本文選題：機(jī)器視覺 + 碳刷表面　； 參考：《江蘇大學(xué)》2016年碩士論文

【摘要】：本課題所研究的對象是汽車上面用到的各種電機(jī)碳刷,碳刷的性能優(yōu)劣將直接影響到各種電機(jī)的運(yùn)轉(zhuǎn)穩(wěn)定性和效率,正是因?yàn)樘妓⑹墙^大部分直流電機(jī)不可或缺的關(guān)鍵部件,對碳刷生產(chǎn)過程中的在線檢測準(zhǔn)確性和高效率必須要得到有力的保證。在各種工業(yè)場合特別是汽車微電機(jī)上,碳刷是必不可少的重要零部件,使用特別廣泛。因此,一旦碳刷存在表面缺陷問題則會帶來輕則停機(jī)重則傷及人身安全的重大事故。為確保有效降低安全事故的發(fā)生,必須在碳刷生產(chǎn)過程中嚴(yán)格把控碳刷質(zhì)量,做到準(zhǔn)確檢測并剔除不良碳刷。經(jīng)對比分析國內(nèi)外碳刷表面缺陷檢測方法的優(yōu)劣勢,最后給出一套實(shí)時、非接觸高效準(zhǔn)確檢測碳刷表面質(zhì)量的解決方案。該解決方案是基于智能機(jī)器視覺的快速發(fā)展而設(shè)計(jì)的,其優(yōu)點(diǎn)是非接觸、快速、準(zhǔn)確,同時在應(yīng)用的電子環(huán)境中具有較強(qiáng)的抗干擾能力,所以在各種工業(yè)生產(chǎn)中應(yīng)用越來越廣泛。為實(shí)現(xiàn)機(jī)器視覺準(zhǔn)確快速檢測碳刷表面缺陷的效果,本文主要做了以下幾方面的工作:首先通過對比人工肉眼檢測、傳統(tǒng)在線檢測、智能視覺系統(tǒng)非接觸檢測各自特點(diǎn),分析了人工肉眼檢測和傳統(tǒng)在線檢測的缺點(diǎn)和不足,同時提出了采用智能視覺系統(tǒng)配合改進(jìn)硬件裝置實(shí)現(xiàn)非接觸在線100%高效檢測碳刷的全自動方案。根據(jù)碳刷表面裂痕檢測系統(tǒng)的指標(biāo)要求,主要包括精度要求、錯檢率和漏檢率要求以及效率要求等,對整個檢測系統(tǒng)的硬件部分進(jìn)行全面設(shè)計(jì)和選型,基于系統(tǒng)運(yùn)行穩(wěn)定性和可靠性考量來對每個環(huán)節(jié)零部件進(jìn)行合理分析與選擇,針對視覺系統(tǒng)拍照過程中存在的相機(jī)微動情況對相機(jī)固定支架架設(shè)方式進(jìn)行了改進(jìn);針對振動理料送料裝置存在卡料且送料慢問題增加了直線送料器,從而保證自動送料的穩(wěn)定和快速;在機(jī)械翻轉(zhuǎn)機(jī)構(gòu)配合下實(shí)現(xiàn)碳刷正反面的裂痕檢測;根據(jù)碳刷表面裂痕的特點(diǎn)和客戶對自動檢測裝置的性能要求,對智能機(jī)器視覺系統(tǒng)中涉及到的幾個關(guān)鍵部件如重點(diǎn)對智能相機(jī)、光源控制器、鏡頭、光源架設(shè)方式等進(jìn)行詳細(xì)分析與對比選擇,最終將視覺系統(tǒng)中每個關(guān)鍵部件合理地確定下來�；谝陨嫌布到y(tǒng)和光學(xué)系統(tǒng)的選型確定后,對整個碳刷表面裂痕缺陷檢測自動線的控制系統(tǒng)進(jìn)行詳細(xì)設(shè)計(jì),同時對該系統(tǒng)的控制器以及外設(shè)電氣部分也予以對比擇優(yōu)選擇。為保障整個碳刷表面裂痕檢測裝置的運(yùn)行穩(wěn)定,對檢測系統(tǒng)的保護(hù)裝置進(jìn)行設(shè)計(jì)和優(yōu)化,同時設(shè)計(jì)了碳刷良品和不良品自動分揀機(jī)構(gòu);本設(shè)計(jì)的創(chuàng)新之處除了首次在碳刷行業(yè)引入智能視覺系統(tǒng)進(jìn)行非接觸100%檢測,還引入監(jiān)控系統(tǒng)對整套自動檢測裝置進(jìn)行實(shí)時監(jiān)控。最后,根據(jù)碳刷表面裂痕缺陷的特點(diǎn),設(shè)計(jì)了采用快速檢測碳刷表面裂痕缺陷的算法和處理軟件。本碳刷表面實(shí)時檢測方案已付諸實(shí)施,設(shè)計(jì)安裝調(diào)試完成了自動在線檢測裝置,給一家碳刷行業(yè)龍頭企業(yè)的生產(chǎn)線上使用本檢測系統(tǒng)已取得了良好的效果,可以實(shí)時準(zhǔn)確判定出碳刷表面有肉眼能看得到的所有裂痕,裝置運(yùn)行時檢測速率有50只/分鐘,比之前耗人耗時且品質(zhì)無法保證的情況有了根本性改觀。目前國內(nèi)碳刷企業(yè)采用機(jī)器視覺在線檢測表面缺陷的尚比較少,因此本裝置具有較廣泛的應(yīng)用價值,同時本裝置通過更改檢測算法后亦可推廣應(yīng)用于其他精密五金產(chǎn)品的在線檢測中。
[Abstract]:The object of this study is the various motor carbon brushes used in the automobile. The performance of carbon brush will directly affect the stability and efficiency of all kinds of motor. It is precisely because carbon brush is the key component of most DC motor. The accuracy and efficiency of on-line detection in the process of carbon brush production must be obtained. Strong assurance. Carbon brushes are essential components in a variety of industrial applications, especially automotive micromotors, and are used especially widely. Therefore, once the surface defects of carbon brushes exist, there will be significant accidents with light weight stopping and physical safety. To ensure the effective reduction of safety accidents, carbon brushes must be produced. In the process, the quality of the controlled carbon brush is strictly detected and eliminated. The advantages and disadvantages of the surface defect detection methods at home and abroad are compared and analyzed. Finally, a set of real-time, non-contact and efficient solution for the accurate detection of the surface quality of carbon brush is given. The solution is designed based on the rapid development of intelligent machine vision. The advantages are non-contact, fast, accurate, and have strong anti-interference ability in the applied electronic environment, so it is more and more widely used in all kinds of industrial production. In order to realize the accuracy and rapid detection of the surface defects of the brush surface, the following work is done in this paper: first by comparing artificial eye detection, transmission. The