CN106584800B - A kind of shaped article online quality control method - Google Patents
A kind of shaped article online quality control method Download PDFInfo
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- CN106584800B CN106584800B CN201611135667.8A CN201611135667A CN106584800B CN 106584800 B CN106584800 B CN 106584800B CN 201611135667 A CN201611135667 A CN 201611135667A CN 106584800 B CN106584800 B CN 106584800B
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B07—SEPARATING SOLIDS FROM SOLIDS; SORTING
- B07C—POSTAL SORTING; SORTING INDIVIDUAL ARTICLES, OR BULK MATERIAL FIT TO BE SORTED PIECE-MEAL, e.g. BY PICKING
- B07C5/00—Sorting according to a characteristic or feature of the articles or material being sorted, e.g. by control effected by devices which detect or measure such characteristic or feature; Sorting by manually actuated devices, e.g. switches
- B07C5/34—Sorting according to other particular properties
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B07—SEPARATING SOLIDS FROM SOLIDS; SORTING
- B07C—POSTAL SORTING; SORTING INDIVIDUAL ARTICLES, OR BULK MATERIAL FIT TO BE SORTED PIECE-MEAL, e.g. BY PICKING
- B07C5/00—Sorting according to a characteristic or feature of the articles or material being sorted, e.g. by control effected by devices which detect or measure such characteristic or feature; Sorting by manually actuated devices, e.g. switches
- B07C5/34—Sorting according to other particular properties
- B07C5/342—Sorting according to other particular properties according to optical properties, e.g. colour
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C45/00—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor
- B29C45/17—Component parts, details or accessories; Auxiliary operations
- B29C45/76—Measuring, controlling or regulating
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Abstract
本发明涉及一种成型产品在线质量检测方法，首先将注塑机成型的塑料胶件通过传送带送至振动盘，通过振动盘控制胶件按照一定频率逐个送往机械手所处的传送带，机械手抓取每个胶件至检测黑箱中，通过补光灯和图像采集装置对胶件进行外形和颜色的检测，然后与标准配件进行接插检测，通过阻尼不同导致的电流信号变化来进行匹配度的检测，然后将采集到的信息传送至控制模块，检测合格的胶件会通过机械手放回到传送带上，不合格的胶件则被放置到胶件回收框中。本发明的优点是：针对塑料成型产品的出现缺胶、多胶、披锋等情况，自动监视并分类流出机台生产的良品和不良品，并且能够将数据及时送入控制系统进行统计，快速完成系统虚拟入库。
The invention relates to an online quality inspection method for molded products. Firstly, the plastic parts formed by an injection molding machine are sent to a vibrating plate through a conveyor belt, and the plastic parts are controlled by the vibrating plate to be sent to the conveyor belt where a manipulator is located one by one at a certain frequency. The manipulator grabs each Put the plastic parts into the detection black box, inspect the shape and color of the plastic parts through the fill light and the image acquisition device, and then conduct the plug-in detection with the standard accessories, and check the matching degree through the current signal changes caused by different damping. Then the collected information is sent to the control module, and the qualified plastic parts will be put back on the conveyor belt by the manipulator, and the unqualified plastic parts will be placed in the plastic part recycling box. The advantages of the present invention are: in view of the lack of glue, excess glue, and overhang of plastic molding products, it can automatically monitor and classify the good and bad products produced by the machine, and can send the data to the control system for statistics in time, quickly Complete system virtual storage.
Description
技术领域technical field
本发明涉及一种塑料成型产品在线质量检测方法，属于塑料加工工业技术领域。The invention relates to an online quality detection method for plastic molding products, which belongs to the technical field of plastic processing industry.
