CN104155310A - 360-degree detection device and method for roller appearance defects - Google Patents
360-degree detection device and method for roller appearance defects Download PDFInfo
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- 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
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Abstract
本发明公开了一种滚子外观缺陷360度检测装置，包括工业计算机控制的物料输送装置和成像单元；所述物料输送装置为托辊输送装置；所述成像单元包括外圆成像单元和两端成像单元；所述托辊输送装置的上方设置外圆成像单元，所述托辊输送装置的两侧分别设置相应的两端成像单元。
The invention discloses a 360-degree detection device for roller appearance defects, which includes a material conveying device and an imaging unit controlled by an industrial computer; the material conveying device is a roller conveying device; the imaging unit includes an outer circle imaging unit and two ends An imaging unit; an outer circle imaging unit is arranged above the idler conveying device, and corresponding two-end imaging units are respectively arranged on both sides of the idler conveying device.
Description
Technical field
The present invention relates to a kind of roller open defect 360 and spend pick-up unit and a kind of detection method, in particular, relate to a kind of for automatically cylindrical or conical roller being carried out to 360 degree optical imageries, the method for carrying out the detection of full angle outward appearance.
Background technology
Roller in roller bearing is important rolling member, and the quality of roller has directly affected quality and the life-span of bearing.The detection of roller at present mainly adopts following several detection method: artificial visually examine, eddy current test, UT (Ultrasonic Testing) and magnetic powder inspection.
In production practices, conventionally above several method is carried out to combination, inspection is entirely examined or inspects by random samples open defect with artificial visually examine eventually.Because above detection method all exists certain suitability and limitations, artificial visually examine need to spend a large amount of testing staff, and testing staff can exist the inconsistent and tired of subjective judgement simultaneously, undetected situation occurs and always occur.So some step during for alternative manual detection, is detected as the important development direction for present roller workpiece sensing by the method for optical imagery to workpiece.Exist at present method that the method that adopts optical imagery detects the open defect of roller or device to mainly contain following several:
A kind of device being proposed as patent " the bearing roller detector (application number 201210372221.2) based on high-resolution CCD technology ", on what it adopted is, under, before, after, left, Camera Test method on right six direction, although the method can detect more face, but because its camera is for fixing, the time that six cameras are taken be only bearing element through six cameras in an instant, and in this moment, owing to there being the major defect of six camera establishing shots, make that the value of its detection can not be very accurately, because any time all needs have supporting plate to hold workpiece, so in detecting, must there is a face all to be recorded.And its testing process is too complicated, need screens, be transported to again the process etc. of taking pictures in corresponding detection casing, serious impact detect work efficiency, especially in the current this process being changed to Intensive economy by extensive economy, this poor efficiency production equipment will fetter greatly input of labor, make the production cost of product too high, the resources of production of serious waste society.
For another example another detection method that patent " a kind of taper roller surface defects detection system (application number 201310147390.0) " proposes, it does not accomplish that at cylindrical imaging side face 360 degree cover accurately and reliably, easily occur undetected, and exist equally testing process loaded down with trivial details, caused the defect that its detection efficiency is lower.
Summary of the invention
The technical problem to be solved in the present invention is to provide a kind of roller open defect 360 and spends pick-up unit and method.
In order to solve the problems of the technologies described above, the invention provides a kind of roller open defect 360 and spend pick-up unit, comprise device for transporting objects and the image-generating unit of Industrial Computer Control; Described device for transporting objects is supporting roller conveying device; Described image-generating unit comprises cylindrical image-generating unit and two ends image-generating unit; The top of described supporting roller conveying device arranges cylindrical image-generating unit, and the both sides of described supporting roller conveying device arrange respectively corresponding two ends image-generating unit.
Improvement as roller open defect 360 of the present invention being spent to pick-up unit: described supporting roller conveying device comprises the power wheel of placing the carrying roller of roller workpiece, the carrying roller carrier chain that drives carrying roller operation and the operation of drive carrying roller carrier chain.
