阅读说明：本技术 一种检测和追踪铝用阳极炭块质量的系统及方法 (System and method for detecting and tracking quality of aluminum anode carbon block ) 是由 何力 祝元兵 杨正华 周春刚 姚永峰 孙占海 姜海超 张利 王健 陈洪 李龙 于 2021-05-31 设计创作，主要内容包括：本发明公开了一种检测和追踪铝用阳极炭块质量的系统,包括依次电连接且均与自动控制机构电连接的视觉识别装置、缺陷检测模块、数据处理模块、数据存储模块、数据管理模块,所述系统还包括质量检测装置,质量检测装置与自动控制机构电连接。检测和追踪方法包括以下步骤：将视觉识别装置拍照后获取的图像样本数据发送给缺陷检测模块；缺陷检测模块从数据存储模块实时读取缺陷样本图像信息并对接收到的图像样本数据进行缺陷检测,形成检测结果；当检测结果为无缺陷时,自动控制机构向旋转台发送指令,旋转台将铝用阳极炭块输送至正常方向；反之,旋转台将铝用阳极炭块输送至废品区。本发明为在线检测提供检测及信息平台,提高了检测效率和准确度。(The invention discloses a system for detecting and tracking the quality of an aluminum anode carbon block, which comprises a visual identification device, a defect detection module, a data processing module, a data storage module and a data management module which are sequentially and electrically connected and are all electrically connected with an automatic control mechanism, and the system also comprises a quality detection device which is electrically connected with the automatic control mechanism. The detection and tracking method comprises the following steps: sending image sample data acquired after the visual recognition device takes a picture to a defect detection module; the defect detection module reads the image information of the defect sample from the data storage module in real time and carries out defect detection on the received image sample data to form a detection result; when the detection result is that the anode carbon block is not defective, the automatic control mechanism sends an instruction to the rotating platform, and the rotating platform conveys the aluminum anode carbon block to the normal direction; otherwise, the rotary table conveys the aluminum anode carbon blocks to a waste area. The invention provides a detection and information platform for online detection, and improves the detection efficiency and accuracy.)

1. A system for detecting and tracking the quality of an aluminum anode carbon block is characterized by comprising a visual identification device (4), a defect detection module, a data processing module, a data storage module and a data management module which are sequentially and electrically connected, and further comprising a quality detection device and an automatic control mechanism (8), wherein the quality detection device, the visual identification device (4), the defect detection module, the data processing module, the data storage module and the data management module are all electrically connected with the automatic control mechanism (8); the quality detection device comprises a conveying mechanism and a position sensor (3), wherein the conveying mechanism comprises a first conveying chain (1), a second conveying chain (6) and a rotating table (5), the conveying direction of the conveying chain is from the first conveying chain (1) to the second conveying chain (6), the first conveying chain (1) is connected with the second conveying chain (6), and the rotating table (5) is installed at the bottom of the second conveying chain (6); the position sensor (3) and the visual recognition device (4) are both arranged around the first conveying chain (1), and the visual recognition device (4) is electrically connected with the position sensor (3); the defect detection module compares and calculates image sample data acquired by the visual recognition device (4), the data processing module is used for processing and classifying the image sample data after comparison and calculation by the defect detection module, the data storage module is used for storing and outputting the image sample data processed and classified by the data processing module, and the data management module is used for presenting the image sample data stored and output by the data storage module.

2. The system for detecting and tracking the quality of the aluminum anode carbon blocks as claimed in claim 1, wherein the quality detection device further comprises guide rails (2), and the guide rails (2) are arranged on two sides of the guide rails of the first conveyor chain (1) and the second conveyor chain (6).

3. The system for detecting and tracking the quality of the aluminum anode carbon block is characterized in that the visual recognition device (4) comprises a light source (9), a plurality of sets of optical lenses (10), a camera (11) and a camera movement adjusting bracket (7), wherein the camera movement adjusting bracket (7) is arranged on the side surface and the upper part of the first conveying chain (1), and the camera (11) is arranged on the camera movement adjusting bracket (7).

