System and method for detecting metal stamping part tapping defects

A system for detecting metal stamping part tapping defects, which comprises a product placing device, a detecting mechanism, a defective product sorting mechanism, a good product discharging mechanism, an analyzing mechanism and a Programmable Logic Control (PLC) system; the product placing device, the defective product sorting mechanism, and the good product discharging mechanism are connected to the PLC system respectively, the PLC system is configured to control the product placing device to place the metal stamping part in a detection position; the detecting mechanism is configured to acquire the tapping hole information of the metal stamping part tapping hole in the detection position.

TECHNICAL FIELD

The present application relates to the field of automatic production of metal stamping part, in particular to a system and method for detecting metal stamping part tapping defects.

BACKGROUND

In recent years, with the maturity of stamping technology in China, the specifications of metal stamping part are getting smaller and smaller, and the processing precision and speed are getting higher and higher, which makes it more difficult to detect the quality of metal stamping part in the later stage. The detection of the tapping hole after metal stamping part tapping is currently performed by manual visual inspection. The manual visual inspection requires the detection of the tapping of the metal stamping part. The inspectors are required to have excellent vision and endurance, and it takes a lot of human resources. Therefore, in the actual production process, the detection of the tapping hole after metal stamping part tapping is performed by manual sampling, which saves human resources, but cannot achieve comprehensive and effective quality control. There are serious hidden dangers in product quality. When metal stamping part tapping defects are not detected in time, the metal stamping parts flow to the product assembly line, which will lead to serious quality defects of the assembled products in the later stage. After the products are installed, the metal stamping parts cannot be detected. The assembly can be removed to re-detect the metal stamping parts after the product has quality problems, causing a lot of rework and waste of raw materials. The product quality problems that occur will result in serious safety accidents and economic losses, and even result in serious personal injury.

SUMMARY

The main object of the present application is to provide a system and method for detecting metal stamping part tapping defects for solving the technical problem that the prior art cannot automatically detect the tapping hole after the metal stamping part tapping.

In order to achieve the above object, the first embodiment of the present application provides a system for detecting metal stamping part tapping defects, wherein the detecting system comprises: a product placing device, a detecting mechanism, a defective product sorting mechanism, a good product discharging mechanism, an analyzing mechanism and a Programmable Logic Control (PLC) system;

the product placing device, the defective product sorting mechanism, and the good product discharging mechanism are connected to the PLC system, respectively, and the detecting mechanism is connected to the analyzing mechanism;

the PLC system is configured to control the operation of the product placing device, and the product placing device is configured to place the metal stamping part in a detection position;

the detecting mechanism is configured to acquire the tapping hole information of the metal stamping part tapping hole in the detection position;

the analyzing mechanism is configured to analyze the state of the tapping hole according to the tapping hole information, and feed back the state result of the tapping hole to the PLC system;

the PLC system is further configured to control the operation of the defective product sorting mechanism or the good product discharging mechanism according to the state result of the tapping hole; and

the defective product sorting mechanism is configured to acquire defective products in the metal stamping part, and the good product discharging mechanism is configured to acquire good products in the metal stamping part.

The second embodiment of the present application provides a method for detecting metal stamping part tapping defects, wherein the detecting method comprises:

controlling, by the PLC system, the operation of the product placing device, and placing, by the product placing device, the metal stamping part in a detection position;

acquiring, by the detecting mechanism, the tapping hole information of the metal stamping part tapping hole in the detection position;

analyzing, by the analyzing mechanism, the state of the tapping hole according to the tapping hole information, and feeding back the state result of the tapping hole to the PLC system;

controlling, by the PLC system, the operation of the defective product sorting mechanism or the good product discharging mechanism according to the state result of the tapping hole; and

acquiring, by the defective product sorting mechanism, defective products in the metal stamping part, and acquiring, by the good product discharging mechanism, good products in the metal stamping part.

