Journal of Textile Research ›› 2020, Vol. 41 ›› Issue (10): 158-163.doi: 10.13475/j.fzxb.20200306006

• Machinery & Accessories • Previous Articles     Next Articles

Investigation on automatic deformation inspection system of long and thin parts with hooks

ZHU Shigen1,2(), YANG Hongxian1,2, BAI Yunfeng1,2, DING Hao1,2, ZHU Qiaolian3   

  1. 1. College of Mechanical Engineering, Donghua University, Shanghai 201620, China
    2. Engineering Research Center of Advanced Textile Machinery, Ministry of Education, Donghua University, Shanghai 201620, China
    3. Yiwu Yunxi New Material Technology Company, Yiwu, Zhejiang 322000,China
  • Received:2020-03-23 Revised:2020-07-08 Online:2020-10-15 Published:2020-10-27

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Abstract:

The existing machine vision automatic deformation inspection system is mainly limited to the detection of small size precision parts or large size non precision parts. For some large-scale, high-precision and large-quantity inspection objects, manual sorting is mainly used in actual production. It is difficult to guarantee high accuracy and efficiency at the same time. Therefore, an automatic deformation inspection method and system based on vision was proposed. First of all, a modular high-speed detection hardware system was designed, and the detection index was quantified by the virtual real image joint detection method. Secondly, using LabVIEW and IMAQ vision visual toolkit as the development environment, according to the shape characteristics of the parts, a partition detection algorithm based on the gap value was designed to avoid various errors of direct detection of the overall deformation. On this basis, the optimal detection scheme was determined according to the shape of the needle hook, and the improved positioning strategy based on multi-references was used to solve the problem of pose deviation. The results show that the system can avoid the false detection of the hook, improve the measurement accuracy of the hook size and the repeatability of the detection results, and the repeat detection rate can reach 91%-96%. Finally, comparing with standard parts, it is verified that the consistency of machine-checked parts meets the needs of installation.

Key words: machine vision, deformation inspection, virtual instrument, LabVIEW, needle, deformation detection algorithm of parts

CLC Number: 

  • TH71

Fig.1

Deformation mode of parts"

Fig.2

Schematic diagram of detection system composition"

Fig.3

Part image"

Fig.4

Software architecture"

Fig.5

Search range and part minimum circumscribed rectangle"

Fig.6

ROI positioning reference"

Fig.7

Test plan. (a) Scheme 1; (b)Scheme 2"

Tab.1

Test results of different test schemes"

方案 机器检测 合格品
误检数		 合格品误
检率/%
合格品 不合格品
一 60 240 7 6.6
二 52 248 0 0

Fig.8

Hook shape of error detection in scheme I"

Fig.9

Change of projection length of parts"

Tab.2

Detection results of gap value before improving positioning mode"

次数 1 2 3 4 5
1 0.055 0.055 0.055 0.055 0.252
2 0.055 0.053 0.055 0.055 0.266
3 0.051 0.043 0.055 0.055 0.266
4 0.047 0.055 0.055 0.055 0.252
5 0.055 0.055 0.055 0.054 0.262
6 0.042 0.048 0.055 0.055 0.270
7 0.055 0.054 0.055 0.051 0.277
8 0.055 0.055 0.055 0.044 0.253
9 0.048 0.045 0.057 0.056 0.252
10 0.054 0.043 0.055 0.054 0.269
测量误差 0.013 0.012 0.002 0.012 0.025

Tab.3

Detection results of gap value after improved positioning method"

次数 1 2 3 4 5
1 0.048 0.055 0.055 0.052 0.279
2 0.055 0.055 0.055 0.045 0.279
3 0.055 0.055 0.055 0.055 0.266
4 0.047 0.055 0.055 0.054 0.279
5 0.055 0.055 0.068 0.055 0.279
6 0.055 0.055 0.069 0.055 0.273
7 0.046 0.055 0.055 0.054 0.279
8 0.050 0.042 0.055 0.055 0.279
9 0.042 0.042 0.055 0.044 0.273
10 0.055 0.055 0.055 0.055 0.279
测量误差 0.013 0.013 0.014 0.011 0.013

Tab.4

System repeat experiment results"

类型 实验次数 初检合
格数		 初检合格品再检
个数 重复检出率/%
改进前 1 106 79 75
2 98 78 80
3 100 83 83
4 106 83 78
改进后 1 99 90 91
2 101 97 96
3 96 87 91
4 96 89 93

Fig.10

Parts arrangement diagram"

Fig.11

Consistency comparison between machine inspection pats and standard parts"

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