Further improvement as roller open defect 360 of the present invention being spent to pick-up unit: described cylindrical image-generating unit comprises the counting assembly that the angle of rotation of carrying roller is counted and takes the cylindrical camera set of controlling by this counting assembly; Described two ends image-generating unit comprises the locating device that roller workpiece is positioned and the end face A camera of controlling by this locating device and end face B camera, and described end face A camera and end face B camera are separately positioned on the both sides of supporting roller conveying device.
Further improvement as roller open defect 360 of the present invention being spent to pick-up unit: described counting assembly comprises displacement encoder and impulse meter; Described displacement encoder sends corresponding pulse signal after the angle of rotation of carrying roller is counted, and described impulse meter calculates the respective angles of roller workpiece by the pulse signal of displacement encoder, and carries out the shooting control of cylindrical camera set; Described locating device is photoelectric sensor.
Further improvement as roller open defect 360 of the present invention being spent to pick-up unit: the cylindrical camera quantity in described cylindrical camera set is at least one.
Further improvement as roller open defect 360 of the present invention being spent to pick-up unit: cylindrical camera, end face A camera and end face B camera in described cylindrical camera set all adopt high speed, high resolution CCD industrial camera.
Roller open defect 360 is spent detection method; Roller workpiece is positioned over to the carrying roller top of supporting roller conveying device, carries roller workpiece by carrying roller; By end face A camera and end face B camera, two of roller workpiece end faces are taken, the open defect that completes two end faces of roller workpiece detects; Carry out the side of roller workpiece by cylindrical camera set and take, the open defect that completes roller side surface of workpiece detects.
Improvement as roller open defect 360 of the present invention is spent to detection method: the job step of described cylindrical camera set is as follows: carrying roller rotates after certain angle, and displacement encoder produces corresponding pulse signal; Impulse meter is counted the corresponding pulses signal that moves scrambler generation, and in the time reaching the angle that needs shooting, all cylindrical cameras of impulse meter control cylindrical camera set are taken.
Improvement one stepping as roller open defect 360 of the present invention being spent to detection method: described roller workpiece is when carrying roller rotates, when calculating carrying roller rotation respective angles by the diameter ratio between roller workpiece and carrying roller, the respective angles value that roller workpiece rotates.
Improvement one stepping as roller open defect 360 of the present invention being spent to detection method: the job step of described end face A camera and end face B camera is as follows: photoelectric sensor is detecting that roller workpiece is through out-of-date, controls end face A camera and end face B camera and takes simultaneously.
Advantage of the present invention is as follows:
One, the present invention adopts unique carrying roller carrier chain structure, in realizing conveying at a high speed, spend (the improvement of the mode of movement by workpiece of continuous angle camera function by adopting displacement encoder and impulse meter to realize cylindrical 360, increase work efficiency, and realized the continuous angle camera function of 360 degree completely).
Two, the present invention has realized the detection of taking pictures at roller two ends simultaneously, does not stay dead angle in roller outward appearance context of detection.
Three, the present invention supports conveying and the detection of cylindrical or conical roller simultaneously with a kind of mechanism.
Four, the present invention adopts high speed, high resolution CCD industrial camera, and detection speed is high, and resolution is high, detection speed can reach 2～40,000 per hour, resolution is to 0.04mm.
Brief description of the drawings
Below in conjunction with accompanying drawing, the specific embodiment of the present invention is described in further detail.
Fig. 1 is main structure chart of the present invention;
Fig. 2 is the Local map that cylindrical of the present invention is taken pictures;
Fig. 3 is the key diagram of taking pictures in two ends of the present invention;
Fig. 4 is critical piece circuit connection diagram of the present invention.
Embodiment
Embodiment 1, Fig. 1～Fig. 4 have provided a kind of roller open defect 360 and have spent pick-up unit and method.
Above-described roller open defect 360 is spent pick-up unit and is comprised supporting roller conveying device 1, cylindrical image-generating unit 2, two ends image-generating unit 3 and industrial computer 402.