According to the above technical solution provided by the present application, the present application provides a system for detecting metal stamping part tapping defects, wherein the system comprises: a product placing device, a detecting mechanism, a defective product sorting mechanism, a good product discharging mechanism, an analyzing mechanism and a PLC system. The product placing device, the defective product sorting mechanism, and the good product discharging mechanism are connected to the PLC system, respectively. The PLC system may control the operation of the product placing device, the defective product sorting mechanism, and the good product discharging mechanism. The PLC system controls the product placing device to place the metal stamping part in a detection position. The detecting mechanism may acquire the tapping hole information of the metal stamping part tapping hole in the detection position. Since the detecting mechanism is connected to the analyzing mechanism, the analyzing mechanism may acquire the tapping hole information. The analyzing mechanism identifies the state of the metal stamping part tapping hole according to the tapping hole information, and feeds back the state of the tapping hole to the PLC system. The PLC system controls the operation of the corresponding defective product sorting mechanism or the good product discharging mechanism according to the state of the tapping hole. The tapping hole after metal stamping part tapping is completed is automatically detected, improving the detection efficiency and accuracy compared to the manual detection of the prior art, and reducing the rising cost of the product after rework.

DESCRIPTION OF THE EMBODIMENTS

The technical solutions in the embodiments of the present application will be clearly and completely described in conjunction with the drawings in the embodiments of the present application in order to make the objects, features and advantages of the present application more obvious and understandable. Obviously, the described embodiments are merely a part of the embodiments of the present application, rather than all of the embodiments. All other embodiments obtained by those skilled in the art based on the embodiments of the present application without any creative work fall within the scope of protection of the present application.

The technical problem that the prior art cannot automatically detect the tapping hole after the metal stamping part tapping exists. In order to solve the above technical problem, the present application provides a system for detecting metal stamping part tapping defects for automatically detecting the tapping hole after the metal stamping part tapping.

Refer toFIG. 1, which is the schematic structural view of a system for detecting metal stamping part tapping defects according to the first embodiment of the present application. The detecting system comprises: a product placing device, a detecting mechanism1, a defective product sorting mechanism2, a good product discharging mechanism3, an analyzing mechanism4and a Programmable Logic Control (PLC) system5, wherein the product placing device, the defective product sorting mechanism2, and the good product discharging mechanism3are connected to the PLC system5, respectively. The detecting mechanism1is connected to the analyzing mechanism4. The PLC system5is configured to control the operation of the product placing device, and the product placing device is configured to place the metal stamping part in a detection position. The detecting mechanism1is configured to acquire the tapping hole information of the metal stamping part tapping hole in the detection position. The analyzing mechanism4is configured to analyze the state of the tapping hole according to the tapping hole information, and feed back the state result of the tapping hole to the PLC system5. The PLC system5is further configured to control the operation of the defective product sorting mechanism2or the good product discharging mechanism3according to the state result of the tapping hole. The defective product sorting mechanism2is configured to acquire defective products in the metal stamping part, and the good product discharging mechanism3is configured to acquire good products in the metal stamping part.

Specifically, the product placing device, the defective product sorting mechanism2, and the good product discharging mechanism3are connected to the PLC system5, respectively, so that the PLC system5can control the operation of the product placing device, the defective product sorting mechanism2, and the good product discharging mechanism3. The PLC system5controls the operation of the product placing device, and the product placing device places the metal stamping part in the detection position. The detection position is located in the detecting mechanism1. After the metal stamping part is placed in the detection position, the detecting mechanism1acquires the tapping hole information of the metal stamping part tapping hole. The analyzing mechanism detects the state of the metal stamping part tapping hole according to the tapping hole information, and feeds back the state result of the detected tapping hole to the PLC system5. The PLC system5controls the operation of one of the defective product sorting mechanism2and the good product discharging mechanism3according to the state result of the tapping hole which is fed back. When the PLC system5controls the operation of the defective product sorting mechanism2, the defective product sorting mechanism2acquires the defective products in the metal stamping part. When the PLC system5controls the operation of the good product discharging mechanism3, the good product discharging mechanism3acquires the good products in the metal stamping parts.

The tapping hole information acquired by the detecting mechanism1is an image of the metal stamping part tapping hole. The analyzing mechanism4analyzes the state of the tapping hole according to the image of the tapping hole. Since the analyzing mechanism4and the PLC system5are connected through a serial port, the analyzing mechanism4outputs the state result of the tapping hole through the serial port to the PLC system5, so that the PLC system5controls the operation of the defective product sorting mechanism2or the good product discharging mechanism3according to the state result of the tapping hole.

