CN113189010A - Part detection mechanism based on machine vision and use method thereof - Google Patents

Part detection mechanism based on machine vision and use method thereof Download PDF

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CN113189010A
CN113189010A CN202110539950.1A CN202110539950A CN113189010A CN 113189010 A CN113189010 A CN 113189010A CN 202110539950 A CN202110539950 A CN 202110539950A CN 113189010 A CN113189010 A CN 113189010A
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control device
electric control
clamping
rotating
camera
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CN113189010B (en
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马军
李晓科
徐倩
曹阳
明五一
何文斌
龙雨
都金光
段留洋
刘琨
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Zhengzhou University of Light Industry
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    • G—PHYSICS
    • G01—MEASURING; TESTING
    • G01N—INVESTIGATING OR ANALYSING MATERIALS BY DETERMINING THEIR CHEMICAL OR PHYSICAL PROPERTIES
    • G01N21/00—Investigating or analysing materials by the use of optical means, i.e. using sub-millimetre waves, infrared, visible or ultraviolet light
    • G01N21/01—Arrangements or apparatus for facilitating the optical investigation
    • G—PHYSICS
    • G01—MEASURING; TESTING
    • G01N—INVESTIGATING OR ANALYSING MATERIALS BY DETERMINING THEIR CHEMICAL OR PHYSICAL PROPERTIES
    • G01N21/00—Investigating or analysing materials by the use of optical means, i.e. using sub-millimetre waves, infrared, visible or ultraviolet light
    • G01N21/84—Systems specially adapted for particular applications
    • G01N21/88—Investigating the presence of flaws or contamination
    • G01N21/89—Investigating the presence of flaws or contamination in moving material, e.g. running paper or textiles
    • G01N21/892—Investigating the presence of flaws or contamination in moving material, e.g. running paper or textiles characterised by the flaw, defect or object feature examined
    • G—PHYSICS
    • G01—MEASURING; TESTING
    • G01N—INVESTIGATING OR ANALYSING MATERIALS BY DETERMINING THEIR CHEMICAL OR PHYSICAL PROPERTIES
    • G01N27/00—Investigating or analysing materials by the use of electric, electrochemical, or magnetic means
    • G01N27/72—Investigating or analysing materials by the use of electric, electrochemical, or magnetic means by investigating magnetic variables
    • G01N27/82—Investigating or analysing materials by the use of electric, electrochemical, or magnetic means by investigating magnetic variables for investigating the presence of flaws
    • G01N27/83—Investigating or analysing materials by the use of electric, electrochemical, or magnetic means by investigating magnetic variables for investigating the presence of flaws by investigating stray magnetic fields
    • G01N27/84—Investigating or analysing materials by the use of electric, electrochemical, or magnetic means by investigating magnetic variables for investigating the presence of flaws by investigating stray magnetic fields by applying magnetic powder or magnetic ink

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Abstract

The invention discloses a part detection mechanism based on machine vision, which comprises a rack, wherein an input transmission mechanism, a clamping shooting mechanism and an output transmission mechanism are sequentially arranged on the rack from upstream to downstream by taking the overall moving direction of a detected part as the downstream direction; the rack is also provided with an electric control device, the electric control device is connected with a display screen and an audible and visual alarm, and an image recognition module is arranged in the electric control device; the clamping shooting mechanism comprises a camera mechanical arm and a clamping device arranged at the middle lower part of the rack; the free end of the camera mechanical arm is provided with a first camera, the free end of the camera mechanical arm or a fixed structure above the camera mechanical arm is provided with a lighting lamp, and the servo motor, the lighting lamp and the first camera are all connected with the electric control device; the clamping device comprises a clamping structure for clamping a part, a longitudinal rotating structure for driving the clamping part to rotate, a transverse rotating structure and a longitudinal overturning structure; also comprises a magnetic powder detection device.

Description

Part detection mechanism based on machine vision and use method thereof
Technical Field
The invention relates to the technical field of part detection, in particular to a part surface defect detection technology based on machine vision.
Background
The surface cracks of the parts not only affect the overall quality of the parts, but also cause interest damage to manufacturers producing the parts and even possibly bring serious accidental injuries. For example, parts made of ferromagnetic materials such as shafts, gears and disc sleeves in the industries of automobiles, war industry, aerospace, orbital transmission and the like have cracks, which may cause serious traffic accidents. Therefore, the detection and identification of cracks on the surface of these magnetic parts has become a necessary measure for the quality of the product. At present, the common detection methods for surface cracks of ferromagnetic materials include a turbine method, an ultrasonic method, a magnetic powder method and the like.
The magnetic powder method is divided into fluorescent and non-fluorescent magnetic powder detection, and the former method has higher contrast and is easy to detect compared with the latter method, so the method is widely applied to the industrial field. At present, the detection of the surface defect of the part is mainly manually carried out; due to the fact that the types and the number of various parts are large, and the structures of some parts are irregular, the situation that the types of the parts are wrong is difficult to avoid in the manual operation process.
In addition, in the manual inspection process, fatigue is easy to occur, for example, when too many parts are observed in a period of time, visual fatigue is easy to occur, so that the qualification rate of the produced products is influenced, and irreparable loss of enterprises is caused.
Therefore, the full-automatic magnetic powder inspection technology adopting automatic image recognition to replace manual judgment is urgent; the existing inspection means mainly adopts a single image processing technology and has a good effect under the condition of an ideal laboratory. However, the environment on the actual production line is more complicated than that in the laboratory, so that many systems cannot achieve an ideal working state on the production line, and the recognition rate of the systems is low.
The invention patent 'part detection method, system and device based on information fusion of a plurality of sensors' application number '201310733416. X' discloses a part detection method, system and electronic device based on information fusion of a plurality of sensors. By the method, the part can be subjected to image acquisition through the plurality of sensors, and the plurality of acquired images are fused, so that the advantages of the plurality of sensors in the part detection process are complemented, the part characteristics can be truly reflected, and the part detection precision and efficiency are improved.
The invention patent of application number ' 201910719946.6 ' an image acquisition camera for assembly line part detection ' discloses an image acquisition camera for assembly line part detection, which comprises a machine body and a rod body; install the mounting bracket on the organism, and install the conveyer belt in the organism, install the clamping piece on the conveyer belt simultaneously to the inside part of placing of clamping piece, camera and stopper looks spiro union for the image acquisition camera that assembly line part detected has and can carry out by the shooting operation from top down to the part, carries out omnidirectional shooting work to the part, realizes the serialization work that the part detected, has improved detection efficiency's characteristics.
The invention patent of ' 201910185667.6 patent for invention ' method and system for detecting parts based on industrial robot ' discloses a method and system for detecting parts based on industrial robot, wherein the method comprises: acquiring a plurality of three-dimensional projection images of the part to be detected, wherein the three-dimensional projection images are obtained by shooting the part to be detected in different shooting directions; and determining a visual coordinate system and a relative spatial position between the industrial robot and the part to be detected in each shooting direction according to the visual directions of the part to be detected in each three-dimensional projection image, and determining a target part detection direction of the industrial robot for detecting the part according to the deviation amount. Therefore, the diversity of the positions of the parts is allowed, the industrial robot is enabled to determine the target detection orientation of the parts in a self-adaptive mode, and the accuracy of part detection is improved.
The invention patent of application number '202010380943.7' discloses a robot for industrial part detection, which comprises a base, a support rod, a cross rod, a detection mechanism, a moving mechanism and a clamping mechanism, wherein the robot for industrial part detection realizes online detection of parts through the detection mechanism, realizes movement of the clamping mechanism through the moving mechanism, realizes clamping of unqualified parts through the clamping mechanism, then moves to a recycling box through the moving mechanism, enables the parts to fall into the recycling box through a baffle plate, and is recycled and reprocessed, the clamping mechanism adopts a flexible clamping mode, and scratches on the surfaces of the parts caused by rigid clamping are avoided.
The above patents can address the needs in certain application scenarios, but cannot address the following issues: the clamping supporting device of the part necessarily shields a part of the surface of the part, so that the omnidirectional image shooting in the real sense can not be realized, and the detection precision is reduced.
Disclosure of Invention
The invention aims to overcome the defects in the prior art, and provides a part detection mechanism based on machine vision, which solves the problem that a clamping support device of a part shields the surface of the part, and improves the detection accuracy through primary and precise automatic detection.