背景技术Background technique
目前大多数塑料胶件加工制造行业的质量检测还停留在人工检测阶段，对颜色的检测是通过人眼观察胶件颜色，然后和标准比色卡进行对比，从而判断颜色是否合格。对外形的检测主要是通过游标卡尺对胶件进行测量，然后与标准件尺寸进行对比，看胶件尺寸是否在允许误差内，从而判断外形是否合格。对接插件匹配度的检测是通过手工去和标准件进行接插测试，凭借经验来判断接插件是否合格。对于胶件局部出现缺胶、多胶、披锋等问题，则更要通过肉眼鉴别。以上检测方法都存在以下几个问题：检测是否合格基本靠质检员的主观判断和经验来完成，没有具体的数字量化对比，存在较大的误差，产品的质量也因此得不到保证。并且，在数量巨大的情况下，目前的人工检测方法只能进行抽样检测，无法做到每一个胶件都进行检测，也不能够实时传递检测信息。再者，人工检测长时间工作容易出现视觉疲劳、工作懈怠等人为因素，会造成质量检测的误差进一步扩大。At present, the quality inspection of most plastic parts processing and manufacturing industries is still in the stage of manual inspection. The color detection is to observe the color of the plastic part with human eyes, and then compare it with the standard color comparison card to judge whether the color is qualified. The detection of the shape is mainly to measure the plastic part with a vernier caliper, and then compare it with the size of the standard part to see if the size of the plastic part is within the allowable error, so as to judge whether the shape is qualified. The detection of the matching degree of the connector is to carry out the plug-in test with the standard parts manually, and judge whether the connector is qualified by experience. For problems such as lack of glue, excess glue, and shading in parts of the glue parts, it is even more necessary to identify them with the naked eye. The above detection methods have the following problems: whether the detection is qualified or not depends on the subjective judgment and experience of the quality inspector. There is no specific numerical comparison, there are large errors, and the quality of the product cannot be guaranteed. Moreover, in the case of a huge quantity, the current manual detection method can only perform sampling detection, and cannot detect every plastic part, nor can it transmit detection information in real time. Furthermore, human factors such as visual fatigue and slack in work are prone to human factors such as manual inspection for a long time, which will further expand the error of quality inspection.
发明内容Contents of the invention
本发明的目的是克服现有技术中存在的不足，提供一种成型产品在线质量检测方法，此方法可以在现有的工控系统基础上进行改进，引入智能化分析，自动的完成质量检测以及虚拟入库。The purpose of the present invention is to overcome the deficiencies in the prior art and provide an online quality inspection method for molded products. This method can be improved on the basis of the existing industrial control system, and intelligent analysis can be introduced to automatically complete the quality inspection and virtual storage.
按照本发明提供的技术方案，所述的成型产品在线质量检测方法包括以下步骤：According to the technical solution provided by the present invention, the online quality detection method for molded products includes the following steps:
步骤1、将注塑机根据模具生产出的塑料胶件，通过传送带送至振动盘中，通过控制振动盘将胶件按照设定频率逐个送往机械手所处的传送带，调试好的机械手从传送带的设定位置夹取待检测胶件；Step 1. Send the plastic parts produced by the injection molding machine according to the mold to the vibrating plate through the conveyor belt, and send the plastic parts to the conveyor belt where the manipulator is located one by one by controlling the vibrating plate according to the set frequency. Set the position to clamp the plastic parts to be detected;
步骤2、机械手逐个抓取胶件至检测黑箱中设定的图像采集区域，并按设定角度摆放胶件，通过补光灯和图像采集装置对胶件进行外形和颜色信息的采集；Step 2. The manipulator grabs the plastic parts one by one to the image acquisition area set in the detection black box, and places the plastic parts according to the set angle, and collects the shape and color information of the plastic parts through the supplementary light and the image acquisition device;
步骤3、机械手将待检测胶件水平翻转180°，再次采集胶件外形、颜色信息；Step 3. The manipulator flips the plastic parts to be detected 180° horizontally, and collects the shape and color information of the plastic parts again;
步骤4、将采集到的外形、颜色信息与数据库中标准件的相关信息进行对比，如果合格，则进行下一道检验工序，如果不合格，机械手将不合格胶件放置到胶件回收框中，并转步骤2；Step 4. Compare the collected shape and color information with the relevant information of standard parts in the database. If it is qualified, proceed to the next inspection process. If it is unqualified, the robot will place the unqualified plastic parts into the plastic part recycling box. And go to step 2;
步骤5、对于外形和颜色检验合格的胶件，机械手将控制该胶件和标准件进行接插件匹配度检测，利用接插过程中阻尼变化引起的电流大小变化来判断接插件匹配度是否合格；如果检测合格，则判断此胶件为良品，并将检测信息传送至控制模块，机械手将胶件放置到良品框中；如果检测不合格，则判断此胶件为不良品，机械手将其放置到胶件回收框中，并转步骤2。Step 5. For the plastic parts that pass the shape and color inspection, the manipulator will control the plastic part and the standard part to detect the matching degree of the connector, and use the current change caused by the damping change during the insertion process to judge whether the matching degree of the connector is qualified; If the test is qualified, it is judged that the plastic part is a good product, and the detection information is sent to the control module, and the manipulator places the plastic part in the good product box; if the test fails, it is judged that the plastic part is a defective product, and the manipulator places it Plastic parts recycling box, and go to step 2.