4. The system for detecting and tracking the quality of an aluminum anode carbon block as claimed in claim 3, wherein the camera (11) is an industrial camera.

5. The system for detecting and tracking the quality of an aluminum anode carbon block according to claim 1, wherein the rotation angle of the rotating table (5) is 0-90 °.

6. The system for detecting and tracking the quality of the aluminum anode carbon block as claimed in claim 1, wherein the automatic control mechanism (8) comprises an image acquisition module for acquiring image sample data acquired by the visual recognition device (4) and sending the acquired result to the defect detection module.

7. The system for detecting and tracking the quality of the anode carbon block for aluminum as claimed in claim 3, wherein the automatic control mechanism (8) comprises an upper computer unit, a lower controller unit and a communication unit; the upper computer unit is interacted with the lower controller unit, the lower controller unit is used for receiving the instruction of the upper computer unit, and the lower controller unit controls the camera (11) to shoot, collect the position information of the aluminum anode carbon block (12) and send an action instruction for the conveying mechanism; the communication unit is used for establishing an interaction channel between the upper computer unit and the lower controller unit.

8. The method for detecting and tracking the quality of an aluminum anode carbon block according to any one of claims 1 to 7, wherein the method comprises the steps of:

step (I): sending image sample data acquired after the visual recognition device takes a picture to a defect detection module;

step (II): the defect detection module reads the image information of the defect sample from the data storage module in real time and carries out defect detection on the received image sample data to form a detection result;

step (three): when the detection result is that the anode carbon block is not defective, the automatic control mechanism sends an instruction to the rotating platform, and the rotating platform conveys the aluminum anode carbon block to the normal direction; and when the detection result shows that the aluminum anode carbon blocks are defective, the automatic control mechanism sends an instruction to the rotary table, and the rotary table conveys the aluminum anode carbon blocks to a waste area.

Technical Field

The invention belongs to the technical field of quality process control of an aluminum anode in the production and manufacturing field of aluminum anode carbon blocks, and particularly relates to a system and a method for detecting and tracking the quality of the aluminum anode carbon block.

Background

The production and manufacture of the carbon block belong to the production and manufacture field of the aluminum anode carbon block, the quality of the product will be changed in the process of baking and baking the green body carbon block into the mature block, and the traditional method of each enterprise on the production line is to arrange the professional staff to visually inspect the quality of the carbon block, on one hand, the inspection method increases the labor cost and has low efficiency, on the other hand, the quality of the green body and the quality of the corresponding baked mature block cannot be linked in the inspection process; the detection data of the traditional detection mode is manually counted, a large data platform is not used for supporting, so that the counting efficiency is low, the historical data is inconvenient to look up, the data value is limited, and particularly, the online quality detection is particularly important when the production scale is large and continuous.

Disclosure of Invention

The invention provides a system and a method for detecting and tracking the quality of an aluminum anode carbon block on line by using an industrial internet, which are in line with the large upgrading direction of national and enterprise industries and realize intellectualization and automation, aiming at the problems that the quality of a green body and the quality of a corresponding roasted block cannot be associated, the labor cost for detection is high, the efficiency is low, the false detection rate is high, the high-temperature and high-dust working environment is not beneficial to the occupational health of staff, the manual statistics of data is realized, a large data platform is not used for supporting, the efficiency is low, the lookup of historical data is inconvenient, the data value is limited, the traceability is not strong and the like in the prior art.