Supporting roller conveying device 1 comprises power wheel 102 and carrying roller carrier chain 101; Carrying roller carrier chain 101 comprises carrying roller 201, carrying roller fixed head 202 and supporting plate 203, the both sides of carrying roller 201 arrange axle, on carrying roller fixed head 202, axle with respect to the both sides of carrying roller 201 arranges corresponding circular hole, carrying roller 201 inserts corresponding axle after corresponding circular hole, forms and rotates with respect to carrying roller fixed head 202; And on carrying roller fixed head 202, arrange after several carrying rollers 201, corresponding supporting plate 203 (maintaining static) is set below carrying roller 201, when carrying roller fixed head 202 is moved, supporting plate 203 can drive carrying roller 201 to make corresponding counter motion based on carrying roller fixed head 202 by friction force.Carrying roller fixed head 202 is set on power wheel 102, clockwise rotates accordingly or rotate counterclockwise by the rotation band carrying roller fixed head 202 of power wheel 102, then drive carrying roller 201 to rotate counterclockwise or clockwise rotate according to this corresponding rotation; And when in use, roller workpiece 100 is on carrying roller 201, by the rotation (be the rotation campaign of carrying roller 201 along with carrying roller fixed head 202, but carrying roller 201 not changing with respect to the relative position of carrying roller fixed head 202) of carrying roller 201, drive roller workpiece 100 to move.
Cylindrical image-generating unit 2 comprises displacement encoder 103, impulse meter 401, cylindrical camera set (can be made up of one or more cylindrical camera 104) and customization light source 204; Displacement encoder 103 is fixedly connected on power wheel 102, for gathering carrying roller rotation displacement information; Impulse meter 401 is electrically connected with displacement encoder 103, cylindrical camera 104, by displacement encoder 103, the rotational angle of power wheel 102 is counted, this counting is exported by the mode of pulse, and the calculating that the pulse signal of output carries out angle by impulse meter 401 (is that power wheel 102 rotates corresponding angle, displacement encoder 103 just sends a pulse signal, and impulse meter 401 can be determined the concrete rotational angle of power wheel 102 by pulse signal, and take corresponding photo according to the angle control cylindrical camera 104 of this rotation); Customization light source 204 here auxiliary cylindrical camera 104 carries out photograph taking; Cylindrical camera 104 is positioned at the top of supporting roller conveying device 1.And two ends image-generating unit 3 comprises photoelectric sensor 301, end face A camera 302 and end face B camera 303, photoelectric sensor 301 is electrically connected with end face A camera 302 and end face B camera 303; End face A camera 302 and end face B camera 303 lay respectively at left and right two sides of supporting roller conveying device 1 (because roller workpiece 100 carries out concrete location by photoelectric sensor 301, so when end face A camera 302 and end face B camera 303 are set, can arrange corresponding two workpiece, also can be in using secondary light source, do not cause interference, carry out arranging every position, as a kind of end face A camera 302 of Fig. 3 and end face B camera 303 asymmetric set-up modes); Photoelectric sensor 301 can be located the particular location of roller workpiece 100 on carrying roller 201, and when roller workpiece 100 is positioned at suitable position, control end face A camera 302 and end face B camera 303 are taken respectively the corresponding photo of left and right two sides of roller workpiece 100.
Industrial computer 402 is electrically connected with cylindrical camera set (some cylindrical cameras 104), end face A camera 302, end face B camera 303, reads in real time the corresponding photographic intelligence of cylindrical camera set (some cylindrical cameras 104), end face A camera 302, end face B camera 303.
