WO2016026358A1

WO2016026358A1 - 360-degree detection device and method for visual defects of roller

Info

Publication number: WO2016026358A1
Application number: PCT/CN2015/083708
Authority: WO
Inventors: 晏毓; 幸洁
Original assignee: 杭州乔戈里科技有限公司
Priority date: 2014-08-19
Filing date: 2015-07-10
Publication date: 2016-02-25
Also published as: CN104155310A; CN104155310B

Abstract

A 360-degree detection device for visual defects of a roller. The detection device comprises a material conveying device and an imaging unit that are controlled by an industrial computer (402). The material conveying device is a carrier roller conveying device (1). The imaging unit comprises a circumferential imaging unit (2) and end imaging units (3). The circumferential imaging unit (2) is arranged above the carrier roller conveying device (1), and the end imaging units (3) are respectively arranged at two sides of the carrier roller conveying device (1).

Description

Roller appearance defect 360 degree detecting device and detecting method

Technical field

The invention relates to a 360 degree detecting device for roller appearance defects and a detecting method thereof, and more particularly to a method for automatically performing 360-degree optical imaging of a cylindrical or conical roller for full-angle appearance inspection. method.

Background technique

The roller in the roller bearing is an important rolling component, and the quality of the roller directly affects the quality and life of the bearing. At present, the detection of the roller mainly uses the following detection methods: manual visual inspection, eddy current inspection, ultrasonic flaw detection and magnetic particle inspection.

In the production practice, the above several methods are usually combined, and the final inspection is performed by manual visual inspection to perform full inspection or sampling inspection of the appearance defects. Because the above detection methods have certain applicability and limitations, manual visual inspection requires a large number of inspectors, and at the same time, the inspectors will have inconsistencies and fatigues of subjective judgments, and the occurrence of missed inspections will always occur. Therefore, in order to replace some steps in manual detection, the detection of the workpiece by optical imaging has become an important development direction of the current roller workpiece detection. At present, there are several methods or devices for detecting the appearance defects of the roller by optical imaging.

A device proposed by the patent "bearing rolling element detector based on high-resolution CCD technology (application No. 201210372221.2)" adopts camera test methods in six directions of up, down, front, back, left and right. Although this method can detect more faces, because the camera is fixed, the time taken by the six cameras is only the moment when the bearing rolls through the six cameras, and at this moment, there are six cameras fixedly fixed. Defects make the value of the detection not very accurate. Since the pallet is required to support the workpiece at any time, there must be a surface that cannot be recorded at all when detecting. Moreover, the detection process is too complicated, requires card slots, and is transported to the corresponding detection box for photographing process, which seriously affects the efficiency of detection, especially in the current transition from extensive economy to intensive economy. In this, the inefficient production equipment will greatly restrain the production labor, making the production cost of the product too high and seriously wasting the production resources of the society.

Another example is the patent “A Tapered Roller Surface Defect Detection System (Application No. 201310147390.0)”, which can not achieve accurate and reliable 360-degree coverage in the outer circle imaging, which is prone to missed detection and also exists. The detection process is cumbersome, resulting in a defect of low detection efficiency.

Summary of the invention

The technical problem to be solved by the present invention is to provide a 360 degree detecting device for roller appearance defects and a detecting method.

In order to solve the above technical problem, the present invention provides a 360 degree detecting device for roller appearance defects, comprising an industrial computer controlled material conveying device and an image forming unit; the material conveying device is a roller conveying device; and the imaging unit includes an outer circle An imaging unit and an imaging unit at both ends; an outer circle imaging unit is disposed above the idler conveying device, and two opposite imaging units are respectively disposed on two sides of the roller conveying device.

As an improvement of the 360 degree detecting device for the appearance defect of the roller according to the present invention, the roller conveying device comprises a roller for placing a roller workpiece, a roller conveying chain for driving the roller, and a transmission for driving the roller conveyor chain. wheel.

Further improvement of the 360 degree detecting device for the roller appearance defect according to the present invention: the outer circular image forming unit includes a counting device that counts a rotation angle of the idle roller, and an outer circle camera group that performs shooting control by the counting device; The two-end imaging unit includes a positioning device that positions the roller workpiece and an end face A camera and an end face B camera that are controlled by the positioning device, and the end face A camera and the end face B camera are respectively disposed on the roller conveyor device side.