The invention adopts the following technical scheme:

a system for detecting and tracking the quality of an aluminum anode carbon block is characterized by comprising a visual identification device (4), a defect detection module, a data processing module, a data storage module and a data management module which are sequentially and electrically connected, and further comprising a quality detection device and an automatic control mechanism (8), wherein the quality detection device, the visual identification device (4), the defect detection module, the data processing module, the data storage module and the data management module are all electrically connected with the automatic control mechanism (8); the quality detection device comprises a conveying mechanism and a position sensor (3), wherein the conveying mechanism comprises a first conveying chain (1), a second conveying chain (6) and a rotating table (5), the conveying direction of the conveying chain is from the first conveying chain (1) to the second conveying chain (6), the first conveying chain (1) is connected with the second conveying chain (6), and the rotating table (5) is installed at the bottom of the second conveying chain (6); the position sensor (3) and the visual recognition device (4) are both arranged around the first conveying chain (1), and the visual recognition device (4) is electrically connected with the position sensor (3); the defect detection module compares and calculates image sample data acquired by the visual recognition device (4), the data processing module is used for processing and classifying the image sample data after comparison and calculation by the defect detection module, the data storage module is used for storing and outputting the image sample data processed and classified by the data processing module, and the data management module is used for presenting the image sample data stored and output by the data storage module.

The system for detecting and tracking the quality of the anode carbon blocks for aluminum is characterized by further comprising guide rails (2), wherein the guide rails (2) are mounted on two sides of the guide rails of the first conveying chain (1) and the second conveying chain (6).

The system for detecting and tracking the quality of the aluminum anode carbon blocks is characterized in that the visual recognition device (4) comprises a light source (9), a plurality of sets of optical lenses (10), a camera (11) and a camera movement adjusting support (7), the camera movement adjusting support (7) is installed on the side face and the upper portion of the first conveying chain (1), and the camera (11) is installed on the camera movement adjusting support (7).

The system for detecting and tracking the quality of the anode carbon block for the aluminum is characterized in that the camera (11) is an industrial camera.

The system for detecting and tracking the quality of the anode carbon block for aluminum is characterized in that the rotating angle of the rotating platform (5) is 0-90 degrees.

The system for detecting and tracking the quality of the aluminum anode carbon block is characterized in that the automatic control mechanism (8) comprises an image acquisition module, and the image acquisition module is used for acquiring image sample data acquired by the visual recognition device (4) and sending an acquired result to the defect detection module.

The system for detecting and tracking the quality of the anode carbon block for aluminum is characterized in that the automatic control mechanism (8) comprises an upper computer unit, a lower controller unit and a communication unit; the upper computer unit is interacted with the lower controller unit, the lower controller unit is used for receiving the instruction of the upper computer unit, and the lower controller unit controls the camera (11) to shoot, collect the position information of the aluminum anode carbon block (12) and send an action instruction for the conveying mechanism; the communication unit is used for establishing an interaction channel between the upper computer unit and the lower controller unit.

The detection and tracking method of the system for detecting and tracking the quality of the anode carbon block for the aluminum is characterized by comprising the following steps of:

step (I): sending image sample data acquired after the visual recognition device takes a picture to a defect detection module;

step (II): the defect detection module reads the image information of the defect sample from the data storage module in real time and carries out defect detection on the received image sample data to form a detection result;

step (three): when the detection result is that the anode carbon block is not defective, the automatic control mechanism sends an instruction to the rotating platform, and the rotating platform conveys the aluminum anode carbon block to the normal direction; and when the detection result shows that the aluminum anode carbon blocks are defective, the automatic control mechanism sends an instruction to the rotary table, and the rotary table conveys the aluminum anode carbon blocks to a waste area.

The invention has the beneficial technical effects that: (1) the invention uses the industrial machine vision technology, the automation control technology, the data analysis technology and other technologies to improve the flexibility and the automation degree of production, uses the machine vision to replace manual detection under the condition of poor environmental conditions, can greatly improve the production efficiency and the automation degree of production, and is easy to realize data information integration by the machine vision. (2) The system and the method of the invention adopt an intelligent and automatic industrial internet production information system, can realize basic defect detection, and adopt a scientific and accurate data output and tracking technology. (3) The system and the method can reduce personnel allocation, reduce labor cost, improve the working environment of quality inspectors and ensure that the quality inspectors do not need to work in a high-temperature and high-dust environment in enterprise production. (4) The invention can solve the problem of associating the green body quality with the baked mature block quality. (5) The invention realizes the computer internet management, provides an information platform for product detection in the enterprise production process by using the internet management technology, the machine vision technology, the big data and the automation control technology, and greatly improves the carbon block quality and process tracking capability. (6) The invention has good system compatibility and lower cost expandability, provides a detection and information platform for online detection, and improves the detection efficiency and accuracy.