According to the system for detecting metal stamping part tapping defects provided above, the present application provides a system for detecting metal stamping part tapping defects, wherein the system comprises: a product placing device, a detecting mechanism, a defective product sorting mechanism, a good product discharging mechanism, an analyzing mechanism and a PLC system. The product placing device, the defective product sorting mechanism, and the good product discharging mechanism are connected to the PLC system, respectively. The PLC system may control the operation of the product placing device, the defective product sorting mechanism, and the good product discharging mechanism. The PLC system controls the product placing device to place the metal stamping part in a detection position. The detecting mechanism may acquire the tapping hole information of the metal stamping part tapping hole in the detection position. Since the detecting mechanism is connected to the analyzing mechanism, the analyzing mechanism may acquire the tapping hole information. The analyzing mechanism identifies the state of the metal stamping part tapping hole according to the tapping hole information, and feeds back the state of the tapping hole to the PLC system. The PLC system controls the operation of the corresponding defective product sorting mechanism or the good product discharging mechanism according to the state of the tapping hole. The tapping hole after metal stamping part tapping is completed is automatically detected, improving the detection efficiency and accuracy compared to the manual detection of the prior art, and reducing the rising cost of the product after rework.

Further, as shown inFIG. 1, the product placing device comprises a loading mechanism6and a product pushing mechanism7. The loading mechanism6comprises a vibrating plate601and a direct vibrator602, and a portion of the vibrating disk601in a vibration feeding direction is connected to the direct vibrator602. The vibrating plate601is configured to sequentially output the metal stamping part into the direct vibrator602, and the direct vibrator602is configured to carry the metal stamping part to an inlet of the product pushing mechanism7. The product pushing mechanism7comprises: a bit optical fiber701, a pushing cylinder702and a feeding cylinder703. The pushing cylinder702and the feeding cylinder703are connected to the PLC system5, respectively. The bit optical fiber701is configured to sense the metal stamping part at the inlet, and output a photoelectrical signal to trigger the operation of the pushing cylinder702after the metal stamping part is sensed. The pushing cylinder702is configured to push the metal stamping part to a feeding position. The feeding cylinder703is configured to feed the metal stamping part in the feeding position to the detection position, so that the analyzing mechanism4analyzes the tapping hole information of the metal stamping part tapping hole.

Specifically, the metal stamping parts are sequentially arranged in the vibrating plate601. The vibrating plate601sequentially transfers the metal stamping parts to the direct vibrator602, and the direct vibrator602carries the metal stamping part to an inlet of the product pushing mechanism7. The bit optical fiber701of the product pushing mechanism7senses that the metal stamping part reaches the pushing mechanism, and the bit optical fiber701outputs a photoelectrical signal to trigger the operation of the pushing cylinder702. The pushing cylinder702pushes the metal stamping part at the inlet to the feeding position. The feeding cylinder703feeds the metal stamping part in the feeding position to the detection position, so that the analyzing mechanism4analyzes the tapping hole information of the metal stamping part tapping hole.

Further, as shown inFIG. 1, the detecting mechanism1comprises a detecting camera101, a detecting light source102, a detecting bracket103, and a detecting optical fiber104. The detecting camera101and the detecting light source102are fixedly connected to the detecting bracket103, respectively, the detecting light source102is below the detecting camera101, and the analyzing mechanism4is connected to the detecting camera101. The detecting optical fiber104is configured to send a photographing signal to the detecting camera after the metal stamping part is sensed in the detection position, and the detecting camera101is configured to acquire a tapping image of the metal stamping part tapping hole. The analyzing mechanism4is configured to acquire the tapping image from the detecting camera101, and identify the tapping image to obtain a tapping detection result of the metal stamping part.

Specifically, the detecting camera101and the detecting light source102are fixedly connected to the detecting bracket103, respectively, thereby fixing the detecting camera101and the detecting light source102to the detecting bracket103. The detecting light source102is below the detecting camera101, and the detection position is below the detecting light source102. When detecting the metal stamping part in the detection position, the detecting optical fiber104sends a signal to be photographed to the detecting camera101, and the signal can cause the detecting camera to take a picture of the metal stamping part and obtain the tapping image of the metal stamping part tapping hole. The analyzing mechanism4is connected to the detecting camera101, so that the analyzing mechanism4can acquire the tapping image of the metal stamping part tapping hole from the detecting camera101. After acquiring the tapping image, the analyzing mechanism4identifies the tapping image to obtain a tapping detection result of the metal stamping part.