Further improvement of the 360 degree detecting device for the appearance defect of the roller according to the present invention: the counting device comprises a displacement encoder and a pulse counter; the displacement encoder outputs a corresponding pulse signal after counting the rotation angle of the roller, The pulse counter calculates a corresponding angle of the roller workpiece by the pulse signal of the displacement encoder, and performs shooting control of the outer circle camera group; the positioning device is a photoelectric sensor.

Further improvement of the 360 degree detecting device for the appearance of the roller according to the present invention is that the number of external cameras in the outer camera group is at least one.

As a further improvement of the 360 degree detecting device for the roller appearance defect of the present invention, the outer circle camera, the end face A camera and the end face B camera in the outer circle camera group each adopt a high speed high resolution CCD industrial camera.

Roller appearance defect 360 degree detection method; the roller workpiece is placed above the idler roller of the idler conveying device, and the roller workpiece is conveyed by the idle roller; the two end faces of the roller workpiece are photographed by the end face A camera and the end face B camera The appearance defect detection of the two end faces of the roller workpiece is completed; the side of the roller workpiece is photographed by the outer camera group, and the appearance defect detection of the side surface of the roller workpiece is completed.

As an improvement of the 360 degree detection method of the roller appearance defect according to the present invention, the working steps of the outer circle camera group are as follows: after the roller rotates at a certain angle, the displacement encoder generates a corresponding pulse signal; The corresponding pulse signal generated by the device is counted, and when the angle to be photographed is reached, the pulse counter controls all the external cameras of the outer camera group to shoot.

As a further improvement of the 360 degree detection method of the roller appearance defect according to the present invention, the roller workpiece calculates the corresponding rotation angle of the roller by the diameter ratio between the roller workpiece and the roller when the roller rotates. The corresponding angle value of the roller workpiece rotation.

As a further improvement of the 360 degree detection method of the roller appearance defect according to the present invention, the working steps of the end face A camera and the end face B camera are as follows: the photoelectric sensor controls the end face A camera and the end face when detecting the passage of the roller workpiece The B camera shoots at the same time.

The advantages of the invention are as follows:

1. The invention adopts a unique roller conveyor chain structure, realizes a 360-degree continuous angle photographing function of the outer circle by using a displacement encoder and a pulse counter at the same time of realizing high-speed conveying (through the improvement of the conveying mode of the workpiece, the work is increased. Efficiency, and achieve a full 360-degree continuous angle camera function).

2. The invention simultaneously realizes the photographing detection of the two ends of the roller, and does not leave a dead angle in the aspect of the roller appearance detection.

3. The present invention uses a mechanism to simultaneously support the transport and detection of cylindrical or conical rollers.

4. The invention adopts a high-speed high-resolution CCD industrial camera with high detection speed and high resolution, and the detection speed can reach 20,000 to 40,000 pieces per hour, and the resolution can reach 0.04 mm.

DRAWINGS

The specific embodiments of the present invention are further described in detail below with reference to the accompanying drawings.

Figure 1 is a diagram showing the structure of a main body of the present invention;

Figure 2 is a partial view of an outer circle photograph of the present invention;

Figure 3 is an explanatory view of photographing at both ends of the present invention;

Figure 4 is a circuit diagram showing the main components of the present invention.

detailed description

Embodiment 1 and FIG. 1 to FIG. 4 show a 360 degree detecting device for a roller appearance defect and a detecting method thereof.

The above-described roller appearance defect 360 degree detecting device includes a roller conveying device 1, an outer circle image forming unit 2, an image forming unit 3 at both ends, and an industrial computer 402.

The roller conveying device 1 includes a transmission wheel 102 and a roller conveyor chain 101; the roller conveyor chain 101 includes a roller 201, a roller fixing plate 202 and a pallet 203, and the roller 201 is provided with shafts on both sides thereof, and the roller fixing plate 202, corresponding holes are provided with respect to the shafts on both sides of the idler 201, and the idler 201 inserts the corresponding shaft into the corresponding circular hole to form a rotation with respect to the idler fixing plate 202; and at the idler fixing plate 202 After a plurality of rollers 201 are disposed, a corresponding pallet 203 (fixed) is disposed under the idler 201, so that when the roller fixing plate 202 is moved, the pallet 203 can drive the roller 201 based on the friction by friction. The roller fixing plate 202 makes a corresponding reverse movement. The roller fixing plate 202 is disposed on the driving wheel 102, and the roller fixing plate 202 is rotated by the rotation of the driving wheel 102 to perform clockwise rotation or counterclockwise rotation, and then the roller 201 is rotated counterclockwise according to the corresponding rotation. The hour hand rotates; while in use, the roller workpiece 100 is on the idler 201 by the rotation of the idler 201 (i.e., the idler 201 rotates with the idler plate 202). While moving, but the relative position of the idler 201 relative to the idler retaining plate 202 does not change, the roller workpiece 100 is moved.