Drawings

FIG. 1 is a schematic diagram of the connection of the system of the present invention;

FIG. 2 is a schematic view of a mass testing device of the present invention;

FIG. 3 is a schematic view of the connection between the turntable and the second conveying chain according to the present invention;

FIG. 4 is a schematic view of a visual identification device of the present invention;

fig. 5 is a network topology diagram of the system of the present invention.

Detailed Description

Referring to fig. 1-5, the system for detecting and tracking the quality of an aluminum anode carbon block comprises a visual identification device (4), a defect detection module, a data processing module, a data storage module and a data management module which are electrically connected in sequence, and further comprises a quality detection device and an automatic control mechanism (8), wherein the quality detection device, the visual identification device (4), the defect detection module, the data processing module, the data storage module and the data management module are all electrically connected with the automatic control mechanism (8); the number of quality check devices depends on the number of production lines, and there are several quality check devices in several production lines. The quality detection device is used for executing the instruction of the automatic control mechanism 8, transmitting the anode carbon block 12 for aluminum to an image acquisition area for image acquisition, and outputting the detected anode carbon block 12 for aluminum to different areas. The quality detection device comprises a transmission mechanism and a position sensor 3, wherein the transmission mechanism comprises a first conveying chain 1, a second conveying chain 6 and a rotating table 5, the conveying direction of the conveying chains is from the first conveying chain 1 to the second conveying chain 6, the first conveying chain 1 is connected with the second conveying chain 6, and the rotating table 5 is arranged at the bottom of the second conveying chain 6; the conveyor chain is used to convey the anode carbon blocks 12 for aluminum on the production line. When the detection result is unqualified, spray-painting marks are fixed on the anode carbon blocks 12 for aluminum at fixed positions, after the marks are finished, the rotating table 5 drives the second conveying chain 6 to rotate, and the second conveying chain 6 shunts and conveys the unqualified anode carbon blocks 12 for aluminum to a waste group without entering a production line; when the detection result is qualified, the rotary table conveys the anode carbon block 12 for aluminum to the normal production direction. The rotation angle of the rotating table 5 is 0-90 deg. The position sensor 3 is installed at the position of the shooting working area of the visual recognition device 4 and used for collecting the position information of the carbon block to be detected in the detection process, and sending a shooting starting instruction to the visual recognition device 4 when the anode carbon block 12 for aluminum reaches the specified position. The position sensor 3 is arranged on the side surface of the first conveying chain 1, the visual recognition device 4 is arranged above the first conveying chain 1, and the visual recognition device 4 is electrically connected with the position sensor 3; the visual recognition device 4 is used for photographing the anode carbon block 12 for aluminum to obtain image information. The visual recognition device 4 further stores the pictures in a designated storage space after the imaging is completed.

The quality detection device also comprises guide rails 2, the guide rails 2 are arranged on two sides of the guide rails of the first conveying chain 1 and the second conveying chain 6, and the guide rails 2 are used for avoiding the deviation of the anode carbon blocks 12 for aluminum when moving on the conveying chains. The visual recognition device 4 comprises a light source 9, a plurality of sets of optical lenses 10, a camera 11 and a camera moving adjusting bracket 7, wherein the light source 9 is used for providing the brightness required by imaging, the light source is controllable, and an active light mode is adopted to avoid the interference of natural light. The optical lens 10 is an essential component in a visual recognition device, and directly affects the quality of imaging quality, and a high-resolution lens is adopted to ensure the imaging quality. The camera 11 is an industrial camera. The camera movement adjusting bracket 7 is used for adjusting the shooting position of the camera. The camera movement adjusting bracket 7 is installed at the side and above the first conveyor chain 1, and the camera 11 is installed at the top of the camera movement adjusting bracket 7. And the anode carbon block for the aluminum to be measured is shot in the transmission and moving process or in a static state, and surface quality detection and analysis are started after imaging is completed.

