The principle, structure and key technology of the intelligent inspection system for the shape and s1

Door and window hinges are crucial components in modern buildings, playing a significant role in the quality and safety of doors and windows. High-grade hinges are typically made of stainless steel. However, due to the limitations of the stamping production process and the difficulty in working with stainless steel, the precision and quality of hinges often suffer. To address these issues, the traditional inspection methods of gauges and tools are inefficient and inaccurate, leading to higher defective product rates and reduced profitability for companies. Therefore, a new intelligent detection system has been developed to ensure precise and rapid detection of hinge parts, ultimately improving manufacturing accuracy and ensuring high-quality assembly.

The new detection system is designed to focus on the main parts of the hinge assembly, consisting of nine components. The system uses machine vision and laser detection technologies for non-contact inspection, primarily focusing on two-dimensional visible contours, shapes, and sizes. This allows for more precise and efficient detection of various specifications.

To accommodate the wide range of hinge products, the system incorporates machine vision, laser detection, and servo control technologies. The system includes a material table installed on a linear guide rail, which can be driven by a servo motor to facilitate the movement of the workpiece for detection.

The system workflow begins with the workpiece being fed into the detection area using the material table. Within the detection area, two cameras and a laser displacement sensor are utilized to measure the outer dimension and flatness of the workpiece. The detection of shape is carried out using two cameras, each dedicated to detecting a specific side of the T piece. The laser displacement sensor is mounted on electric slides, enabling vertical and horizontal movement to accommodate various workpiece dimensions.

The system also incorporates machine vision inspection to measure the total length of the workpiece. Given the large range of workpiece lengths, a combination of servo control and machine vision is used to accurately calculate the length. By utilizing calibration and coordinating the movement of the workpiece, the system ensures precise length measurement.

Similarly, the relative position and diameter of the workpiece holes are detected using servo control and machine vision. By feeding the appropriate number of pulses, the system accurately measures the distance between the two holes and calculates their coordinates within the camera's field of view. To account for any imperfections resulting from hole punching, a meticulous approach is taken to detect the aperture and center coordinates of the holes.

The system also caters to the detection of the workpiece hole's symmetry relative to the width direction of the workpiece. Through image preprocessing and edge detection techniques, the system can extract accurate and clear edge information, ensuring reliable measurements.

To further enhance detection accuracy, the system employs a sub-pixel algorithm using bilinear interpolation during image contour extraction. This algorithm increases the pixel resolution, positively impacting the stability and accuracy of the system. The overall detection uncertainty is maintained below 0.005mm.

With over 1,000 types of hinge products, manually setting detection parameters for each specific part is an intricate and time-consuming task. To simplify this process, the system employs barcode scanning to classify workpieces based on the parameters to be detected. This allows for the automatic extraction of detection parameters and facilitates precise positioning of the workpiece during inspection.

In conclusion, the developed detection system has proven highly effective in ensuring precise detection of large-scale workpieces, despite limitations in machine vision detection resolution. The system generates statistical reports within minutes, promotes interoperability and interchangeability, adapts to parts of various specifications, and even generates CAD files based on inspection data. With its Internet of Things interface, the system seamlessly integrates with manufacturing systems, streamlining the operation of detection information. This system is widely applicable to the meticulous inspection of hinges, slide rails, and other similar products, ensuring high-quality and safe building components.