Based on machine vision technology, an efficient and reliable automatic spring detection system is designed to replace the cumbersome labor of operators. The system should meet the requirements of real-time, reliability and easy maintenance while accurately identifying defects and accurately measuring dimensions.
The hardware portion of the system is primarily based on a line scan imaging system. After the motion mechanism cooperates with the line array camera to collect the spring-expanded image, it is sent to the computer for processing by the NI PCI-1428 image acquisition card. In the software part, LabVIEW is used as a development platform. In combination with IMAQ, SQL Toolkit and other development kits, the spring automatic detection system is developed in a short time to detect spring surface defects and dimensions (including spring free length, wire diameter, pitch and effective number of turns).
introductionSpring surface quality inspection is an important part of spring processing. During the test, the performance of the spring is measured by various test methods, so that the mass of the spring is quantitatively quantified, which provides a correct evaluation basis for the quality management and tracking of the enterprise. The inspection of the finished product of the spring mainly includes the appearance inspection, size detection and load detection of the spring. Here we mainly complete the appearance inspection and size detection of the spring (including spring length, wire diameter, wire diameter spacing and effective number of turns).
The existing spring detection methods in China are generally manually visualized with tools such as vernier calipers, which are not only inefficient but also have large errors. Some companies also import advanced equipment from abroad for automatic spring detection, which greatly increases production costs, and on the other hand, equipment maintenance is also difficult. In view of the above deficiencies, it is of great significance to independently develop a spring automatic detection system based on machine vision. The system is mainly developed based on NI LabVIEW graphical programming environment, the interface is simple and friendly, and it is convenient for the inspection personnel to operate. For springs of the same specification, the system compares the springs with all the data of the springs and compares them with the corresponding standard values. The experimental results show that compared with the traditional manual detection method, the method has faster detection speed, higher precision and stronger reliability.
I. Spring detection platform hardware composition1.1 Components of the inspection system
The hardware structure of the spring automatic detection system is shown in Fig. 1. The spring is horizontally placed on the white rotating shaft, and the stepping motor drives the shaft to rotate. In addition to being responsible for the rotation of the pulse-driven motor, the PLC also uses this pulse as an external trigger signal to access the image acquisition card to ensure that a proportional image is acquired. The camera adopts Basler L101k-2k, a line camera series from Basler, Germany, and cooperates with NI's PCI-1428 image acquisition card to complete image acquisition. The unfolded spring of the acquisition is shown in Figure 1. After the camera captures the expanded view of a frame of springs, it is sent to the computer for processing via the image capture card. The computer mainly completes the functions of hardware configuration and initialization, image processing, data analysis and saving. After image processing to obtain the key parameters of the surface defects and dimensions of the spring, the computer compares it with the spring standard library information of the corresponding specification to identify the unqualified spring.
Figure 1 Schematic diagram of the spring automatic detection system
1.2 line array camera and capture card cooperation
The principle of taking a line camera is different from that of a face array. It only collects one line of image at a time, and only one frame of complete 2D image can be acquired only when there is relative motion between the lens and the object being photographed. In Fig. 2, the longitudinal direction is the direction of the line sensor, and the resolution is determined by the line CCD; the horizontal direction indicates the scanning direction of the camera, and the resolution is determined by the minimum step size of the stepping motor. If the motor moves too fast, the image will be compressed, as shown in Figure 2(b); if the speed is too small, the image will be stretched, as shown in Figure 2(c).
Figure 2 Corresponding imaging effects when the speed of motion is different
In order to get an equal proportion of images, set the camera to work in the external edge trigger mode, as shown in Figure 3. In this mode, the line sweep rate of the camera is completely determined by the frequency of the external signal. The relationship between the two is: line sweep rate = 1 / external signal frequency. NI's PCI-1428 frame grabber provides four pairs of external trigger ports (from Trig_(0) to Trig_(3), input signal type is TTL level), and supports the external sync mode of the line camera. The pulse from the PLC is connected to any external trigger port of the PCI-1428 capture card, thus achieving the correspondence between the motor speed and the line sweep rate. MAX (Measurement & AutomaTIon Explorer) is a software developed by National Instruments to facilitate user setup and testing of various hardware. In MAX, you can configure the basic parameters of the capture card, such as the image capture mode, image size, and trigger signal type.
Figure 3 External Edge Trigger Mode (ExSync, Edged-controlled Mode)
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