defects and shortcomings of artificial naked eye detection and traditional online detection are analyzed by on-line detection and non contact detection of intelligent visual system. A full automatic scheme using intelligent visual system and improved hardware device to realize non-contact on-line 100% high efficiency detection of carbon brush is proposed. According to the index of the carbon brush surface crack detection system Requirements, mainly including precision requirements, error detection rate and leakage rate requirements as well as efficiency requirements, all the hardware parts of the whole detection system are fully designed and selected. Based on the stability and reliability of the system, the reasonable analysis and selection of the parts of each link are carried out, and the camera micro motion in the process of visual system photography is made. The method of fixing the fixed frame of the camera is improved, and the linear feeder is added to the material feeding device of the vibrating material feeding device and the feeding is slow, thus ensuring the stability and speed of the automatic feeding, and the crack detection of the carbon brush positive and negative surfaces is realized under the coordination of the mechanical turnover mechanism; according to the characteristics of the surface cracks of the carbon brush and the customer's self The performance requirements of the dynamic testing device are analyzed and contrasted with the key components involved in the intelligent machine vision system, such as the intelligent camera, the light source controller, the lens, the light source erection mode and so on. Finally, each key component in the visual system is reasonably determined. Based on the above hardware and optical systems, After the selection is determined, the control system of the surface flaw detection automatic line of the carbon brush surface is designed in detail, and the controller and the peripheral electrical part of the system are also selected. In order to ensure the stability of the whole carbon brush surface crack detection device, the protection device of the detection system is designed and optimized. In addition to the design of carbon brush and defective products automatic sorting mechanism, the innovation of this design in addition to the first in the carbon brush industry, the introduction of intelligent visual system for non-contact 100% detection, and the introduction of monitoring system for the complete set of automatic monitoring device for real-time monitoring. Finally, according to the characteristics of the carbon brush surface flaw defects, the design of rapid detection is adopted. The real time detection scheme of the carbon brush surface has been put into practice. The automatic on-line detection device has been completed by the design and installation and debugging. It has achieved good results for the use of this detection system on the production line of a carbon brush industry leading enterprise. It can accurately determine the surface of the brush on the carbon brush in real time. In all the cracks, the detection rate of the device is 50 / minute, compared with the time consuming and the quality can not be guaranteed. At present, the domestic carbon brush enterprises are still relatively small in the use of machine vision to detect surface defects on line. Therefore, this device has a wide application value, and the device has been checked by change inspection. It can also be applied to other precision metal products on-line testing.
【學(xué)位授予單位】：江蘇大學(xué)
【學(xué)位級別】：碩士
【學(xué)位授予年份】：2016
【分類號】：U468.2;TP391.41

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