In order to achieve the purpose, the part detection mechanism based on machine vision comprises a rack, wherein an input conveying mechanism, a clamping shooting mechanism and an output conveying mechanism are sequentially arranged on the rack from upstream to downstream by taking the overall moving direction of a detected part as the downstream direction; the conveying surface of the input conveying mechanism is flush with the conveying surface of the output conveying mechanism; the rack is also provided with an electric control device, the electric control device is connected with a display screen and an audible and visual alarm, and an image recognition module is arranged in the electric control device;
the clamping shooting mechanism comprises a camera mechanical arm hinged to the top of the rack and a clamping device arranged at the middle lower part of the rack; the camera mechanical arm is driven by a servo motor;
the free end of the camera mechanical arm is provided with a first camera, the free end of the camera mechanical arm or a fixed structure above the camera mechanical arm is provided with a lighting lamp, and the servo motor, the lighting lamp and the first camera are all connected with the electric control device;
the clamping device comprises a clamping structure for clamping a part, a longitudinal rotating structure for driving the clamping part to rotate, a transverse rotating structure and a longitudinal overturning structure;
in the initial state, the overturning direction of the longitudinal overturning structure, the rotating direction of the longitudinal rotating structure and the rotating direction of the transverse rotating structure are vertical to each other;
the magnetic powder detection device comprises a detection table, one side of the detection table is fixedly connected with a powder storage box, and magnetic powder is stored in the powder storage box; the detection table is provided with a part position for placing parts, the detection table is provided with an electric spray gun, a powder suction device and a connecting rod, a feeding pipe of the electric spray gun is connected with the bottom of the powder storage box, and the spraying direction of the electric spray gun faces to the parts at the part position; the powder suction port of the powder suction device faces the part at the part position, and the powder outlet port of the powder suction device faces the powder storage box; a second camera is arranged on the connecting rod, and the shooting direction of the second camera faces to the part at the part position; the electric spray gun, the powder suction device and the second camera are all connected with the electric control device.
The longitudinal overturning structure comprises a supporting frame, the front end of the supporting frame is upwards connected with a bottom frame in a rotating mode through a rotating shaft, the middle rear portion of the bottom frame is downwards hinged with an overturning cylinder used for driving the bottom frame to overturn longitudinally, the overturning cylinder is downwards hinged with the rack, and the overturning cylinder is connected with an electric control device;
the transverse rotating structure comprises a rotating speed reducing motor and a rotating frame, an output shaft of the rotating speed reducing motor is a rotating part of the rotating speed reducing motor, a shell of the rotating speed reducing motor is a fixed part of the rotating speed reducing motor, and the fixed part and the rotating part of the rotating speed reducing motor are respectively connected with the bottom frame or the rotating frame; the rotation speed reducing motor is connected with the electric control device;
the longitudinal rotating structure comprises a mounting frame fixedly connected to the rotating frame, the mounting frame is rotatably connected with a first rotating ring and a second rotating ring which are oppositely arranged in parallel, one side of the first rotating ring is convexly provided with a first rolling guide ring along the circumferential direction, and one side of the second rotating ring is convexly provided with a second rolling guide ring along the circumferential direction; two first grooved wheels used for supporting the first rolling guide ring are arranged on the mounting frame below the first rolling guide ring, and the first rolling guide ring is inserted into the grooves of the first grooved wheels;
two second grooved wheels used for supporting the second rolling guide ring are arranged on the mounting frame below the second rolling guide ring, and the second rolling guide ring is inserted into the grooves of the second grooved wheels;
the two first grooved wheels and the two second grooved wheels form a supporting grooved wheel set, at least one grooved wheel in the supporting grooved wheel set is connected with a grooved wheel driving motor, the grooved wheel serves as a driving grooved wheel, and the grooved wheel driving motor is connected with an electric control device;
a pressing wheel is mounted on the mounting frame and is pressed downwards to be in pressure joint with the inner surface of the bottom of the first rotating ring or the inner surface of the bottom of the second rotating ring;
the clamping structure comprises a front connecting plate and a rear connecting plate which are fixedly connected between the first rotating ring and the second rotating ring, two clamping rollers are arranged between the front connecting plate and the rear connecting plate, electromagnets are respectively arranged in the two clamping rollers, and the electromagnets are connected with the electric control device; a driving roller is arranged between the two clamping rollers, the driving roller is arranged between the front connecting plate and the rear connecting plate, the driving roller is connected with a roller driving motor, and the roller driving motor is connected with an electric control device; the two clamping rollers are used for rolling and conveying parts and magnetically clamping the parts; the roller driving motor is used for finely adjusting the position of the part during photographing;
the two clamping rollers and the driving roller are positioned on the same plane, and the plane is called a clamping plane; the clamping structure is in a butt joint state, and when the clamping structure is in the butt joint state, the clamping plane is flush with the conveying surface of the input conveying mechanism and the conveying surface of the output conveying mechanism and is in butt joint;
and a part sensor for detecting parts is arranged on the rotating frame or the mounting rack below the roller for clamping, and the part sensor is connected with the electric control device.
The top of the frame is provided with a horizontally arranged screen baffle, the camera mechanical arm is hinged on the screen baffle of the frame, and the illuminating lamp is an annular LED lamp panel arranged on the screen baffle.
The input conveying mechanism and the output conveying mechanism are identical in structure and respectively comprise a plurality of conveying rollers which are arranged on the roller frame side by side at intervals, each conveying roller comprises a driving roller and a plurality of driven rollers, and the roller frame is arranged on the rack; and a roller driving motor for driving the driving roller is arranged on the frame or the roller frame, and the roller driving motor is connected with the electric control device.
Be equipped with between magnetic particle testing device and the clamping structure and be used for transporting the transportation manipulator on the magnetic particle testing device with the part.
The first rotating ring and the second rotating ring are respectively provided with a dynamic balancing mechanism;
the first rotating ring and the second rotating ring are collectively called as rotating rings, and the dynamic balancing mechanism comprises an upper dynamic balancing mechanism arranged above the clamping mechanism and a lower dynamic balancing mechanism arranged below the clamping mechanism;
the upper dynamic balancing mechanism and the lower dynamic balancing mechanism have the same structure and respectively comprise double-rotor linear motors arranged along the chord direction of the rotating ring, and two rotors of the double-rotor linear motors are respectively provided with a balancing weight for adjusting the gravity center position of the integral structure formed by the rotating ring, the clamping mechanism and the clamped workpiece;
the wheel carriers at the wheel shafts of the first sheave and the second sheave are respectively provided with a stress strain sensor for monitoring the stress condition of the first sheave and the second sheave, and the stress strain sensors and the double-rotor linear motors are connected with an electric control device.