And the defect detection module is used for detecting whether the image comprises a pixel set with the pixel gray scale changing sharply so as to realize the defect detection of the surface of the detected object and form a detection result. The defect detection module compares and calculates image sample data acquired by the visual recognition device 4, the data processing module is used for processing and classifying the image sample data after comparison and calculation by the defect detection module, the data storage module is used for storing and outputting the image sample data processed and classified by the data processing module, and the data management module is used for presenting the image sample data stored and output by the data storage module. The defect detection module comprises a sample image database establishing unit, a defect detection unit and a coding identification module, wherein the sample image database establishing unit is used for processing the collected image sample data, establishing a sample image database, automatically finishing the warehousing of the sample image, and establishing and modifying corresponding data information. The defect detection unit is used for reading image sample data of the image acquisition module in real time, comparing the image sample data with a sample image database established by the sample image database establishing unit, calculating, detecting whether a pixel set with sharply changed pixel gray levels is included in an image so as to realize defect detection of the surface of a detected object, and classifying various features, such as: detecting time, whether defects exist, defect types, sizes, local screenshots and the like to form a final qualified detection result. The defect detection unit comprises defect detection on the appearance quality of the detected object, such as cracks, oxidation, edge drop, corner drop and the like. The defect detection unit is used for reading image information from the sample image database in real time, processing and calculating to complete appearance quality inspection, and detecting various unqualified aluminum anode carbon blocks such as cracks, unfilled corners, oxidation and the like. The defect detection technical method adopted by the invention is to identify points with obvious brightness change in the digital image, and the obvious change in the image attribute usually reflects the important events and changes of the image; the method comprises the steps of discontinuity in depth, discontinuity in surface direction, change of material properties and change of scene illumination, and the defect detection of the surface of the object to be detected is realized through a pixel set with peripheral pixel gray scale remarkably changed caused by the surface defect of the object to be detected. The code identification module is used for identifying and establishing individual information of the anode carbon block 12 for aluminum. The code recognition module comprises an OCR recognition unit which is used for recognizing code information on the aluminum anode carbon block 12 and information flow records in the carbon block production process.

The data processing module calculates, processes and classifies the data in the system. The data processing module is used for processing and classifying all the acquired image data in the system, including basic information of a newly-built image; a sorted list is made for various features, such as: test time, whether there is a defect, type of defect, size, partial screenshot, etc. And the data storage module is used for performing classified statistics on the carbon block information subjected to over-detection through the accumulation of big data to establish a statistical platform, and the data storage module is used for storing and outputting the data of the system according to a set mode. The data storage module stores the detection result into a designated memory, integrates the stored image data and generates a report, and the data storage module comprises a data query unit and a report generation unit, wherein the data query unit is used for numbering the acquired images of each aluminum anode carbon block, so that sample data can be conveniently stored and queried; for data query and analysis display: the number of carbon blocks detected per day/week/month, the percent of pass, the percent of fail, the types and images of defects of the defective carbon blocks, the classification and the proportion of the defects of the defective carbon blocks, and the like. The report generation unit is used for reporting the daily/weekly/monthly quality inspection and the ledger, analyzing the quality of the over-inspected carbon blocks, the qualification rate, the reject ratio, the defective carbon block defect types and images, and classifying and accounting the defective carbon block defects to generate reports; it is also possible to process the remaining data other than the logical control of the present apparatus. The data management module comprises monitoring, statistics, inquiry, setting and the like, is used for data presentation of the system and comprises human-computer interaction functions of data display, data statistics analysis, authority setting and the like; and the data management module is used for combining the statistical classification result with the production process factors and analyzing the reason for generating the defects of the anode carbon block 12 for the aluminum.