It should be noted that the image illustrating the metal stamping part tapping hole is the acquired tapping image.

Further, the detecting light source102is an annular light source. The annular light source is soft and concentrated, which can effectively avoid interference of external light on the product and improve the precision of the tapping detection result of the metal stamping part.

Further, the analyzing mechanism4is a Charge Coupled Device (CCD) detecting mechanism, and the CCD detecting mechanism is configured to identify the acquired tapping image and output corresponding defective product signals or good product signals according to the identified tapping detection result.

Specifically, a CCD detecting software is provided in the CCD detecting mechanism. The CCD detecting software acquires a tapping image, and identifies the tapping image to determine whether there is a tapping defect in the metal stamping part. When there is a tapping defect, the CCD detecting software outputs a defective product signal, and the metal stamping part is a defective product; when there is no tapping defect, the CCD detecting software outputs a good product signal, and the metal stamping part is a good product.

It should be noted that both the good product signal and the defective product signal described above are two different transmittable electrical signals indicating the state of detecting the tapping hole. When there is a tapping defect as the tapping detection result of the metal stamping part, a defective product signal is output. When there is no tapping defect as the tapping detection result of the metal stamping part, a good product signal is output.

Further, as shown inFIG. 1, the detecting system further comprises a cabinet8in which each of the loading mechanism6, the product pushing mechanism7, the detecting mechanism1, the defective product sorting mechanism2, and the good product discharging mechanism3is provided, ensuring the integrity of the detecting system.

Further, as shown inFIG. 1, the defective product sorting mechanism2comprises: a sensing optical fiber201, a defective product processing cylinder202, and a mechanical finger203. The mechanical finger203is connected to the defective product processing cylinder202, and the sensing optical fiber201is configured to sense the detected metal stamping part. The defective product processing cylinder202is configured to drive the mechanical finger203to move when receiving a defective product signal, and the mechanical finger203is configured to bring the defective products in the metal stamping part to the defective product area.

Specifically, the PLC system5receives the defective product signal. After the sensing optical fiber201senses the detected metal stamping part, the PLC system5controls the operation of the defective product processing cylinder202. The operation of the defective product processing cylinder202drives the mechanical finger203to move to the operating position. The defective product processing cylinder202blows the metal stamping part into the mechanical finger203, and the mechanical finger203brings the metal stamping part to the defective product area to complete the screening of defective products.

Further, as shown inFIG. 1, the good product discharging mechanism3comprises: a good product discharging guide rail301, an air blowing device302, and a receiving box303. The good product discharging guide rail301is obliquely mounted on the cabinet8, and the receiving box303is below the good product discharging guide rail301. The good product discharging guide rail301is used as the track for discharging the good products in the metal stamping part, and the air blowing device302is configured to blow the good products to the receiving box303.

Specifically, the PLC system5receives the good product signal. After the sensing optical fiber201senses the detected metal stamping part, the PLC system5controls the operation of the air blowing device302. The air blowing device302blows the metal stamping part to the good product discharging guide rail301. The metal stamping part moves on the inclined good product discharging guide rail301under the assistance of the air blowing device, and finally flows into the receiving box303to complete the discharging of the good products.

Further, the air blowing device302comprises a solenoid valve3021and an air pipe3022. The blowing device302is used to speed up the processing speed of the good products and improve the overall detection efficiency.

It should be noted that the bit optical fiber701, the detecting optical fiber104and the sensing optical fiber201in the method all trigger the operation of other mechanisms by outputting a photoelectrical signal.

It can be seen from the above detecting system that using the detecting system of the present application, the detection on the tapping defects of good products in the metal stamping parts is completed by a plurality of structures together. The detecting system is smooth in operation, automatic in detection in the whole process, high in degree of automation, simple in structure, and easy to achieve.

The second embodiment of the present application provides a method for detecting metal stamping part tapping defects, which is applied to the system for detecting metal stamping part tapping defects provided by the first embodiment.