The invention also discloses a use method of the part detection mechanism based on the machine vision, which comprises the following steps:
the first step is feeding;
the detected part enters the input conveying mechanism from the previous process, enters the clamping structure in a butt joint state under the driving of the roller driving motor, the electric control device closes the roller driving motor, starts the roller driving motor, and drives the part by the driving roller;
the part sensor sends a signal to the electric control device after detecting the part, the electric control device closes the roller driving motor to finish feeding, and the part is supported by the driving roller and the two clamping rollers;
the second step is clamping;
the electric control device starts the electromagnets in the two clamping rollers to position the parts through magnetic adsorption;
the third step is to shoot the upper surface of the part;
the electric control device obtains an image of the upper surface of the part through shooting by the first camera;
the fourth step is to shoot the back surface image of the part;
the electric control device controls the overturning cylinder to drive the bottom frame to overturn upwards and simultaneously controls the mechanical arm of the camera to rotate, so that the first camera shoots an image of the rear surface of the part in the direction opposite to the rear surface of the part;
the fifth step is to shoot the left surface image of the part;
the electric control device controls the reduction motor for rotation to drive the rotating frame and the part to rotate for 90 degrees continuously until the left surface of the part is opposite to the first camera; then the electric control device enables the first camera to shoot an image of the left surface of the part in the direction opposite to the left surface of the part;
the sixth step is to shoot the front surface image of the part;
the electric control device controls the rotating speed reduction motor to drive the rotating frame and the part to rotate for 90 degrees continuously, so that the front surface of the part is opposite to the first camera; then the electric control device enables the first camera to shoot the front surface image of the part in the direction opposite to the front surface of the part;
the seventh step is to shoot the right surface image of the part;
the electric control device controls the rotating speed reduction motor to drive the rotating frame and the part to rotate for 90 degrees continuously, so that the right surface of the part is opposite to the first camera; then the electric control device enables the first camera to shoot the right surface image of the part in the direction opposite to the right surface of the part;
the eighth step is that the part is reset once;
the electric control device controls the rotating speed reduction motor to drive the rotating frame and the part to rotate for 90 degrees continuously, and simultaneously controls the turnover air cylinder to reset, so that the part returns to the original position in the second step;
the ninth step is to shoot a first image on the lower surface of the part;
the electric control device controls the sheave driving motor to start, and the sheave driving motor drives the first rotating ring and the second rotating ring to integrally rotate for 180 degrees through the first sheave or the second sheave and then stops to enable the lower surface of the part to face upwards; the electric control device controls the mechanical arm of the camera to rotate to a position where the shooting direction of the camera faces to the right lower part, and then the electric control device enables the first camera to shoot a first image on the lower surface of the part in the direction opposite to the lower surface of the part;
the tenth step is the secondary resetting of the parts;
the electric control device controls the sheave driving motor to start, and the sheave driving motor drives the first rotating ring and the second rotating ring to integrally rotate for 180 degrees through the first sheave or the second sheave and then stops to reset the part;
the eleventh step is to shoot a second image of the lower surface of the part;
the electric control device closes the electromagnets in the two clamping rollers, the diameters of the clamping rollers and the driving rollers are both d, the roller driving motor is started, the roller driving motor is closed when the driving rollers drive the part to move for 2d, and at the moment, the part, which is shielded by the clamping rollers and the driving rollers, of the bottom surface of the part in the first image is exposed;
the electric control device starts the electromagnets in the two clamping rollers, positions the part through magnetic adsorption, then controls the sheave driving motor to start, and the sheave driving motor drives the first rotating ring and the second rotating ring to integrally rotate for 180 degrees through the first sheave or the second sheave and then stops to enable the lower surface of the part to face upwards; then the electric control device enables the first camera to shoot a second image of the lower surface of the part in the direction opposite to the lower surface of the part;
the twelfth step is that the parts are reset for three times;
the electric control device controls the sheave driving motor to start, and the sheave driving motor drives the first rotating ring and the second rotating ring to integrally rotate for 180 degrees through the first sheave or the second sheave and then stops, so that the part is reset to the position with the upper surface facing upwards;
the thirteenth step is image recognition and blanking;
the electric control device identifies the image of the part through the image identification module and judges whether the surface of the part has defects or not;
if the image recognition module detects that a certain surface of the part is suspected to have a defect, the electric control device displays the surface suspected to have the defect on the display screen; the electric control device turns on the audible and visual alarm to give an alarm until the part sensor detects that the transferring manipulator takes out the part and then turns off the audible and visual alarm;
if the surface of the part has no defect, the electric control device simultaneously closes the electromagnets in the two rollers for clamping, starts the roller driving motor and the roller driving motor of the output conveying mechanism, so that the part moves to the output conveying mechanism and is conveyed to the next procedure by the output conveying mechanism.
In the thirteenth step, when the surface of the part has defects and the part is taken out by the transfer manipulator, the part is placed at the part position on the detection platform, the surface suspected to have defects faces upwards, and the part is subjected to secondary detection;
the secondary detection is carried out according to the following method:
the electric control device controls the electric spray gun to uniformly spray magnetic powder on the surface of the part suspected to have defects, then the second camera is controlled to shoot the surface of the part, an image recognition module in the electric control device recognizes the image of the surface of the part adsorbed with the magnetic powder, judges whether the surface has the defects or not, and displays the judgment result on the display screen; the electric control device opens the powder suction device to suck the magnetic powder on the surface of the part back to the powder storage box;
after the detection is finished, manually placing the parts which do not have defects into a storage position of good parts; for parts with a certain defect, it is manually put into a defective part storage position.
When the part is placed at the part position on the detection table, the electric control device moves the part according to a transfer manipulator space three-dimensional path control method;
the method for controlling the spatial three-dimensional path of the transfer manipulator comprises the following steps:
a space model of the part detection mechanism based on machine vision is prestored in the electric control device;
the top of the rack is provided with a first laser radar, the transfer manipulator is provided with a second laser radar, and the top of the connecting rod is provided with a third laser radar;
the method for controlling the spatial three-dimensional path of the transfer manipulator comprises the following steps:
the first step is to construct a Kriging model of the obstacle;
the electric control device is internally provided with the size and joint angle information of the transfer manipulator, a space environment model is established based on a grid method according to the space model, and an obstacle model is established; the specific construction process of the obstacle model comprises the following sub-steps:
the first substep is to photograph the obstacle;
the electric control device photographs the obstacle through the first laser radar, the second laser radar and the third laser radar, respectively disperses the surface of the obstacle into 10000 points, and obtains the space coordinate of each point in the space environment model;
the second substep is to construct the Kriging model;
the electric control device randomly selects 100 points from 10000 points, the X coordinate and the Y coordinate of the 100 points are used as design variables, the Z coordinate is used as a Kriging approximate model for responding and constructing the obstacle, and the Kriging model is constructed together;
the third substep is to realize the envelope of the Kriging model to the whole obstacle;
the electric control device predicts the Z seats at 10000 sample points in the first step by using the constructed Kriging modelMarking value
Figure BDA0003071278380000071
If it is not good
Figure BDA0003071278380000072
If the obstacle is located inside the obstacle, points are selected again to construct a Kriging model until all points on the boundary of the obstacle are located inside a Kriging prediction model, so that the envelope of the Kriging model on the whole obstacle is realized;
the second step is that the transfer manipulator transfers the part; the electric control device judges whether the linear motion of the part driven by the transfer manipulator from the starting point A to the end point B interferes with the Kriging model; the point A is determined by a first laser radar, and the point B is a predetermined part position on the detection table and is stored in the electric control device in advance;
if the interference is avoided, setting the motion of the transfer manipulator as the linear motion from the starting point A to the end point B;
if interference occurs, setting the end point of the intersection line segment of the straight line AB and the obstacle Kriging model, which is adjacent to the point A, as the point C, and setting the end point of the intersection line segment of the straight line AB and the obstacle Kriging model, which is adjacent to the point B, as the point D;
the movement of the transfer manipulator driving the part is divided into the following three substeps:
the first substep is: the electric control device controls the transfer manipulator to move the part to a point C from a starting point A along a straight line;
the second substep is: the electric control device controls the transfer manipulator to move the part from the point C to the point D along the surface of the Kriging model;
the third substep is: the electric control device controls the transfer manipulator to move the part from the D point to the B point along a straight line, and the part is moved to the detection table by the clamping shooting mechanism.
The invention has the following advantages:
the space three-dimensional coordinate is provided with XYZ three mutually perpendicular axes, the turning direction of the longitudinal turning structure, the rotating direction of the longitudinal rotating structure and the rotating direction of the transverse rotating structure in the invention are pairwise perpendicular, so that the parts can be driven to rotate to a required angle in the three-dimensional direction, the requirement of omnibearing shooting is met, and online automatic detection is realized under the control of the electric control device. According to the invention, the parts are mainly detected through the first camera, and the parts with problems are secondarily detected through the second camera, so that the detection accuracy is improved.
According to the invention, the vertical rotation of the clamping structure is realized through the longitudinal turnover mechanism, the transverse rotation of the clamping structure is realized through the transverse rotation structure, the part can be rotated to a butt joint state to enter and exit the clamping structure, and the part can be rotated to a rotary photographing state to be photographed by the first camera.
The electromagnet is arranged in the clamping roller, has double functions of rolling and conveying parts and magnetic clamping parts, does not work when the parts are rolled and conveyed, so that the parts cannot be magnetically adsorbed and positioned, and are driven to move by the rotation of the clamping roller; when taking a picture, the roller driving motor does not work, and the electromagnet is electrified to work, so that the part can be firmly adsorbed on the roller for clamping.
When the part is shot, the part is adsorbed on the rollers for clamping, and when the bottom surface of the part is shot, the part is blocked by the two rollers for clamping and one roller for driving, so that all part images cannot be obtained. During the shooting, the position of the part can be finely adjusted through the roller driving motor, so that the bottom surface of the part can be shot again after the position of the part is finely adjusted, an image of a position which is shielded by the two rollers for clamping and the roller for driving in the previous shooting is obtained, and a basis is provided for generating an all-dimensional dead-angle-free part image through image fusion.
The pinch roller is pressed with the first rotating ring or the second rotating ring downwards, so that the pinch roller can be prevented from upwards leaving the grooved wheel with the first rotating ring and the second rotating ring, and the structure can be stably operated while the structure flexibility is very high. The part sensor can detect whether the part is in place or not, and provides a basis for automatic control of the electric control device.
The annular LED lamp plate can produce the light source effect of similar shadowless lamp to the quality of image is shot in the promotion.