When the present invention works, mainly undertaken by following step:
1, start power wheel 102, after moving clockwise by power wheel 102, drive carrying roller fixed head 202 to do clockwise motion, after several carrying rollers 201 on carrying roller fixed head 202 and 203 frictions of fixed supporting plate, do accordingly and rotate counterclockwise;
2, roller workpiece 100 is placed on carrying roller 201, under the drive of carrying roller 201, does clockwise motion (keeping synchronizeing with power wheel 102), and the maintenance displacement movement identical with carrying roller fixed head 202;
3, according to transmission rule, there is fixing proportionate relationship in the velocity of rotation of the velocity of rotation of power wheel 102 and roller workpiece 100, can calculate by the velocity of rotation of power wheel 102 velocity of rotation (according to prior art, the technician in the industry can extrapolate this result easily) of roller workpiece 100; Be that displacement encoder 103 is by recording the corresponding velocity of rotation of power wheel 102, just can determine the corresponding data that roller workpiece 100 rotates, as when the minute angle of the every rotation of roller workpiece 100, displacement encoder 103 sends a pulse, impulse meter 401 adds up to this pulse, according to pre-conditioned, turn to after certain angle at roller workpiece 100, impulse meter 401 sends trigger pip, and all cylindrical cameras 104 in control cylindrical camera set carry out cylindrical (side of roller workpiece 100) and take pictures.Different and relevant pre-conditioned according to roller workpiece 100 diameters like this, take a photo after can accurately controlling the every rotation specified angle of roller workpiece 100, until after 360 degree have rotated, realize the full angle of roller workpiece 100 cylindricals and take pictures.
4, when roller workpiece 100 enters end face at every turn and takes pictures position, the light that shading light electric transducer 301 sends, photoelectric sensor 301 sends trigger pulse, controls end face A camera 302 and end face B camera 303 and takes pictures.
5, the picture transmission that cylindrical camera set (cylindrical camera 104), end face A camera 302 and end face B camera 303 photographed is to industrial computer 402, image acquisition and image analysis processing software by operation on industrial computer 402 positions, image pre-service and defect recognition, thereby cylindrical 360 degree of realizing roller workpiece 100 detect and the detection of two ends defect.
According to optical path analysis and experimental verification, realize 360 degree full angle imagings, need to carry out taking pictures of 9～12 continuous angles to a roller workpiece 100, although existing technology also can realize continuous shooting, but due to the time point of uncontrollable shooting, then can cause the same side of roller workpiece 100 to occur repeatedly taking, the situation that some sides are not photographed completely, such testing result is inaccurate completely.And roller open defect 360 in the present invention is spent pick-up unit and can be gone out the instant angle value of roller workpiece 100 by displacement encoder 103 indirect calculation on power wheel 102, by this value, just can carry out corresponding angle shot by controlling cylindrical camera 104, and by this method, can realize at the arbitrary face of roller workpiece 100 and carry out nothing coincidence shooting, be to draw after by accurate calculating cylindrical camera 104 time of taking, realizing each side image that cylindrical camera 104 takes is all unique side images, can't occur repeatedly to take by side the multiple data that produce same position, affect the phenomenon of final testing result.
In comparative example 1, prior art, as a kind of technical scheme that patent " taper roller surface defects detection system (application number 2013101472715) " is proposed, what this scheme adopted is a kind of fixture, stepper motor, camera head coordinate rear formation 360 to spend without dead angle to take; In this scheme, need to coordinate with fixture by stepper motor, stepper motor rotates a circle only can detect a taper roller, and cannot be continuous detect, very low of the efficiency that causes its detection; Another aspect, adopt fixture to place one by one roller on the universal stage of stepper motor, in the time that roller dimension and shape change, need to fixture and associated mechanisms be changed and be regulated, the adjusting workload of changing like this roller model is large, and the complexity of equipment increases.
The roller workpiece 100 being undertaken by apparatus and method of the present invention detects, in in one second, roller workpiece 100 quantity of passing through be 12 (by coordinating between supporting roller conveying device 1 and cylindrical image-generating unit 2, roller workpiece 100 constantly rolls on supporting roller conveying device 1, coordinating roll angle value, just make cylindrical image-generating unit 2 to carry out without dead angle record roller workpiece 100, and carry out detecting separately after gripping without the roller workpiece 100 to single), , within the time of 0.08 second, device of the present invention just can detect a roller workpiece 100, and equipment in comparative example 1 is to being the detection time of single workpiece 0.5 to 3 second, apparatus and method of the present invention adopt the mode of carrying roller that roller workpiece 100 is carried out continuous rolling conveying and taken pictures, while changing roller model, do not need mechanism to regulate, changing roller model does not need mechanism to regulate, device structure is simple, maintainable high.