具体的，所述图像采集装置拍下胶件翻转前和翻转后的照片，然后进行图像识别，提取出待检测胶件的外形和颜色特征，并传送至控制模块与数据库中标准件的外形和颜色特征进行对比，如果误差在良品规定的范围内，则判定待检测胶件的外形和颜色检验合格。Specifically, the image acquisition device takes pictures of the plastic parts before and after flipping, and then performs image recognition to extract the shape and color characteristics of the plastic parts to be detected, and transmits them to the control module and the standard parts in the database. The color characteristics are compared, if the error is within the range specified by the good product, it is judged that the shape and color of the plastic part to be tested are qualified.
具体的，所述接插件匹配度检测的方法为：在标准件上安装高精度压力传感器，输出信号为电流，当待测胶件与标准件进行接插测试时，两者之间的阻尼会引起压力传感器输出电流的变化，计算实测电流与标准件之间接插时记录的标准电流的差值，判断该差值是否在允许的范围内来判断是否合格。Specifically, the method for detecting the matching degree of the connector is: install a high-precision pressure sensor on the standard part, and the output signal is a current. Cause the output current of the pressure sensor to change, calculate the difference between the measured current and the standard current recorded when the standard parts are plugged in, and judge whether the difference is within the allowable range to judge whether it is qualified.
具体的，可在标准件不同位置上安装多个高精度压力传感器，测试时分别产生的电流之和为实测电流Ic，而标准件之间接插时多个高精度压力传感器产生的电流之和为标准电流Ib，计算实测电流和标准电流的差值来判断误差电流是否在允许的范围内，如下式所示：Specifically, multiple high-precision pressure sensors can be installed on different positions of the standard parts. The sum of the currents generated during the test is the actual measured current Ic , and the sum of the currents generated by multiple high-precision pressure sensors when the standard parts are plugged As the standard current Ib , calculate the difference between the measured current and the standard current to judge whether the error current is within the allowable range, as shown in the following formula:
(Ib-δ)＜Ic＜(Ib+δ)(I b -δ)<I c <(I b +δ)
其中δ为一给定的正数，它的值根据不同胶件的接插件规格要求来确定；如果实测电流Ic处于这个误差范围内，则判定匹配度检测合格。Among them, δ is a given positive number, and its value is determined according to the specifications of the connectors of different plastic parts; if the measured current I c is within this error range, it is determined that the matching degree test is qualified.
具体的，所述补光灯采用LED阵列光源。Specifically, the supplementary light adopts an LED array light source.
本发明的优点是：针对塑料成型产品的出现缺胶、多胶、披锋等情况，自动监视并分类流出机台生产的良品和不良品，并且能够将数据及时送入控制系统进行统计，快速完成系统虚拟入库。The advantages of the present invention are: in view of the lack of glue, excess glue, and overhang of plastic molding products, it can automatically monitor and classify the good and bad products produced by the machine, and can send the data to the control system for statistics in time, quickly Complete system virtual storage.
附图说明Description of drawings
图1是本发明的流程图。Fig. 1 is a flow chart of the present invention.
图2是一种在线质量检测装置的结构示意图。Fig. 2 is a schematic structural diagram of an online quality detection device.