The part is clamped and positioned, any surface of the part is not shielded in shooting, and the problem of shooting the part to carry out machine vision detection is solved. The part detection mechanism based on machine vision and the use method thereof solve the problem, and all surfaces of the part except the bottom surface are not contacted with the clamping structure through magnetic adsorption, so that only one surface, namely the bottom surface, is shielded by the clamping structure. The clamping roller rotates to drive the part to move, so that the part is exposed out of the original shielded part, and the image fusion is carried out after the bottom surface is shot for the second time, so that a complete bottom surface image which is not shielded is obtained.
The using method of the invention automatically finishes the actions of feeding, clamping, overturning parts to different positions, shooting, blanking and the like under the control of the electric control device, and has higher working efficiency.
According to the spatial three-dimensional path control method for the transfer manipulator, in the process that the transfer manipulator moves the part from the clamping structure to the detection table of the magnetic powder detection device, collision between the part and an obstacle in the movement process of the transfer manipulator is avoided, the part (namely the tail end of the transfer manipulator) is guaranteed to have the shortest movement path, the energy consumption is low, and the transfer efficiency is high.
Drawings
FIG. 1 is a schematic structural view of the present invention;
FIG. 2 is a schematic view of the structure of the part being inspected;
FIG. 3 is a schematic perspective view of the input transfer mechanism, the clamping and shooting mechanism and the output transfer mechanism;
FIG. 4 is a schematic view of the structure at the clamping configuration; the dual mover linear motor is not shown in fig. 4.
FIG. 5 is a schematic view of the part entering the input transport mechanism;
FIG. 6 is a schematic view of the structure of the upper surface of the part being photographed;
FIG. 7 is a schematic view of the structure when the rear surface of the part is photographed;
FIG. 8 is a schematic view of the structure when the left surface of the part is photographed;
FIG. 9 is a schematic view of the structure when the front surface of the part is photographed;
FIG. 10 is a schematic view of the structure when the right surface of the part is photographed;
FIG. 11 is a schematic view of the structure of the lower surface of the part being photographed;
FIG. 12 is a schematic view of the structure of the eleventh step in which the part is moved by a distance of 2 d;
FIG. 13 is a schematic view of the eleventh step of taking a second image of the lower surface of the part;
FIG. 14 is a schematic view of the structure of the parts being transferred to the next process step by the output transfer mechanism;
FIG. 15 is a schematic view of the magnetic particle testing apparatus;
FIG. 16 is a schematic view of the structure at the clamping device;
fig. 17 is a schematic view of a structure at the rotating reduction motor;
fig. 18 is an electrical control schematic of the present invention.
Detailed Description
As shown in fig. 1 to 18, the part inspection mechanism based on machine vision of the present invention includes a frame 2, and an input conveying mechanism 51, a clamping shooting mechanism 52 and an output conveying mechanism 53 are sequentially arranged on the frame 2 from upstream to downstream, with the overall moving direction of the inspected part 31 as downstream; the conveying surface of the input conveying mechanism 51 is flush with the conveying surface of the output conveying mechanism 53; the rack 2 is also provided with an electric control device 20, the electric control device 20 is connected with a display screen 13 and a sound-light alarm 19, and an image recognition module is arranged in the electric control device 20;
the clamping shooting mechanism 52 comprises a camera mechanical arm 12 hinged to the top of the frame 2 and a clamping device arranged at the middle lower part of the frame 2; the camera robot arm 12 is driven by a servo motor 32; specifically, the servo motor 32 is located at the joint (articulation) of the camera robot arm 12; the camera arm 12 has several joints and the servo motors 32 are correspondingly provided in several numbers.
A first camera 10 is arranged at the free end of the camera mechanical arm 12, an illuminating lamp 11 is arranged at the free end of the camera mechanical arm 12 or on a fixed structure above the camera mechanical arm 12, and the servo motor 32, the illuminating lamp 11 and the first camera 10 are all connected with an electric control device 20; the outer cover of the illuminating lamp 11 is provided with a diffusion plate 33, and the diffusion plate 33 is used for scattering light emitted by the illuminating lamp 11, so that the illumination is more uniform.
The clamping device comprises a clamping structure for clamping the part 31, a longitudinal rotating structure for driving the clamping part to rotate, a transverse rotating structure and a longitudinal overturning structure;
in the initial state, the overturning direction of the longitudinal overturning structure, the rotating direction of the longitudinal rotating structure and the rotating direction of the transverse rotating structure are vertical to each other; namely, the turning direction of the longitudinal turning structure is vertical to the rotating direction of the longitudinal rotating structure, the rotating direction of the longitudinal rotating structure is vertical to the rotating direction of the transverse rotating structure, and the turning direction of the longitudinal turning structure is vertical to the rotating direction of the transverse rotating structure.
The magnetic powder detection device comprises a detection table 36, a powder storage box 39 is fixedly connected to one side of the detection table 36, and magnetic powder (namely magnetic powder) is stored in the powder storage box 39; the detection table 36 is provided with a part position for placing the part 31, the detection table 36 is provided with an electric spray gun 40, a powder suction device 38 and a connecting rod 37, a pipe of the electric spray gun 40 is connected with the bottom of a powder storage box 39, and the spraying direction of the electric spray gun 40 faces the part 31 at the part position; the powder suction port of the powder suction device 38 faces the part 31 at the part position, and the powder outlet port of the powder suction device 38 faces the powder storage box 39; the connecting rod 37 is provided with a second camera 54, and the shooting direction of the second camera 54 faces to the part 31 of the part position;
the electric spray gun 40, the powder absorber 38 and the second camera 54 are all connected with the electric control device 20;
the electric control device 20 is a PLC or an industrial control computer, and the structures of the electric control device 20, the audible and visual alarm 19, the powder suction device 38, the electric spray gun 40, the camera mechanical arm 12 and the servo motor 32 driven mechanical arm 12 are all the prior art and are not described again.
The space three-dimensional coordinate is provided with XYZ three mutually perpendicular axes, the turning direction of the longitudinal turning structure, the rotating direction of the longitudinal rotating structure and the rotating direction of the transverse rotating structure in the invention are pairwise perpendicular, the part 31 can be driven to rotate to a required angle in the three-dimensional direction, the requirement of omnibearing shooting is met, and the online automatic detection is realized under the control of the electric control device 20. According to the invention, the first camera 10 is used for mainly detecting the part 31, and the second camera 54 is used for secondarily detecting the part 31 with problems, so that the detection accuracy is improved.
In fig. 2, reference numeral 55 is the upper surface of the part 31, reference numeral 56 is the rear surface of the part 31, reference numeral 57 is the lower surface of the part 31, reference numeral 58 is the front surface of the part 31, reference numeral 59 is the left surface of the part 31, and reference numeral 60 is the right surface of the part 31. Reference numeral 4 in fig. 3 is a table provided on the frame.
The longitudinal overturning structure comprises a supporting frame 61, the front end of the supporting frame 61 is upwards connected with a bottom frame 62 in a rotating mode through a rotating shaft, the middle rear portion of the bottom frame 62 is downwards hinged with an overturning cylinder 63 for driving the bottom frame 62 to overturn longitudinally, the overturning cylinder 63 is downwards hinged with the rack 2, and the overturning cylinder 63 is connected with the electric control device 20;
the horizontal rotation structure includes a rotation reduction motor 64 and a rotation frame 65, an output shaft of the rotation reduction motor 64 is a rotation portion thereof and a housing thereof is a fixed portion thereof, and the fixed portion and the rotation portion of the rotation reduction motor 64 are connected to the bottom frame 62 or the rotation frame 65, respectively. That is, when the bottom frame 62 is connected to the fixed portion of the rotation reduction motor 64, the rotating frame 65 is connected to the rotating portion of the rotation reduction motor 64; when the bottom frame 62 is connected with the rotating part of the speed reducing motor 64 for rotation, the rotating frame 65 is connected with the fixed part of the speed reducing motor 64 for rotation; the speed reduction motor 64 for rotation is connected with the electric control device 20;
the longitudinal rotating structure comprises a mounting frame 66 fixedly connected to the rotating frame 65, the mounting frame 66 is rotatably connected with a first rotating ring 67 and a second rotating ring 16 which are oppositely arranged in parallel, one side of the first rotating ring 67 is convexly provided with a first rolling guide ring 68 along the circumferential direction, and one side of the second rotating ring 16 is convexly provided with a second rolling guide ring 69 along the circumferential direction; two first grooved wheels 70 for supporting the first rolling guide ring 68 are arranged on the mounting frame 66 below the first rolling guide ring 68, and the first rolling guide ring 68 is inserted into the grooves of the first grooved wheels 70;
two second grooved wheels 71 for supporting the second rolling guide ring 69 are arranged on the mounting frame 66 below the second rolling guide ring 69, and the second rolling guide ring 69 is inserted into the grooves of the second grooved wheels 71;
the two first grooved wheels 70 and the two second grooved wheels 71 form a support grooved wheel set, at least one grooved wheel in the support grooved wheel set is connected with a grooved wheel driving motor 72 and is used as a driving grooved wheel, and the grooved wheel driving motor 72 is connected with the electric control device 20;
a pressing wheel 73 is arranged on the mounting frame 66, and the pressing wheel 73 is pressed downwards and connected with the inner surface of the bottom of the first rotating ring 67 or the inner surface of the bottom of the second rotating ring 16 in a pressing mode; the pinch roller 73 prevents the whole body formed by the first rotating ring 67 and the second rotating ring 16 through the clamping structure from leaving the supporting grooved wheel set, and the clamping structure cannot fall off during longitudinal rotation.