The outer circle imaging unit 2 includes a displacement encoder 103, a pulse counter 401, an outer circle camera set (which may be composed of one or more outer circle cameras 104), and a custom light source 204; the displacement encoder 103 is fixedly coupled to the drive wheel 102, The roll rotation displacement information is collected; the pulse counter 401 is electrically connected to the displacement encoder 103 and the outer circle camera 104, and the rotation angle of the transmission wheel 102 is counted by the displacement encoder 103, and the count is output by pulse, and the output is output. The pulse signal is calculated by the pulse counter 401 (ie, the transmission wheel 102 is rotated by a corresponding angle, the displacement encoder 103 issues a pulse signal, and the pulse counter 401 can determine the specific rotation angle of the transmission wheel 102 by the pulse signal, and according to the The angle of rotation controls the outer camera 104 to take a corresponding photo); the custom light source 204 here assists the outer camera 104 in taking a photo; the outer camera 104 is located above the roller conveyor 1. The two end imaging units 3 include a photosensor 301, an end face A camera 302 and an end face B camera 303. The photosensor 301 is electrically connected to the end face A camera 302 and the end face B camera 303; the end face A camera 302 and the end face B camera 303 are respectively located on the idler roller. The left and right sides of the conveying device 1 (because the roller workpiece 100 is specifically positioned by the photosensor 301, when the end face A camera 302 and the end face B camera 303 are provided, two workpieces can be correspondingly set, In order to prevent interference when using the auxiliary light source, the spacer setting is performed, such as the asymmetric arrangement of the end face A camera 302 and the end face B camera 303 of FIG. 3; the photosensor 301 can position the idle roller 201 to roll up. The specific position of the sub-workpiece 100, while the roller workpiece 100 is in the proper position, controls the end face A camera 302 and the end face B camera 303 to respectively take corresponding photos of the left and right sides of the roller workpiece 100.

The industrial computer 402 is electrically connected to the outer camera group (several outer camera 104), the end face A camera 302, and the end face B camera 303, and reads the outer camera group (several outer circle cameras 104), the end face A camera 302, and the end face B in real time. Corresponding photo information of the camera 303.

When the present invention works, it mainly proceeds through the following steps:

1. The driving wheel 102 is started, and after the clockwise movement of the driving wheel 102, the roller fixing plate 202 is driven to move clockwise, and after the plurality of rollers 201 on the roller fixing plate 202 are rubbed against the fixed pallet 203, Make the corresponding counterclockwise rotation;

2. The roller workpiece 100 is placed on the idler roller 201, and under the driving of the idler roller 201, the clockwise movement (synchronized with the transmission wheel 102) is performed, and the same displacement movement as the roller fixed plate 202 is maintained;

3. According to the transmission law, the rotational speed of the transmission wheel 102 has a fixed proportional relationship with the rotational speed of the roller workpiece 100, that is, the rotational speed of the roller workpiece 100 can be calculated by the rotational speed of the transmission wheel 102 (according to the prior art, Those skilled in the art can easily calculate this result; that is, the displacement encoder 103 can determine the corresponding data of the rotation of the roller workpiece 100 by recording the corresponding rotational speed of the transmission wheel 102, such as every rotation of the roller workpiece 100. One At a slight angle, the displacement encoder 103 emits a pulse, and the pulse counter 401 accumulates the pulse. According to a preset condition, after the roller workpiece 100 is rotated to a certain angle, the pulse counter 401 issues a trigger signal to control the outer camera group. All of the outer circle cameras 104 are photographed with an outer circle (the side of the roller workpiece 100). Thus, according to the different diameters of the roller workpiece 100 and the related preset conditions, it is possible to accurately control the roller workpiece 100 to take a photo after each rotation of the specified angle, and to complete the full-angle photographing of the outer circumference of the roller workpiece 100 after the 360-degree rotation is completed.

4. When the roller workpiece 100 enters the end photographing position, the light emitted by the photosensor 301 is blocked, the photosensor 301 emits a trigger pulse, and the end face A camera 302 and the end face B camera 303 are controlled to take a photograph.