具体实施方式Detailed ways
下面结合附图和实施例对本发明作进一步说明。The present invention will be further described below in conjunction with drawings and embodiments.
如图1所示，本发明所述的一种成型产品在线质量检测方法总体流程如下：As shown in Figure 1, the overall flow of a method for online quality detection of molded products according to the present invention is as follows:
步骤1、将注塑机根据模具生产出的塑料胶件，通过传送带送至振动盘中，通过控制振动盘将胶件按照设定频率逐个送往机械手所处的传送带，调试好的机械手从传送带的设定位置夹取待检测胶件；Step 1. Send the plastic parts produced by the injection molding machine according to the mold to the vibrating plate through the conveyor belt, and send the plastic parts to the conveyor belt where the manipulator is located one by one by controlling the vibrating plate according to the set frequency. Set the position to clamp the plastic parts to be detected;
步骤2、机械手逐个抓取胶件至检测黑箱中设定的图像采集区域，并按设定角度摆放胶件，通过补光灯和图像采集装置对胶件进行外形和颜色信息的采集；Step 2. The manipulator grabs the plastic parts one by one to the image acquisition area set in the detection black box, and places the plastic parts according to the set angle, and collects the shape and color information of the plastic parts through the supplementary light and the image acquisition device;
步骤3、机械手将待检测胶件水平翻转180°，再次采集胶件外形、颜色信息；Step 3. The manipulator flips the plastic parts to be detected 180° horizontally, and collects the shape and color information of the plastic parts again;
步骤4、将采集到的外形、颜色信息与数据库中标准件的相关信息进行对比，如果合格，则进行下一道检验工序，如果不合格，机械手将不合格胶件放置到胶件回收框中，并转步骤2；Step 4. Compare the collected shape and color information with the relevant information of standard parts in the database. If it is qualified, proceed to the next inspection process. If it is unqualified, the robot will place the unqualified plastic parts into the plastic part recycling box. And go to step 2;
步骤5、对于外形和颜色检验合格的胶件，机械手将控制该胶件和标准件进行接插件匹配度检测，利用接插过程中阻尼变化引起的电流大小变化来判断接插件匹配度是否合格；如果检测合格，则判断此胶件为良品，并将检测信息传送至控制模块，机械手将胶件放置到良品框中；如果检测不合格，则判断此胶件为不良品，机械手将其放置到胶件回收框中，并转步骤2。Step 5. For the plastic parts that pass the shape and color inspection, the manipulator will control the plastic part and the standard part to detect the matching degree of the connector, and use the current change caused by the damping change during the insertion process to judge whether the matching degree of the connector is qualified; If the test is qualified, it is judged that the plastic part is a good product, and the detection information is sent to the control module, and the manipulator places the plastic part in the good product box; if the test fails, it is judged that the plastic part is a defective product, and the manipulator places it Plastic parts recycling box, and go to step 2.
本发明可以在现有的工控系统上进行改进，在传送带、机械手的控制系统基础上增加图像采集、图像识别装置以及胶件图像数据库以及胶件参数数据库。The present invention can be improved on the existing industrial control system, and image acquisition, image recognition device, adhesive image database and adhesive parameter database are added on the basis of the control system of the conveyor belt and the manipulator.
本发明需要建立胶件多角度图像数据库，可以由MES(制造企业生产过程执行管理系统)提供。还需要使用胶件图像识别软件，进行实物和标准图像的对比，做出产品缺胶、多胶等分析；以及数据采集软件，将良品和不良品信息送入MES数据库。The present invention needs to establish a multi-angle image database of adhesive parts, which can be provided by MES (Manufacturing Enterprise Production Process Execution Management System). It is also necessary to use the glue part image recognition software to compare the actual object with the standard image, and make an analysis of the lack of glue and excess glue of the product; and the data acquisition software to send the good and bad product information into the MES database.