The clamping structure comprises a front connecting plate 14 and a rear connecting plate 74 which are fixedly connected between the first rotating ring 67 and the second rotating ring 16, two clamping rollers 17 are arranged between the front connecting plate 14 and the rear connecting plate 74, electromagnets 75 are respectively arranged in the two clamping rollers 17, and the electromagnets 75 are connected with the electric control device 20; a driving roller 18 is arranged between the two clamping rollers 17, the driving roller 18 is arranged between the front connecting plate 14 and the rear connecting plate 74, the driving roller 18 is connected with a roller driving motor 76, and the roller driving motor 76 is connected with the electric control device 20; the two clamping rollers 17 are used for rolling and conveying the parts 31 and positioning the clamping parts 31 through magnetic force; the roller driving motor 76 is used for finely adjusting the position of the part 31 during photographing; the roller drive motor 76 is mounted on the front attachment plate 14 or the rear attachment plate 74.
The two clamping rollers 17 and the driving roller 18 are located on the same plane, and the plane is called a clamping plane; the clamping structure has a butt joint state and a rotary photographing state, and when the clamping structure is located in the butt joint state, a clamping plane is flush with the conveying surface of the input conveying mechanism 51 and the conveying surface of the output conveying mechanism 53 and is in butt joint;
a part sensor 77 for detecting the parts 31 is provided on the rotating frame 65 or the mounting frame 66 below the two clamping rollers 17, and the part sensor 77 is connected to the electronic control device 20.
According to the invention, the vertical rotation of the clamping structure is realized through the longitudinal turnover mechanism, the transverse rotation of the clamping structure is realized through the transverse rotation structure, the part 31 can be rotated to a butt joint state to clamp the structure, and the part can also be rotated to a rotary photographing state to be photographed by the first camera 10.
The clamping roller 17 is internally provided with the electromagnet 75, has double functions of the rolling conveying part 31 and the magnetic clamping part 31, does not work when the part 31 is rolled and conveyed, so that the part 31 is not attracted by magnetic force, and the part 31 is driven to move by the rotation of the clamping roller 17; when photographing, the drum drive motor 76 is not operated and the electromagnet 75 is energized, so that the component 31 can be firmly attached to the chuck drum 17.
When the part 31 is picked up, the part is attracted to the chuck rollers 17, and when the bottom surface of the part 31 is picked up, the part is shielded by the two chuck rollers 17 and the one driving roller 18, and thus all the part images cannot be obtained. During shooting, the position of the part 31 can be finely adjusted through the roller driving motor 76, so that the bottom surface of the part can be shot again after the position of the part 31 is finely adjusted, an image of a part which is shot in the previous time and is shielded by the two clamping rollers 17 and the driving roller 18 is obtained, and a basis is provided for generating an all-dimensional dead-angle-free part image through image fusion.
The pinch roller 73 is pressed downwards to be in pressure connection with the first rotating ring 67 or the second rotating ring 16, so that the pinch roller can be prevented from upwards leaving the grooved wheel with the first rotating ring 67 and the second rotating ring 16, and the stability of the structure operation is ensured while the structure flexibility is very high. The part sensor 77 can detect whether the part 31 is in place, and provide a basis for automatic control of the electronic control device 20.
Specifically, a horizontally arranged screen baffle 1 is arranged at the top of the frame 2, the camera mechanical arm 12 is hinged on the screen baffle 1 of the frame 2, and the illuminating lamp 11 is preferably an annular LED lamp panel arranged on the screen baffle 1. The annular LED lamp plate can produce the light source effect of similar shadowless lamp to the quality of image is shot in the promotion.
The input conveying mechanism 51 and the output conveying mechanism 53 have the same structure and respectively comprise a plurality of conveying rollers 78 which are arranged on a roller frame 79 side by side at intervals, each conveying roller 78 comprises a driving roller and a plurality of driven rollers, and the roller frame 79 is arranged on the machine frame 2; a roller driving motor 80 for driving the driving roller is arranged on the frame 2 or the roller frame 79, and the roller driving motor 80 is connected with an electric control device. Be equipped with between magnetic particle testing device and the clamping structure and be used for transporting the transportation manipulator 81 on the magnetic particle testing device with the part.
The first rotating ring 67 and the second rotating ring 16 are respectively provided with a dynamic balancing mechanism;
the first rotating ring 67 and the second rotating ring 16 are collectively called as rotating rings, and the dynamic balancing mechanism comprises an upper dynamic balancing mechanism arranged above the clamping mechanism and a lower dynamic balancing mechanism arranged below the clamping mechanism;
the upper dynamic balancing mechanism and the lower dynamic balancing mechanism have the same structure and respectively comprise a double-rotor linear motor 91 arranged along the chord direction of the rotating ring, and two rotors 93 of the double-rotor linear motor 91 are respectively provided with a balancing weight for adjusting the gravity center position of the integral structure formed by the rotating ring, the clamping mechanism and the clamped workpiece. The weight itself is conventional and not shown.
Stress strain sensors 92 for monitoring stress conditions of the first sheave 70 and the second sheave 71 are respectively arranged on wheel carriers at wheel shafts of the first sheave 70 and the second sheave 71, and the stress strain sensors 92 monitor changes of stress through the wheel shafts; the stress strain sensor 92 and each double-rotor linear motor 91 are connected with the electric control device 20.
When the sheave driving motor 72 drives the first rotating ring 67 and the second rotating ring 16 to rotate integrally through the first sheave 70 or the second sheave 71, the electric control device monitors the change of the gravity center position of the integral structure formed by the rotating ring, the clamping mechanism and the clamped workpiece through the stress strain sensor 92, correspondingly controls the action of each double-rotor linear motor 91, and moves the position of each counterweight block by each rotor 93, so that the gravity center position of the integral structure formed by the rotating ring, the clamping mechanism and the clamped workpiece is close to the axis of the rotating ring as much as possible, and a better dynamic balance state is kept in the rotating process.