The automatic control mechanism 8 is the logical control basis of the system, and comprises the control of the transmission mechanism and the data acquisition and control of the electric elements, and the electric elements comprise acquisition sensors of various signals, such as position, temperature and the like. The automatic control mechanism 8 is used for sending out an instruction, transmitting the anode carbon block 12 for aluminum to an image acquisition area, and sending out an instruction according to a detection result to output the anode carbon block 12 for aluminum to different areas. The automatic control mechanism 8 comprises an image acquisition module, the image acquisition module is used for acquiring image sample data acquired by the visual recognition device 4, judging whether the appearance of the carbon block to be detected is qualified or not according to the image information, and sending the detection result to the software algorithm module. The automatic control mechanism 8 comprises an upper computer unit, a lower controller unit and a communication unit; the upper computer unit is used for interacting with the lower controller unit and feeding back a detection result to the lower controller unit for processing in time, the lower controller unit is used for receiving an instruction of the upper computer unit, and the lower controller unit controls the camera 11 to shoot, collect position information of the anode carbon block 12 for aluminum and send an action instruction to the conveying mechanism; the communication unit is used for establishing an interaction channel between the upper computer unit and the lower controller unit, namely a data and instruction transmission channel,

the communication module of the present invention uses an industrial ethernet network as a communication network, but is not limited thereto. When the communication module adopts an industrial Ethernet, the communication module is used for realizing rapid and smooth data communication between each module and different protocols through the Ethernet TCP/IP, and ensuring that the aluminum anode carbon block appearance quality online detection system stably and reliably operates. The communication module has an open standard system, the back end is designed based on an open TCP/IP network platform, a plurality of network protocols are supported, the interconnection, intercommunication and mutual control among the systems can be facilitated, and the system follows a standard general interface standard, so that the mutual restriction and influence among a hardware environment, a communication environment, a software environment and an operation platform are minimized.

The invention has good man-machine interaction interface and strong data processing function, and can set the identification standard according to the requirements of enterprises, set the standard statistical analysis and output the statistical report forms, and the like.

The detection and tracking method of the system for detecting and tracking the quality of the aluminum anode carbon block comprises the following steps:

step (I): and sending image sample data acquired after the visual recognition device 4 takes a picture to a defect detection module.

Step (II): the defect detection module reads the image information of the defect sample from the data storage module in real time and carries out defect detection on the received image sample data, and the defect detection on the surface of the detected object is realized by judging the pixel set with the sharp change of the pixel gray level in the detected image, so as to form a detection result. The method comprises the following specific steps: reading defect sample image information from a data storage module in real time; identifying points with obvious brightness change in the sample image information as defect points; reading the sampled image information from the quality detection device in real time; according to the points with obvious brightness change in the sample digital image, comparing the obvious change of the pixel gray scale in the sample image, and then comparing the discontinuity in depth, the discontinuity of the surface direction and the change of the material attribute; according to the comparison result, judging through a pixel set with sharp change of peripheral pixel gray caused by the surface defect of the object to be detected, and judging that the surface of the object to be detected is defective if the pixel set is consistent with a point domain value with obvious brightness change in the sample digital image; otherwise, the defect is not existed, thereby realizing the defect detection of the surface of the detected object.

Step (three): when the detection result is no defect, the lower controller unit of the automatic control mechanism 8 sends an instruction to the rotary table 5, and the rotary table 5 conveys the anode carbon block 12 for aluminum to the normal direction; when the detection result shows that the defect exists, the lower controller unit of the automatic control mechanism 8 sends an instruction to the rotary table 5, and the rotary table 5 conveys the anode carbon block 12 for aluminum to the waste area.

Step (IV): the code identification module records the individual information of the anode carbon block 12 for aluminum, including the number, the size, the product quality and the like.

Step (V): and the data storage module carries out classified statistics on the information table established by the code identification module.

Step (six): and the data management module is used for combining the statistical result with the production process factors and analyzing the reasons for generating the defects of the anode carbon block 12 for the aluminum.