如图2所示，搭建了一个成型产品在线质量检测装置，包括：注塑机1、振动盘2、机械手A(抓取待测胶件9)3、机械手B(抓取标准件10)4、位于检测黑箱5中的LED阵列光源6(补光灯)、图像采集装置7，右侧表示控制模块8整体，可以包括FPGA、CPU、DSP、MES服务器等，根据现场检测需要而设计。装置实现的主要功能有：塑料胶件外形检测、产品颜色检测、接插件匹配度检测。As shown in Figure 2, an online quality inspection device for molded products is built, including: injection molding machine 1, vibrating plate 2, manipulator A (grabbing the rubber parts 9 to be tested) 3, manipulator B (grabbing standard parts 10) 4, The LED array light source 6 (fill light) and the image acquisition device 7 located in the detection black box 5, and the right side shows the whole control module 8, which may include FPGA, CPU, DSP, MES server, etc., and is designed according to the needs of on-site detection. The main functions realized by the device are: shape detection of plastic parts, product color detection, and matching degree detection of connectors.
机械手工作流程：Manipulator workflow:
1、胶件抓取。通过各个电机相互配合，机械手A3可以从与振动盘2相连的传送带上夹取待检测胶件9。1. Plastic parts grabbing. Through the mutual cooperation of the motors, the manipulator A3 can clamp the rubber part 9 to be detected from the conveyor belt connected to the vibrating plate 2 .
2、胶件放置在图像采集处。夹取胶件9后，机械手A3将胶件9送至图像采集区域。2. The plastic part is placed in the image acquisition place. After gripping the glue piece 9, the manipulator A3 sends the glue piece 9 to the image acquisition area.
3、翻转胶件。图像采集过程中，通过机械手A3将胶件9翻转，实现对胶件形状和颜色信息的全方位采集。3. Flip the rubber parts. During the image acquisition process, the plastic part 9 is turned over by the manipulator A3 to realize the all-round collection of the shape and color information of the plastic part.
4、推送至接插件处，检测匹配度。控制机械手A3和机械手B4进行胶件匹配度测试，根据待检测胶件9与标准件10接插过程中不同阻尼引起的电流变化来判断是否合格。4. Push it to the connector to check the matching degree. Control manipulator A3 and manipulator B4 to test the matching degree of rubber parts, and judge whether it is qualified according to the current change caused by different damping during the insertion process of the rubber part 9 to be tested and the standard part 10.
5、合格品放回至传送带，不合格品放回胶件回收筐。5. The qualified products are put back to the conveyor belt, and the unqualified products are put back into the plastic recycling basket.
图像采集装置拍下胶件翻转前和翻转后的照片，然后进行图像识别，提取出待检测胶件的外形和颜色特征，并传送至控制模块与数据库中标准件的外形和颜色特征进行对比，如果误差在良品规定的范围内，则判定待检测胶件的外形和颜色检验合格。The image acquisition device takes photos of the plastic parts before and after flipping, and then performs image recognition to extract the shape and color features of the plastic parts to be detected, and transmits them to the control module for comparison with the shape and color features of the standard parts in the database. If the error is within the range specified by the good product, it is judged that the shape and color of the plastic part to be tested are qualified.
其中胶件的摆放位置和角度是有规定的，在图像采集区域上设有限位件或者支撑件，使得胶件必须按照规定位置和角度摆放，这样图像采集装置拍下的胶件照片为特定视图面，极大的便于图像处理软件处理识别，提高识别效率。Among them, the placement position and angle of the plastic parts are regulated, and there are limit pieces or support parts on the image acquisition area, so that the plastic parts must be placed according to the specified position and angle, so that the photo of the plastic parts taken by the image acquisition device is The specific view surface greatly facilitates the processing and recognition of image processing software and improves the recognition efficiency.
所述接插件匹配度检测的方法具体为：在标准件上安装高精度压力传感器，输出信号为电流，当待测胶件与标准件接插测试时，两者之间的阻尼会引起压力传感器输出电流的变化，计算实测电流与标准件之间接插时的标准电流的差值，判断该差值是否在允许的范围内来判断是否合格。The method for detecting the matching degree of the connectors is specifically: installing a high-precision pressure sensor on the standard part, and the output signal is a current. When the rubber part to be tested and the standard part are plugged and tested, the damping between the two will cause the pressure sensor to The change of the output current, calculate the difference between the measured current and the standard current when the standard parts are plugged in, and judge whether the difference is within the allowable range to judge whether it is qualified.