5. The photographs taken by the outer camera group (outer circle camera 104), the end face A camera 302, and the end face B camera 303 are transmitted to the industrial computer 402, and the image acquisition and image analysis processing software running on the industrial computer 402 is used for positioning and image. Pre-processing and defect identification, thereby achieving 360-degree detection of the outer circumference of the roller workpiece 100 and detection of defects at both ends.

According to optical path analysis and experimental verification, to achieve 360-degree full-angle imaging, it is necessary to take a picture of 9 to 12 consecutive angles of a roller workpiece 100. Although the existing technology can also achieve continuous shooting, it is impossible to control the shooting. The time point, in turn, causes multiple shots on the same side of the roller workpiece 100, while some sides are completely unphotographed, and such detection results are completely inaccurate. The 360 degree detecting device for the roller appearance defect in the present invention can indirectly calculate the instantaneous angle value of the roller workpiece 100 by the displacement encoder 103 on the transmission wheel 102. By this value, the outer circle camera 104 can be controlled accordingly. By angle shooting, and by this method, it is possible to perform no-coupling shooting on any face of the roller workpiece 100, that is, the time taken by the outer-circle camera 104 is accurately calculated, and each of the outer-circle cameras 104 is photographed. The side images are the only side images, and there is no occurrence of multiple data from the same part by multiple shots on the side, which affects the final detection result.

Comparative Example 1. In the prior art, a technical solution proposed by the patent "tapered roller surface defect detecting system (Application No. 2013101472715)" adopts a jig, a stepping motor and a camera device for cooperation. After 360 degrees without dead angle shooting, in this scheme, it is necessary to cooperate with the clamp by the stepping motor. The stepping motor can only detect one tapered roller after one rotation, and cannot continuously detect, resulting in the efficiency of detection. In a further aspect, the rollers are placed one by one on the rotating table of the stepping motor. When the size and shape of the roller changes, the fixture and related mechanisms need to be replaced and adjusted, so that the roller type is replaced. The adjustment workload is large and the complexity of the equipment is increased.

The roller workpiece 100 is tested by the apparatus and method of the present invention, and the number of roller workpieces 100 passed in one second is 12 (by the cooperation between the idler conveying device 1 and the outer circular imaging unit 2, rolling The sub-workpiece 100 is continuously rolled on the idler conveying device 1, and the rolling angle value is matched so that the outer circular image forming unit 2 can perform the dead angle recording on the roller workpiece 100 without clamping the single roller workpiece 100. After separate detection), ie, at The apparatus of the present invention can detect a roller workpiece 100 for a period of 0.08 seconds, while the apparatus of Comparative Example 1 detects a single workpiece for 0.5 to 3 seconds; the apparatus and method of the present invention employs a roller pair The roller workpiece 100 performs continuous rolling conveyance and photographing. When the roller model is replaced, the mechanism does not need to be adjusted. The replacement of the roller model does not require adjustment of the mechanism, and the device has a simple structure and high maintainability.

Comparative Example 2, in the prior art, such as "a detecting device for detecting a surface defect of a tapered roller, (Application No. 201320430398.3)", a device for detecting a roller, but the two rollers of the device are performing the workpiece In the process of transportation, if you want to get the best transportation effect, you need to set the corresponding thread (spiral groove) on a roller to realize the longitudinal movement of the workpiece, but in this process, the surface of the workpiece will often be wheeled. The risk of thread scraping on the upper thread causes an accidental failure rate of the workpiece; in addition, the device has the following defects: First, the outer circle image collecting unit 3 is not associated with the rotation angle of the guide wheels 1, 2 when photographing, generally According to the speed, each workpiece is photographed at several angles (6~9). This kind of shooting method is prone to leakage and other phenomena. Secondly, the advancement of the longitudinal operation is slow because of its long stroke, and generally it can only advance one or so in one second, and the work efficiency is slightly lower. When the two workpieces are running in the longitudinal direction, the front and rear end faces may contact each other, and since the front and rear end faces can completely maintain the same trajectory, the two workpieces are likely to stick together, resulting in unstable detection results. (Because of the minimum interval required for detection, if it is less than this minimum interval, it will cause misjudgment, resulting in the detection result not being accurate).