The invention also discloses a use method of the part detection mechanism based on the machine vision, which comprises the following steps:
the first step is feeding;
the detected part 31 (the part 31 is made of iron or steel and can be magnetically adsorbed) enters the input conveying mechanism 51 from the previous working procedure, enters the clamping structure in a butt joint state under the driving of the roller driving motor 80, the electric control device 20 closes the roller driving motor 80, starts the roller driving motor 76, and drives the part 31 through the driving roller 18;
the part sensor 77 sends a signal to the electric control device 20 after detecting the part 31, the electric control device 20 closes the roller driving motor 76 to finish feeding, and at the moment, the part 31 is supported by the driving roller 18 and the two clamping rollers 17;
the second step is clamping;
the electric control device 20 starts the electromagnets 75 in the two clamping rollers 17 to position the part 31 through magnetic adsorption;
the third step is to photograph the upper surface of the part 31;
the electric control device 20 obtains an image of the upper surface of the part 31 through shooting by the first camera 10;
the fourth step is to photograph the rear surface image of the part 31;
the electric control device 20 controls the overturning cylinder 63 to drive the bottom frame 62 to overturn upwards, and simultaneously controls the camera mechanical arm 12 to rotate, so that the first camera 10 shoots the image of the rear surface of the part 31 in the direction opposite to the rear surface of the part 31;
the fifth step is to photograph the left surface image of the part 31;
the electric control device 20 controls the reduction motor 64 for rotation to drive the rotating frame 65 and the part 31 to rotate for 90 degrees continuously until the left surface of the part 31 is opposite to the first camera 10; then the electronic control device 20 makes the first camera 10 shoot the left surface image of the part 31 in the direction opposite to the left surface of the part 31;
the sixth step is to take an image of the front surface of the part 31;
the electric control device 20 controls the reduction motor 64 for rotation to drive the rotating frame 65 and the part 31 to rotate for 90 degrees continuously, so that the front surface of the part 31 is opposite to the first camera 10; then the electronic control device 20 makes the first camera 10 shoot the image of the front surface of the part 31 in the direction opposite to the front surface of the part 31;
the seventh step is to photograph the right surface image of the part 31;
the electric control device 20 controls the reduction motor 64 for rotation to drive the rotating frame 65 and the part 31 to rotate for 90 degrees continuously, so that the right surface of the part 31 is opposite to the first camera 10; the electronic control device 20 then causes the first camera 10 to take an image of the right surface of the part 31 in a direction opposite to the right surface of the part 31;
the eighth step is a one-time resetting of the part 31;
the electric control device 20 controls the reduction motor 64 for rotation to drive the rotating frame 65 and the part 31 to continuously rotate for 90 degrees, and simultaneously the electric control device 20 controls the turnover cylinder 63 to reset, so that the part 31 returns to the original position in the second step;
the ninth step is to take a first image of the lower surface of the part 31;
the electric control device 20 controls the sheave driving motor 72 to start, and the sheave driving motor 72 drives the first rotating ring 67 and the second rotating ring 16 to integrally rotate for 180 degrees through the first sheave 70 or the second sheave 71 and then stops, so that the lower surface of the part 31 faces upwards; the electric control device 20 controls the camera mechanical arm 12 to rotate to a position where the shooting direction of the camera faces to the right lower part, and then the electric control device 20 enables the first camera 10 to shoot a first image on the lower surface of the part 31 in the direction opposite to the lower surface of the part 31;
the tenth step is the secondary resetting of the part 31;
the electric control device 20 controls the sheave driving motor 72 to start, and the sheave driving motor 72 drives the first rotating ring 67 and the second rotating ring 16 to integrally rotate for 180 degrees through the first sheave 70 or the second sheave 71 and then stops, so that the part 31 is reset;
the eleventh step is to take a second image of the lower surface of the part 31;
the electric control device 20 closes the electromagnets 75 in the two clamping rollers 17, the diameters of the clamping rollers 17 and the driving rollers 18 are d, the roller driving motor 76 is started, the roller driving motor 76 is closed when the driving rollers 18 drive the part 31 to move for 2d, and at the moment, the part shielded by the clamping rollers 17 and the driving rollers 18 on the bottom surface of the part 31 in the first image is exposed;
the electric control device 20 starts the electromagnets 75 in the two clamping rollers 17, positions the part 31 through magnetic adsorption, then the electric control device 20 controls the sheave driving motor 72 to start, and the sheave driving motor 72 drives the first rotating ring 67 and the second rotating ring 16 to integrally rotate for 180 degrees through the first sheave 70 or the second sheave 71 and then stops, so that the lower surface of the part 31 faces upwards; then the electronic control device 20 makes the first camera 10 shoot a second image of the lower surface of the part 31 in the direction opposite to the lower surface of the part 31;
the twelfth step is that the part 31 is reset three times;
the electric control device 20 controls the sheave driving motor 72 to start, and the sheave driving motor 72 drives the first rotating ring 67 and the second rotating ring 16 to integrally rotate for 180 degrees through the first sheave 70 or the second sheave 71 and then stops, so that the part 31 is reset to the position with the upper surface facing upwards;
the thirteenth step is image recognition and blanking;
the electronic control device 20 identifies the image of the part 31 through the image identification module, and judges whether the surface of the part 31 has pores, cracks or scratch defects;
if the image recognition module detects that a surface of the part 31 is suspected of having a defect, the electronic control device 20 displays the surface (such as the front surface or the upper surface) suspected of having the defect on the display 13; the electric control device 20 turns on the audible and visual alarm 19 to give an alarm until the part sensor 77 detects that the part 31 is taken out by the transfer manipulator 81 (namely, the part 31 disappears), and then turns off the audible and visual alarm 19;
if there is no defect on the surface of the part 31, the electronic control device 20 simultaneously turns off the electromagnets 75 in the two clamping rollers 17, starts the roller drive motor 76 and the roller drive motor 80 of the output transfer mechanism 53, and moves the part 31 onto the output transfer mechanism 53 and transfers it to the next process by the output transfer mechanism 53.
Clamping the positioning part 31 and not blocking any surface of the part 31 in shooting are difficult problems in shooting the part 31 for machine vision detection. The part detection mechanism based on machine vision and the use method thereof solve the problem, and all surfaces except the bottom surface of the part 31 are not contacted with the clamping structure through magnetic adsorption, so that only one surface, namely the bottom surface, is shielded by the clamping structure. The rotation of the clamping roller 17 can drive the part 31 to move, so that the part 31 exposes the originally shielded part, and the image fusion is performed after the bottom surface is shot for the second time, so that a complete bottom surface image which is not shielded is obtained.
The using method of the invention automatically finishes the actions of feeding, clamping, overturning the part 31 to different positions, shooting, blanking and the like under the control of the electric control device 20, and has higher working efficiency.
In the thirteenth step, when the surface of the part 31 has a defect and the transfer robot 81 takes out the part 31, the part 31 is placed at the part position on the inspection table 36 so that the surface suspected of having the defect faces upward, and the part 31 is secondarily inspected;
the secondary detection is carried out according to the following method:
the electric control device 20 controls the electric spray gun 40 to uniformly spray magnetic powder on the surface of the part 31 suspected to have defects, then controls the second camera 54 to shoot the surface of the part 31, and an image recognition module in the electric control device 20 recognizes the image of the surface of the part 31 adsorbed with the magnetic powder, judges whether the surface really has defects or not, and displays the judgment result on the display screen 13; the electric control device 20 opens the powder suction device 38 to suck the magnetic powder on the surface of the part 31 back to the powder storage box 39;
after the detection is finished, manually placing the parts 31 which do not have defects in practice into a storage position of good parts; for the part 31 having a defect, it is manually put into a defective part storage position.
When the part is placed at the part position on the detection table, the electric control device moves the part according to a transfer manipulator space three-dimensional path control method;
the method for controlling the spatial three-dimensional path of the transfer manipulator comprises the following steps:
a space model of the part detection mechanism based on machine vision is prestored in the electric control device; the space model can be constructed on the basis of surveying and mapping the environmental information, or the standard relative position relations among an input conveying mechanism, a clamping shooting mechanism, an output conveying mechanism and a magnetic powder detection device in a part detection mechanism based on machine vision are defined in advance, and all parts are ensured to be in the standard relative positions during installation; the space model is constructed based on the standard relative position relations of the input conveying mechanism, the clamping shooting mechanism, the output conveying mechanism and the magnetic powder detection device which are defined in advance, so that the trouble of surveying and drawing after installation can be avoided.
The top of the rack is provided with a first laser radar, the transfer manipulator is provided with a second laser radar, and the top of the connecting rod is provided with a third laser radar;
the method for controlling the spatial three-dimensional path of the transfer manipulator comprises the following steps:
the first step is to construct a Kriging model of the obstacle;
the electric control device 20 is internally provided with the size and joint angle information of the transfer manipulator 81, a space environment model is established based on a grid method according to the space model, and an obstacle model is established; the specific construction process of the obstacle model comprises the following sub-steps:
the first substep is to photograph the obstacle;
the electric control device 20 photographs the obstacle through the first laser radar 41, the second laser radar 42 and the third laser radar 43, respectively discretizes the surface of the obstacle into 10000 points, and obtains the space coordinate of each point in the space environment model;
the second substep is to construct the Kriging model;
the electric control device 20 randomly selects 100 points from 10000 points, and takes the X (axis) coordinate and the Y coordinate of the 100 points as design variables, and the Z coordinate as a Kriging approximate model for responding and constructing the obstacle to jointly construct the Kriging model;
the third substep is to realize the envelope of the Kriging model to the whole obstacle;
the electric control device 20 predicts the Z coordinate values at 10000 sample points in the first step by using the constructed Kriging model
Figure BDA0003071278380000161
If it is not good
Figure BDA0003071278380000162
If the obstacle is located inside the obstacle, points are selected again to construct a Kriging model until all points on the boundary of the obstacle are located inside a Kriging prediction model, so that the envelope of the Kriging model on the whole obstacle is realized;
the second step is that the transfer robot 81 transfers the part 31; the electric control device 20 judges whether the linear motion of the part 31 driven by the transfer manipulator 81 from the starting point A to the end point B interferes with the Kriging model; the point A is determined by a first laser radar 41, and the point B is the position of the part 31 on the predetermined detection table and is stored in the electric control device 20 in advance;
if not, the movement of the transfer robot 81 is set to a linear movement from the start point a to the end point B;
if interference occurs, setting the end point of the intersection line segment of the straight line AB and the obstacle Kriging model, which is adjacent to the point A, as the point C, and setting the end point of the intersection line segment of the straight line AB and the obstacle Kriging model, which is adjacent to the point B, as the point D;
the movement of the transfer robot 81 to drive the part 31 is divided into the following three sub-steps:
the first substep is: the electric control device 20 controls the transfer manipulator 81 to move the part 31 from the starting point A to the point C along a straight line;
the second substep is: the electric control device 20 controls the transfer manipulator 81 to move the part 31 from the point C to the point D along the surface of the Kriging model; preferably, the shortest path from the point C to the point D on the Kriging surface is selected by using a shortest tangent method;
the third substep is: the electric control device 20 controls the transfer manipulator 81 to move the part 31 from the point D to the point B along a straight line, and the operation of moving the part 31 to the detection table from the clamping shooting mechanism is completed.
