entire sensor harness assembly 10 to naturally droop.

Further, the sensor head limit frame 5 is also provided with at least one trigger switch 52. The programmable logic controller 4 is in communication with a trigger switch 52 on the sensor head limit stop 5. The sensor head 12 is held in the holding part 51 and triggers the at least one trigger switch 52 to emit a readiness signal.

Further, the programmable logic controller 4 has a signal transceiver module and a data processing module. The signal transceiver module is capable of receiving the ready signal sent by the trigger switch 52, and the data processing module processes the received ready signal and sends out a photographing instruction.

Further, the industrial camera 1 has a photographing element (not shown) that receives and photographs the sensor harness assembly 10 according to a photographing instruction. As shown in fig. 2, the industrial camera 1 takes a photograph while containing four groups of sensor harness assemblies 10. The image pickup card 2 picks up a photograph taken by the industrial camera 1. The computer 3 has a transceiver module and an image processing module. The transceiver module of the computer 3 can receive the photos collected by the image collection card 2 and transmit the photos to the image processing module, and the image processing module of the computer 3 is responsible for analyzing and processing the collected photos.

Further, the image processing module of the computer 3 has a calculation analysis module and a comparison module (not shown). The calculation and analysis module of the image processing module is capable of calculating and analyzing photographs and obtaining the installation phase angle of the sheet metal part 11 on the sensor harness assembly 10. As shown in fig. 2, the installation phase angle is the swing angle of the sheet metal part 11 located at the upper and lower positions on the sensor harness assembly 10 with respect to the vertical axis circumference of the sensor head 12. The comparison module of the image processing module can compare the calculated and analyzed installation phase angle with a preset required phase angle to judge whether the installation phase angle meets the requirement. If the comparison results are consistent, the sheet metal part 11 of the sensor harness assembly 10 is installed to meet the requirements, then the image processing module can send out a qualified signal to the programmable logic controller 4 through the transceiver module of the computer 3, and if the result is not met, a disqualified signal is sent out.

Further, the machine vision-based sensor harness sheet metal part detection system is also provided with an indicator lamp 6. The indicator light 6 is communicatively connected to the programmable logic controller 4. The programmable logic controller 4 is capable of controlling the indicator light 6 to indicate a pass or fail signal based on the received pass or fail signal. For example, if the indicator lamp 6 is acceptable, green is indicated, and if the indicator lamp is unacceptable, red is indicated.

Further, the machine vision-based sensor harness sheet metal part detection system is further provided with a sorting mechanism 7, and the sorting mechanism 7 is in communication connection with the programmable logic controller 4. The programmable logic controller 4 can control the sorting mechanism 7 to sort out the qualified or unqualified sensor harness assembly 10 based on the received qualified or unqualified signals. As shown in fig. 2, if there are defective products in the four-group sensor harness assembly 10, the sorting mechanism 7 picks up the defective sensor harness assembly 10 according to the control instruction and sends it to the round trip repair warehouse 8. The remaining acceptable sensor harness assembly 10 proceeds smoothly to the next process.

Referring to fig. 2, the production line detection process is as follows:

first, in the production line, the produced sensor harness assembly 10 is put on the sensor head restraint 5 by a worker. The sensor head restraint 5 transfers the sensor harness assembly 10 to be tested to the detection zone. The detection area is positioned below the industrial camera 1, the sensor harness assembly 10 naturally hangs down, and the sensor head 12 is opposite to the industrial camera 1.

Then, photographing is performed by the industrial camera 1 from directly above the sensor harness assembly 10, and the obtained picture is transmitted to the computer 3 via the image pickup card 2.

An image processing module within the computer 3, such as analysis software or the like, automatically processes the pictures to identify the profile data of the sheet metal part 11. And analyzing and calculating the spatial mounting phase angle in the industrial camera coordinate system based on the profile data. The installation phase angle is then compared with a predetermined phase angle interval. If the angle range is within the angle range, the computer 3 outputs a qualified signal to the sorting mechanism 7 through the programmable logic controller 4, meanwhile, the indicator lamp 6 is controlled to display green, the sorting mechanism 7 does not act at the moment, and the product enters a qualified product range and is sent to the next production link; if the angle interval is outside, the computer 3 outputs a disqualification signal to the sorting mechanism 7 through the programmable logic controller 4, and simultaneously controls the indicator lamp 6 to display red, at the moment, the sorting mechanism 7 acts to push disqualification products into a repair area, such as a repair product warehouse 8, for further processing.

While the utility model has been described in terms of preferred embodiments, the utility model is not so limited. Any person skilled in the art shall not depart from the spirit and scope of the present utility model and shall accordingly fall within the scope of the utility model as defined by the appended claims.

Claims (11)

1. The utility model provides a sensor pencil sheet metal component detecting system based on machine vision for whether detect the installation phase angle of sheet metal component on the sensor pencil assembly meets the requirements, its characterized in that, detecting system includes industrial camera, image acquisition card, computer, programmable logic controller and sensor head limit frame; the output end of the industrial camera is in communication connection with the image acquisition card, the image acquisition card is in communication connection with the computer, and the programmable logic controller is respectively in communication connection with the industrial camera, the computer and the sensor head limiting frame.

2. The machine vision based sensor harness sheet metal part detection system of claim 1, wherein the sensor head restraint has at least one catch in which a sensor head on the sensor harness assembly can catch and cause the entire sensor harness assembly to naturally sag.

3. The machine vision based sensor harness sheet metal part detection system of claim 2 wherein the sensor head limit frame has four clamping portions in which the sensor heads on four sets of the sensor harness assemblies are respectively clamped and such that the four sets of the sensor harness assemblies all naturally sag.

4. A machine vision based sensor harness sheet metal part detection system as claimed in claim 2 or 3 wherein said sensor head limit frame further has at least one trigger switch thereon, said programmable logic controller being in communication with said trigger switch on said sensor head limit frame; the sensor head is clamped in the clamping part and triggers the at least one trigger switch to send out a ready signal.

5. The machine vision based sensor harness sheet metal part detection system of claim 4 wherein the programmable logic controller has a signal transceiver module responsible for receiving the ready signal and a data processing module responsible for processing the ready signal received and issuing a photograph command.

6. The machine vision based sensor harness sheet metal part detection system of claim 5, wherein the industrial camera has a photographing element that receives and photographs the sensor harness assembly according to the photographing instruction.

7. The machine vision-based sensor harness sheet metal part detection system of claim 6, wherein the image acquisition card is connected with the industrial camera to acquire a shot picture, the computer is provided with a transceiver module and an image processing module, the transceiver module of the computer is connected with the image acquisition card, and the image processing module of the computer is connected with the transceiver module.

8. The machine vision-based sensor harness sheet metal part detection system of claim 7, wherein the image processing module of the computer is provided with a calculation analysis module and a comparison module; the comparison module is connected with the calculation analysis module; the receiving and transmitting module of the computer is connected with the comparison module; the programmable logic controller is connected with the transceiver module of the computer.

9. The machine vision based sensor harness sheet metal part detection system of claim 8, further comprising at least one indicator light communicatively coupled to the programmable logic controller to indicate a pass signal or a fail signal.

10. The machine vision based sensor harness sheet metal part detection system of claim 9, further comprising at least one sorting mechanism, wherein the sorting mechanism is communicatively coupled to the programmable logic controller.

11. The machine vision-based sensor harness sheet metal part detection system of any one of claims 1-10, wherein the communication connection is a wired communication connection or a wireless communication connection.