面向生产现场的注塑齿轮快速分选检测系统

Rapid sorting and inspecting system for plastic gears in production site

注塑齿轮生产效率高、批量大,而传统的人工检测效率低、精度差,为确保产品质量和生产效率,研发了一种面向生产现场的注塑齿轮快速分选检测系统。该系统耦合在生产线上,利用传送带上料、玻璃转盘传送、气动装置分选;利用工业相机采集被测齿轮图像,采用机器视觉的方法测量齿顶圆直径、中孔直径、同心度等基本参数,并与其公差范围进行对比,判断产品质量;通过图像分割、边缘提取、特征提取、缺陷判别等方法,对缺齿、黑点、披锋等表面缺陷进行检测;最后,该系统根据检测结果进行良次品分选,具有快速、在线、自动化、非接触等特点。试验结果表明,该系统测量重复性≤0.005 mm,检测速度大于150个/min,缺陷判别及分选功能准确无误,且长时间运行稳定。该系统可以满足注塑齿轮生产现场大批量、高效率、高可靠的分选检测需求。

The production efficiency of plastic gears is high,and their batches are large;while the traditional manual inspection is low and the accuracy is poor.To ensure product quality and production efficiency,a rapid sorting and inspection system for plastic gears was developed.The system was combined with a production line and used a conveyor belt for loading,a glass rotary for transmission,and a pneumatic device for sorting.Plastic gear images were captured using an industrial camera,and basic parameters such as the tip diameter,the hole diameter,and the concentricity were measured by a machine vision method;the tolerance ranges were compared,in order to judge the product quality.By using algorithms such as image segmentation,edge extraction,feature extraction,and defect identification,surface defects such as missing teeth,black spots,and burr were inspected.Finally,the system separated good and defective products according to the test results.The system could carry out fast,online,automatic,and non-contact separation and inspection.The test results showed that the measurement repeatability of the system was less than 0.005 mm,the inspection speed was greater than 150 piece/min,the defect identification and sorting functions were accurate,and the system could run stably for a long time.Hence,the proposed system can meet the requirements of large-scale,high-efficiency,and high-reliability sorting and inspection at a plastic gear production site.