实施例中，在标准件不同位置上安装多个高精度压力传感器，测试时分别产生的电流之和为实测电流Ic，而标准件之间接插时多个高精度压力传感器产生的电流之和为标准电流Ib，计算实测电流和标准电流的差值来判断误差电流是否在允许的范围内。比如在标准件上设置4个压力传感器，四个传感器实测电流为Ic1，Ic2，Ic3和Ic4，四个传感器标准电流为Ib1，Ib2，Ib3和Ib4。In the embodiment, a plurality of high-precision pressure sensors are installed on different positions of the standard parts, and the sum of the currents generated respectively during the test is the actual measured current I c , while the sum of the currents generated by the multiple high-precision pressure sensors when the standard parts are plugged in As the standard current I b , calculate the difference between the measured current and the standard current to determine whether the error current is within the allowable range. For example, four pressure sensors are set on the standard part, the measured currents of the four sensors are I c1 , I c2 , I c3 and I c4 , and the standard currents of the four sensors are I b1 , I b2 , I b3 and I b4 .
则实测电流Ic＝Ic1+Ic2+Ic3+Ic4 Then the measured current I c =I c1 +I c2 +I c3 +I c4
标准电流Ib＝Ib1+Ib2+Ib3+Ib4 Standard current I b ＝I b1 +I b2 +I b3 +I b4
通过计算实测电流和标准电流的差值来判断误差电流是否在允许的范围内，如下式所示：Determine whether the error current is within the allowable range by calculating the difference between the measured current and the standard current, as shown in the following formula:
(Ib-δ)＜Ic＜(Ib+δ)(I b -δ)<I c <(I b +δ)
其中δ为一给定的小正数，它的值根据不同胶件的接插件规格要求来确定，从而界定了一个电流的标准范围。如果实测电流Ic处于这个标准范围内，则说明匹配度检测合格。机械手在移动过程中，实测电流大于标准范围，说明产品外形过大或内径过小，实测电流小于标准范围，说明产品外形过小或内径过大。Among them, δ is a given small positive number, and its value is determined according to the specification requirements of connectors of different plastic parts, thereby defining a standard range of current. If the measured current I c is within the standard range, it means that the matching degree test is qualified. When the manipulator is moving, the measured current is greater than the standard range, indicating that the product is too large or the inner diameter is too small, and the measured current is less than the standard range, indicating that the product is too small or the inner diameter is too large.
本发明的机械手驱动模块可以采用现有的电机驱动器和控制器，也可以将控制器功能整合进我们新增在控制模块中的处理器，省略原先的控制器。The drive module of the manipulator of the present invention can adopt the existing motor driver and controller, and can also integrate the controller function into our new processor in the control module, omitting the original controller.
MES服务器模块可以提供标准图片库功能，同时接受其他处理器处理的产品外形检测状态、产品颜色检测状态；还可以提供机器动作口令、接收接插件匹配度检测结果。这样动态检测机台生产的良品和不良品，且将数据及时送入系统进行统计，快速完成系统虚拟入库。The MES server module can provide the standard picture library function, and at the same time accept the product shape detection status and product color detection status processed by other processors; it can also provide machine action passwords and receive connector matching degree detection results. In this way, the good and bad products produced by the machine are dynamically detected, and the data is sent to the system in time for statistics, and the virtual storage of the system is quickly completed.
可以看到，本发明能够充分利用企业现有的软硬件设施，加入小成本的图像采集和图像处理分析装置，很好的控制了升级改造的成本。标准件的制作也并不复杂，非常适合中小型企业使用。It can be seen that the present invention can make full use of the existing software and hardware facilities of the enterprise, add low-cost image acquisition and image processing and analysis devices, and well control the cost of upgrading and transformation. The production of standard parts is not complicated, which is very suitable for small and medium-sized enterprises.
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