According to the method for controlling the spatial three-dimensional path of the transfer manipulator 81, in the process that the transfer manipulator 81 moves the part 31 to the detection table of the magnetic powder detection device from the clamping structure, collision between the part 31 and a barrier in the motion process of the transfer manipulator 81 is avoided, the part 31 (namely the tail end of the transfer manipulator 81) is guaranteed to have the shortest motion path, the energy consumption is low, and the transfer efficiency is high.
Although the present invention has been described in detail with reference to the above embodiments, it should be understood by those skilled in the art that: modifications and equivalents may be made thereto without departing from the spirit and scope of the invention and it is intended to cover in the claims the invention as defined in the appended claims.

Claims (9)

1. The part detection mechanism based on machine vision comprises a rack, wherein an input conveying mechanism, a clamping shooting mechanism and an output conveying mechanism are sequentially arranged on the rack from upstream to downstream by taking the overall moving direction of a detected part as the downstream direction; the conveying surface of the input conveying mechanism is flush with the conveying surface of the output conveying mechanism; the rack is also provided with an electric control device, the electric control device is connected with a display screen and an audible and visual alarm, and an image recognition module is arranged in the electric control device;
the method is characterized in that: the clamping shooting mechanism comprises a camera mechanical arm hinged to the top of the rack and a clamping device arranged at the middle lower part of the rack; the camera mechanical arm is driven by a servo motor;
the free end of the camera mechanical arm is provided with a first camera, the free end of the camera mechanical arm or a fixed structure above the camera mechanical arm is provided with a lighting lamp, and the servo motor, the lighting lamp and the first camera are all connected with the electric control device;
the clamping device comprises a clamping structure for clamping a part, a longitudinal rotating structure for driving the clamping part to rotate, a transverse rotating structure and a longitudinal overturning structure;
in the initial state, the overturning direction of the longitudinal overturning structure, the rotating direction of the longitudinal rotating structure and the rotating direction of the transverse rotating structure are vertical to each other;
the magnetic powder detection device comprises a detection table, one side of the detection table is fixedly connected with a powder storage box, and magnetic powder is stored in the powder storage box; the detection table is provided with a part position for placing parts, the detection table is provided with an electric spray gun, a powder suction device and a connecting rod, a feeding pipe of the electric spray gun is connected with the bottom of the powder storage box, and the spraying direction of the electric spray gun faces to the parts at the part position; the powder suction port of the powder suction device faces the part at the part position, and the powder outlet port of the powder suction device faces the powder storage box; a second camera is arranged on the connecting rod, and the shooting direction of the second camera faces to the part at the part position; the electric spray gun, the powder suction device and the second camera are all connected with the electric control device.
2. The machine-vision based part inspection mechanism of claim 1, wherein:
the longitudinal overturning structure comprises a supporting frame, the front end of the supporting frame is upwards connected with a bottom frame in a rotating mode through a rotating shaft, the middle rear portion of the bottom frame is downwards hinged with an overturning cylinder used for driving the bottom frame to overturn longitudinally, the overturning cylinder is downwards hinged with the rack, and the overturning cylinder is connected with an electric control device;
the transverse rotating structure comprises a rotating speed reducing motor and a rotating frame, an output shaft of the rotating speed reducing motor is a rotating part of the rotating speed reducing motor, a shell of the rotating speed reducing motor is a fixed part of the rotating speed reducing motor, and the fixed part and the rotating part of the rotating speed reducing motor are respectively connected with the bottom frame or the rotating frame; the rotation speed reducing motor is connected with the electric control device;
the longitudinal rotating structure comprises a mounting frame fixedly connected to the rotating frame, the mounting frame is rotatably connected with a first rotating ring and a second rotating ring which are oppositely arranged in parallel, one side of the first rotating ring is convexly provided with a first rolling guide ring along the circumferential direction, and one side of the second rotating ring is convexly provided with a second rolling guide ring along the circumferential direction; two first grooved wheels used for supporting the first rolling guide ring are arranged on the mounting frame below the first rolling guide ring, and the first rolling guide ring is inserted into the grooves of the first grooved wheels;
two second grooved wheels used for supporting the second rolling guide ring are arranged on the mounting frame below the second rolling guide ring, and the second rolling guide ring is inserted into the grooves of the second grooved wheels;
the two first grooved wheels and the two second grooved wheels form a supporting grooved wheel set, at least one grooved wheel in the supporting grooved wheel set is connected with a grooved wheel driving motor, the grooved wheel serves as a driving grooved wheel, and the grooved wheel driving motor is connected with an electric control device;
a pressing wheel is mounted on the mounting frame and is pressed downwards to be in pressure joint with the inner surface of the bottom of the first rotating ring or the inner surface of the bottom of the second rotating ring;
the clamping structure comprises a front connecting plate and a rear connecting plate which are fixedly connected between the first rotating ring and the second rotating ring, two clamping rollers are arranged between the front connecting plate and the rear connecting plate, electromagnets are respectively arranged in the two clamping rollers, and the electromagnets are connected with the electric control device; a driving roller is arranged between the two clamping rollers, the driving roller is arranged between the front connecting plate and the rear connecting plate, the driving roller is connected with a roller driving motor, and the roller driving motor is connected with an electric control device; the two clamping rollers are used for rolling and conveying parts and magnetically clamping the parts; the roller driving motor is used for finely adjusting the position of the part during photographing;
the two clamping rollers and the driving roller are positioned on the same plane, and the plane is called a clamping plane; the clamping structure is in a butt joint state, and when the clamping structure is in the butt joint state, the clamping plane is flush with the conveying surface of the input conveying mechanism and the conveying surface of the output conveying mechanism and is in butt joint;
and a part sensor for detecting parts is arranged on the rotating frame or the mounting rack below the roller for clamping, and the part sensor is connected with the electric control device.
3. The machine-vision based part inspection mechanism of claim 1, wherein: the top of the frame is provided with a horizontally arranged screen baffle, the camera mechanical arm is hinged on the screen baffle of the frame, and the illuminating lamp is an annular LED lamp panel arranged on the screen baffle.
4. The machine-vision based part inspection mechanism of any one of claims 1-3, wherein: the input conveying mechanism and the output conveying mechanism are identical in structure and respectively comprise a plurality of conveying rollers which are arranged on the roller frame side by side at intervals, each conveying roller comprises a driving roller and a plurality of driven rollers, and the roller frame is arranged on the rack; and a roller driving motor for driving the driving roller is arranged on the frame or the roller frame, and the roller driving motor is connected with the electric control device.
5. The machine-vision based part inspection mechanism of claim 4, wherein: be equipped with between magnetic particle testing device and the clamping structure and be used for transporting the transportation manipulator on the magnetic particle testing device with the part.
6. The machine-vision based part inspection mechanism of claim 1, wherein: the first rotating ring and the second rotating ring are respectively provided with a dynamic balancing mechanism;
the first rotating ring and the second rotating ring are collectively called as rotating rings, and the dynamic balancing mechanism comprises an upper dynamic balancing mechanism arranged above the clamping mechanism and a lower dynamic balancing mechanism arranged below the clamping mechanism;
the upper dynamic balancing mechanism and the lower dynamic balancing mechanism have the same structure and respectively comprise double-rotor linear motors arranged along the chord direction of the rotating ring, and two rotors of the double-rotor linear motors are respectively provided with a balancing weight for adjusting the gravity center position of the integral structure formed by the rotating ring, the clamping mechanism and the clamped workpiece;
the wheel carriers at the wheel shafts of the first sheave and the second sheave are respectively provided with a stress strain sensor for monitoring the stress condition of the first sheave and the second sheave, and the stress strain sensors and the double-rotor linear motors are connected with an electric control device.