The device of the present invention can completely overcome the above-mentioned drawbacks, that is, after the angle of the transmission wheel 102 is calculated, the rotation angle of the current roller workpiece 100 can be obtained, and according to the calculation of the rotation angle, the current roller workpiece 100 can be obtained. The side information is taken according to this point, so that the shooting of the outer circle camera 104 covers the side of the roller workpiece 100 of three hundred and sixty degrees, and the phenomenon of missed shot is impossible, and the two end faces are taken together. Achieve 360-degree shooting without dead ends. Further, the present invention adopts a pipeline transportation mode in which the transmission wheel 102 and the roller conveyor chain 101 cooperate, so that the transmission speed is very fast, and the roller workpiece 100 only needs to be placed on the transportation line, and can be transported according to the transportation. The rotational speed of the transmission wheel 102 in the line is stably and uniformly advanced, and the transport speed achieved is at least 3 to 5 times that of the prior art. Finally, the device of the present invention has a simple structure, and various components can be assembled in a modular manner, and if any of the workpieces are damaged or aged, the maintenance of the entire device can be completed only by replacing the components. Convenience.

Finally, it should also be noted that the above list is only one specific embodiment of the invention. It is apparent that the present invention is not limited to the above embodiment, and many variations are possible. All modifications that can be directly derived or conceived by those of ordinary skill in the art from the disclosure of the present invention are considered to be the scope of the present invention.

Claims

Roller appearance defect 360 degree detecting device, comprising industrial computer controlled material conveying device and imaging unit; characterized in that: the material conveying device is a roller conveying device;

The imaging unit includes an outer circle imaging unit and two end imaging units;

An outer circle imaging unit is disposed above the roller conveying device, and two opposite imaging units are respectively disposed on two sides of the roller conveying device.
A 360 degree detecting device for roller appearance defects according to claim 1, wherein said roller conveying device comprises a roller for placing a roller workpiece, a roller conveying chain for driving the roller, and a conveyor roller for driving the roller. Running drive wheel.
A 360 degree detecting device for a roller appearance defect according to claim 2, wherein said outer circular image forming unit includes a counting means for counting a rotation angle of the idle roller and an outer circumference camera for performing shooting control by the counting means group;

The two-end imaging unit includes a positioning device that positions the roller workpiece and an end face A camera and an end face B camera that are controlled by the positioning device, and the end face A camera and the end face B camera are respectively disposed on the roller conveyor device side.
A 360 degree detection device for roller appearance defects according to claim 3, wherein said counting means comprises a displacement encoder and a pulse counter;

The displacement encoder outputs a corresponding pulse signal after counting the rotation angle of the roller, and the pulse counter calculates a corresponding angle of the roller workpiece by the pulse signal of the displacement encoder, and performs shooting control of the outer circle camera group;

The positioning device is a photoelectric sensor.
The 360-degree detection device for roller appearance defects according to claim 4, wherein the number of external cameras in the outer camera group is at least one.
The 360 degree detecting device for roller appearance defects according to claim 5, wherein the outer circle camera, the end face A camera and the end face B camera in the outer camera group adopt a high speed and high resolution CCD industrial camera.
Roller appearance defect 360 degree detection method; characterized in that: the roller workpiece is placed above the idler roller of the roller conveyor, and the roller workpiece is conveyed by the roller;

The end faces of the roller workpiece are photographed by the end face A camera and the end face B camera to complete the appearance defect detection of the two end faces of the roller workpiece;

The side of the roller workpiece is photographed by the outer camera group to complete the appearance defect detection on the side of the roller workpiece.
The 360 degree detection method for the appearance defect of a roller according to claim 7, wherein said outer camera group The work steps are as follows:

After the roller rotates at a certain angle, the displacement encoder generates a corresponding pulse signal;

The pulse counter counts the corresponding pulse signals generated by the shift encoder. When the angle to be photographed is reached, the pulse counter controls all the outer cameras of the outer camera group to shoot.
A 360 degree detection method for the appearance defect of a roller according to claim 8, wherein: when the roller rotates, the roller workpiece calculates a rotation of the roller by a diameter ratio between the roller workpiece and the idler roller. Angle, according to the corresponding angle value of the rotation of the roller and the corresponding angle value of the rotation of the roller workpiece, the corresponding angle value of the rotation of the roller workpiece is calculated.
The 360 degree detection method of the roller appearance defect according to claim 9, wherein when the photosensor detects that the roller workpiece passes, the end face A camera and the end face B camera are simultaneously photographed.