Refer toFIG. 2, which is a schematic flow chart of a method for detecting metal stamping part tapping defects according to the second embodiment of the present application. The detecting method is used in the detecting system of the first embodiment, and the detecting method comprises steps101to105.

At step101, the PLC system controls the operation of the product placing device, and the product placing device places the metal stamping part in a detection position.

At step102, the detecting mechanism acquires the tapping hole information of the metal stamping part tapping hole in the detection position.

At step103, the analyzing mechanism analyzes the state of the tapping hole according to the tapping hole information, and feeds back the state result of the tapping hole to the PLC system.

At step104, the PLC system controls the operation of the defective product sorting mechanism or the good product discharging mechanism according to the state result of the tapping hole, the defective product sorting mechanism acquires defective products in the metal stamping part, and the good product discharging mechanism acquires good products in the metal stamping part.

Specifically, the PLC system can control the operation of the product placing device, the defective product sorting mechanism, and the good product discharging mechanism. The PLC system controls the operation of the product placing device, and the product placing device places the metal stamping part in the detection position. The detection position is located in the detecting mechanism. After the metal stamping part is placed in the detection position, the detecting mechanism acquires the tapping hole information of the metal stamping part tapping hole. The analyzing mechanism analyzes the state of the metal stamping part tapping hole according to the tapping hole information, and feeds back the state result of the analyzed tapping hole to the PLC system. The PLC system controls the operation of one of the defective product sorting mechanism and the good product discharging mechanism according to the state result of the tapping hole which is fed back. When the PLC system controls the operation of the defective product sorting mechanism, the defective product sorting mechanism acquires the defective products in the metal stamping part. When the PLC system controls the operation of the good product discharging mechanism, the good product discharging mechanism acquires the good products in the metal stamping parts.

The tapping hole information acquired by the detecting mechanism is an image of the metal stamping part tapping hole. The analyzing mechanism analyzes the state of the tapping hole according to the image of the tapping hole and then feeds back the state result to the PLC system for further operation.

According to the method for detecting metal stamping part tapping defects provided above, in the method, the PLC system controls the product placing device to place the metal stamping part in a detection position. The detecting mechanism may acquire the tapping hole information of the metal stamping part tapping hole in the detection position. The analyzing mechanism identifies the state of the metal stamping part tapping hole according to the tapping hole information, and feeds back the state of the tapping hole to the PLC system. The PLC system controls the operation of the corresponding defective product sorting mechanism or the good product discharging mechanism according to the state of the tapping hole. The tapping hole after metal stamping part tapping is completed is automatically detected, improving the detection efficiency and accuracy compared to the manual detection of the prior art, and reducing the rising cost of the product after rework.

Further, as shown inFIG. 3,FIG. 3is a schematic flow chart of the refining step of step101. The refining step of step101comprises steps201to202.

At step201, the vibrating plate sequentially outputs the metal stamping part into the direct vibrator, and the direct vibrator carries the metal stamping part to an inlet of the product pushing mechanism.

At step202, the bit optical fiber in the product pushing mechanism outputs a photoelectrical signal to trigger the operation of the pushing cylinder after sensing the metal stamping part at the inlet, the pushing cylinder pushes the metal stamping part to a feeding position, and the feeding cylinder feeds the metal stamping part in the feeding position to the detection position.

Specifically, the metal stamping parts are sequentially arranged in the vibrating plate. The vibrating plate sequentially transfers the metal stamping part to the direct vibrator, and the direct vibrator carries the metal stamping part to an inlet of the product pushing mechanism. The bit optical fiber in the product pushing mechanism senses that the metal stamping part reaches the pushing mechanism, and the bit optical fiber outputs a photoelectrical signal to trigger the operation of the pushing cylinder. The pushing cylinder pushes the metal stamping part at the inlet to the feeding position. The feeding cylinder feeds the metal stamping part in the feeding position to the detection position, so that the analyzing mechanism analyzes the tapping hole information of the metal stamping part tapping hole.

Further, as shown inFIG. 4,FIG. 4is a schematic flow chart of the refining step of step102. The refining step of step102comprises steps301to302.