In comparative example 2, prior art, in " a kind of pick-up unit that detects taper roller surface imperfection; (application number 201320430398.3) ", the device that a kind of roller proposing detects, but two rollers of this device are carrying out in the process of workpiece transport, if want to obtain best transport effect, corresponding screw thread (spiral groove) need to be set on a roller, realize vertically moving of workpiece, but in this process, surface of the work often has the risk being scratched by the screw thread on roller, causes the unexpected disqualification rate of workpiece; In addition, first, cylindrical image acquisition units 3 is associated with the corner of guide wheel 1,2 while taking pictures also there is following defect in this device:, being generally to take some angles (6～9) according to the each workpiece of rotating speed,, easily there is leaking the phenomenons such as bat in such image pickup method.Secondly the propelling, longitudinally moving is because its stroke is longer, so the speed of its propelling is very slow, a general seconds can only advance a left and right, and the efficiency of work is lower slightly.And two workpiece are longitudinally when operation, because front/rear end may be in contact with one another, and because front/rear end running orbit now can be consistent completely, so two phenomenons that workpiece probably can stick together, cause detect unstable result (due to detect time, need minimum interval, if be less than this minimum interval, can cause erroneous judgement, cause the result detecting can not keep accurate).
And device of the present invention can overcome above-described defect completely, by after the angle calculation of power wheel 102, can obtain the angle of rotation of current roller workpiece 100, can obtain again the side-information of current roller workpiece 100 according to the calculating of this angle of rotation, carry out the intercepting of shooting time point according to this point, make the shooting of cylindrical camera 104 cover the side of roller workpiece 100 360 degs, and can not there is leaking the phenomenon of clapping, coordinate again the shooting of two end faces, realize taking without dead angle of 360 deg.And further, the present invention is the streamline means of transportation that power wheel 102 and carrying roller carrier chain 101 coordinate due to what adopt, very fast of the speed that makes transmission, 100 needs of roller workpiece are placed on supply line, just can be according at the uniform velocity the advancing of the stabilization of speed of power wheel in supply line 102, the travelling speed of its realization is at least 3～5 times of the prior art.Finally, apparatus structure of the present invention is simple, can adopt modular mode to assemble between all parts, and if wherein arbitrarily workpiece damage or aging after, all can only complete the maintenance of whole equipment by the mode that these parts are replaced, convenience very.
Finally, it is also to be noted that, what more than enumerate is only a specific embodiment of the present invention.Obviously, the invention is not restricted to above embodiment, can also have many distortion.All distortion that those of ordinary skill in the art can directly derive or associate from content disclosed by the invention, all should think protection scope of the present invention.
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| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| CN201410407835.9A CN104155310B (en) | 2014-08-19 | 2014-08-19 | 360 degree of detection devices of roller open defect and method |
| PCT/CN2015/083708 WO2016026358A1 (en) | 2014-08-19 | 2015-07-10 | 360-degree detection device and method for visual defects of roller |
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| Application Number | Priority Date | Filing Date | Title |
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| CN201410407835.9A CN104155310B (en) | 2014-08-19 | 2014-08-19 | 360 degree of detection devices of roller open defect and method |
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| CN104155310A true CN104155310A (en) | 2014-11-19 |
| CN104155310B CN104155310B (en) | 2018-08-14 |
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| WO (1) | WO2016026358A1 (en) |
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| Publication number | Publication date |
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| CN104155310B (en) | 2018-08-14 |
| WO2016026358A1 (en) | 2016-02-25 |
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Denomination of invention: Roller appearance defect 360 DEG detection apparatus and method Effective date of registration: 20200115 Granted publication date: 20180814 Pledgee: Changhe Branch of Hangzhou United Rural Commercial Bank Co., Ltd. Pledgor: HANGZHOU QOGORI TECHNOLOGY INC. Registration number: Y2020330000038 |