7. The method of using a machine vision based part inspection mechanism as recited in claim 4, characterized by the steps of:
the first step is feeding;
the detected part enters the input conveying mechanism from the previous process, enters the clamping structure in a butt joint state under the driving of the roller driving motor, the electric control device closes the roller driving motor, starts the roller driving motor, and drives the part by the driving roller;
the part sensor sends a signal to the electric control device after detecting the part, the electric control device closes the roller driving motor to finish feeding, and the part is supported by the driving roller and the two clamping rollers;
the second step is clamping;
the electric control device starts the electromagnets in the two clamping rollers to position the parts through magnetic adsorption;
the third step is to shoot the upper surface of the part;
the electric control device obtains an image of the upper surface of the part through shooting by the first camera;
the fourth step is to shoot the back surface image of the part;
the electric control device controls the overturning cylinder to drive the bottom frame to overturn upwards and simultaneously controls the mechanical arm of the camera to rotate, so that the first camera shoots an image of the rear surface of the part in the direction opposite to the rear surface of the part;
the fifth step is to shoot the left surface image of the part;
the electric control device controls the reduction motor for rotation to drive the rotating frame and the part to rotate for 90 degrees continuously until the left surface of the part is opposite to the first camera; then the electric control device enables the first camera to shoot an image of the left surface of the part in the direction opposite to the left surface of the part;
the sixth step is to shoot the front surface image of the part;
the electric control device controls the rotating speed reduction motor to drive the rotating frame and the part to rotate for 90 degrees continuously, so that the front surface of the part is opposite to the first camera; then the electric control device enables the first camera to shoot the front surface image of the part in the direction opposite to the front surface of the part;
the seventh step is to shoot the right surface image of the part;
the electric control device controls the rotating speed reduction motor to drive the rotating frame and the part to rotate for 90 degrees continuously, so that the right surface of the part is opposite to the first camera; then the electric control device enables the first camera to shoot the right surface image of the part in the direction opposite to the right surface of the part;
the eighth step is that the part is reset once;
the electric control device controls the rotating speed reduction motor to drive the rotating frame and the part to rotate for 90 degrees continuously, and simultaneously controls the turnover air cylinder to reset, so that the part returns to the original position in the second step;
the ninth step is to shoot a first image on the lower surface of the part;
the electric control device controls the sheave driving motor to start, and the sheave driving motor drives the first rotating ring and the second rotating ring to integrally rotate for 180 degrees through the first sheave or the second sheave and then stops to enable the lower surface of the part to face upwards; the electric control device controls the mechanical arm of the camera to rotate to a position where the shooting direction of the camera faces to the right lower part, and then the electric control device enables the first camera to shoot a first image on the lower surface of the part in the direction opposite to the lower surface of the part;
the tenth step is the secondary resetting of the parts;
the electric control device controls the sheave driving motor to start, and the sheave driving motor drives the first rotating ring and the second rotating ring to integrally rotate for 180 degrees through the first sheave or the second sheave and then stops to reset the part;
the eleventh step is to shoot a second image of the lower surface of the part;
the electric control device closes the electromagnets in the two clamping rollers, the diameters of the clamping rollers and the driving rollers are both d, the roller driving motor is started, the roller driving motor is closed when the driving rollers drive the part to move for 2d, and at the moment, the part, which is shielded by the clamping rollers and the driving rollers, of the bottom surface of the part in the first image is exposed;
the electric control device starts the electromagnets in the two clamping rollers, positions the part through magnetic adsorption, then controls the sheave driving motor to start, and the sheave driving motor drives the first rotating ring and the second rotating ring to integrally rotate for 180 degrees through the first sheave or the second sheave and then stops to enable the lower surface of the part to face upwards; then the electric control device enables the first camera to shoot a second image of the lower surface of the part in the direction opposite to the lower surface of the part;
the twelfth step is that the parts are reset for three times;
the electric control device controls the sheave driving motor to start, and the sheave driving motor drives the first rotating ring and the second rotating ring to integrally rotate for 180 degrees through the first sheave or the second sheave and then stops, so that the part is reset to the position with the upper surface facing upwards;
the thirteenth step is image recognition and blanking;
the electric control device identifies the image of the part through the image identification module and judges whether the surface of the part has defects or not;
if the image recognition module detects that a certain surface of the part is suspected to have a defect, the electric control device displays the surface suspected to have the defect on the display screen; the electric control device turns on the audible and visual alarm to give an alarm until the part sensor detects that the transferring manipulator takes out the part and then turns off the audible and visual alarm;
if the surface of the part has no defect, the electric control device simultaneously closes the electromagnets in the two rollers for clamping, starts the roller driving motor and the roller driving motor of the output conveying mechanism, so that the part moves to the output conveying mechanism and is conveyed to the next procedure by the output conveying mechanism.
8. Use according to claim 7, characterized in that: in the thirteenth step, when the surface of the part has defects and the part is taken out by the transfer manipulator, the part is placed at the part position on the detection platform, the surface suspected to have defects faces upwards, and the part is subjected to secondary detection;
the secondary detection is carried out according to the following method:
the electric control device controls the electric spray gun to uniformly spray magnetic powder on the surface of the part suspected to have defects, then the second camera is controlled to shoot the surface of the part, an image recognition module in the electric control device recognizes the image of the surface of the part adsorbed with the magnetic powder, judges whether the surface has the defects or not, and displays the judgment result on the display screen; the electric control device opens the powder suction device to suck the magnetic powder on the surface of the part back to the powder storage box;
after the detection is finished, manually placing the parts which do not have defects into a storage position of good parts; for parts with a certain defect, it is manually put into a defective part storage position.
9. Use according to claim 8, characterized in that: when the part is placed at the part position on the detection table, the electric control device moves the part according to a transfer manipulator space three-dimensional path control method;
the method for controlling the spatial three-dimensional path of the transfer manipulator comprises the following steps:
a space model of the part detection mechanism based on machine vision is prestored in the electric control device;
the top of the rack is provided with a first laser radar, the transfer manipulator is provided with a second laser radar, and the top of the connecting rod is provided with a third laser radar;
the method for controlling the spatial three-dimensional path of the transfer manipulator comprises the following steps:
the first step is to construct a Kriging model of the obstacle;
the electric control device is internally provided with the size and joint angle information of the transfer manipulator, a space environment model is established based on a grid method according to the space model, and an obstacle model is established; the specific construction process of the obstacle model comprises the following sub-steps:
the first substep is to photograph the obstacle;
the electric control device photographs the obstacle through the first laser radar, the second laser radar and the third laser radar, respectively disperses the surface of the obstacle into 10000 points, and obtains the space coordinate of each point in the space environment model;
the second substep is to construct the Kriging model;
the electric control device randomly selects 100 points from 10000 points, the X coordinate and the Y coordinate of the 100 points are used as design variables, the Z coordinate is used as a Kriging approximate model for responding and constructing the obstacle, and the Kriging model is constructed together;
the third substep is to realize the envelope of the Kriging model to the whole obstacle;
the electric control device predicts Z coordinate values of 10000 sample points in the first step by using the constructed Kriging model
Figure FDA0003071278370000061
If it is not good
Figure FDA0003071278370000062
If the obstacle is located inside the obstacle, points are selected again to construct a Kriging model until all points on the boundary of the obstacle are located inside a Kriging prediction model, so that the envelope of the Kriging model on the whole obstacle is realized;
the second step is that the transfer manipulator transfers the part; the electric control device judges whether the linear motion of the part driven by the transfer manipulator from the starting point A to the end point B interferes with the Kriging model; the point A is determined by a first laser radar, and the point B is a predetermined part position on the detection table and is stored in the electric control device in advance;
if the interference is avoided, setting the motion of the transfer manipulator as the linear motion from the starting point A to the end point B;
if interference occurs, setting the end point of the intersection line segment of the straight line AB and the obstacle Kriging model, which is adjacent to the point A, as the point C, and setting the end point of the intersection line segment of the straight line AB and the obstacle Kriging model, which is adjacent to the point B, as the point D;
the movement of the transfer manipulator driving the part is divided into the following three substeps:
the first substep is: the electric control device controls the transfer manipulator to move the part to a point C from a starting point A along a straight line;
the second substep is: the electric control device controls the transfer manipulator to move the part from the point C to the point D along the surface of the Kriging model;
the third substep is: the electric control device controls the transfer manipulator to move the part from the D point to the B point along a straight line, and the part is moved to the detection table by the clamping shooting mechanism.
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