At step301, the detecting optical fiber sends a photographing signal to the detecting camera after the metal stamping part is sensed in the detection position, and the detecting camera acquires a tapping image of the metal stamping part tapping hole.

At step302, the analyzing mechanism acquires the tapping image from the detecting camera, and identifies the tapping image to obtain a tapping detection result of the metal stamping part.

Specifically, when detecting the metal stamping part in the detection position, the detecting optical fiber sends a signal to be photographed to the detecting camera, and the signal can cause the detecting camera to take a picture of the metal stamping part and obtain the tapping image of the metal stamping part tapping hole. The analyzing mechanism can acquire the tapping image of the metal stamping part tapping hole from the detecting camera. After acquiring the tapping image, the analyzing mechanism identifies the tapping image to obtain a tapping detection result of the metal stamping part.

The CCD detecting mechanism mainly detects the CCD detecting software. The CCD detecting software acquires a tapping image, and identifies the tapping image to determine whether there is a tapping defect in the metal stamping part. When there is a tapping defect, the CCD detecting software outputs a defective product signal, and the metal stamping part is a defective product; when there is no tapping defect, the CCD detecting software outputs a good product signal, and the metal stamping part is a good product.

It should be noted that both the good product signal and the defective product signal described above are two different transmittable electrical signals indicating the state of detecting the tapping hole. When there is a tapping defect as the tapping detection result of the metal stamping part, a defective product signal is output. When there is no tapping defect as the tapping detection result of the metal stamping part, a good product signal is output.

It should also be noted that the above describes that the image of the metal stamping part tapping hole is the acquired tapping image.

Further, refer toFIG. 5, which is a schematic flow chart of the refining step of step104. The refining step of step104comprises steps401to404.

At step401, the PLC system receives a signal output by the analyzing mechanism.

At step402, it is determined whether the signal is a defective product signal.

At step403, if the signal is a defective product signal, the defective product sorting mechanism operates.

At step404, if the signal is not a defective product signal, the good product discharging mechanism operates.

Specifically, the analyzing mechanism outputs two different electrical signals after analyzing the tapping image. The PLC system receives two sets of electrical signals output by the analyzing mechanism. If the electrical signal is a defective product signal, the PLC system controls the operation of the defective product sorting mechanism, and the defective product sorting mechanism screens out the defective products of the metal stamping parts. If the electrical signal is a good product signal, the PLC system controls the operation of the good product discharging mechanism, and the good product discharging mechanism operates to collect the good products of the metal stamping parts.

The PLC system controls the operation of the defective product sorting mechanism or the good product discharging mechanism in such a manner that after the sensing optical fiber senses the metal stamping part, the sensing optical fiber outputs a photoelectric signal to trigger the PLC system to control the operation of the defective product sorting mechanism or the good product discharging mechanism.

The specific steps of the operation of the defective product sorting mechanism are as follows: the defective product processing cylinder drives the mechanical finger to move, and the mechanical finger brings the defective products in the metal stamping part to the defective product area. The operation of the good product discharging mechanism is as follows: the air blowing device blows the metal stamping parts of the good products into the good product discharging guide rail, the good products of the metal stamping parts roll in the inclined good product discharging guide rail, and finally enter the receiving box to complete collecting metal stamping parts of good products.

It should be noted that, in the method, each of the bit optical fiber, the detecting optical fiber and the sensing optical fiber triggers the operation of other mechanisms by outputting a photoelectrical signal.

It should be noted that, for the sake of brevity, each of the above method embodiments is described as a combination of a series of actions, but those skilled in the art should understand that the present application is not limited by the described action sequence because certain steps may be performed in other sequences or concurrently in accordance with the present application. Secondly, those skilled in the art should also understand that the embodiments described in the specification are all preferred embodiments, and the actions and modules involved are not necessarily required by the present application.

In the above embodiments, the descriptions of the various embodiments are different, and the details that are not detailed in a certain embodiment can refer to the related descriptions of other embodiments.

The above is a description of a system and method for detecting metal stamping part tapping defects provided by the present application. For those skilled in the art, in accordance with the idea of the embodiment of the present application, the specific embodiment and the application range may be changed. In conclusion, the content of this specification is not to be construed as limiting the present application.