The present invention relates to a device configured to detect screws, especially to a device with a linear carrying rail, which is used to carry screws, and automatically controlling and adjusting mechanisms through a controlling module to detect screws of different sizes.
In screw production industry, to reduce labor costs and lower a detection error rate, a screw detection device is used to detect screws nowadays. The screw detection device comprises multiple detection cameras and a rotary disk. The rotary disk has multiple detection recesses. The multiple detection cameras are disposed around and face the rotary disk to photograph. The screw detection device rotates the rotary disk.
While processing screw detection, a screw-feeding device feeds multiple screws to the rotary disk and puts each of the screws into a respective one of the multiple detection recesses. The screw detection device rotates the rotary disk to move the screws to pass through the front of the multiple detection cameras. By the multiple detection cameras photographing each screw, the screw detection device detects and determines whether said screw is defective.
A screw factory often produces screws of different sizes. Corresponding to screws of different sizes, detection recesses in a rotary disk also have different sizes. So, to detect screws of different sizes, the rotary disk in the screw detection device needs to be changed. This is less convenient, and also the multiple detection cameras of the screw detection device have to be refocused, and changing the rotary disk and refocusing the multiple detection cameras are manually operated. However, manual adjustments are prone to errors, hence increasing the detection error rate and product defect rate, and therefore it is hard to tell whether a defective product is caused by errors of a detection device or by errors of production, and therefore improvements are still needed.
The main objective of the present invention is to provide a screw detection device to resolve drawbacks that a detection device nowadays needs to change rotary disks and refocus detection cameras manually, hence being inconvenient, increasing a detection error rate and a product defect rate, and causes of a defective product are hard to tell.
The screw detection device comprises a device base, a carrying mechanism, a top visual-detection mechanism and a lateral visual-detection mechanism. The device base has an installing plate and a controlling module mounted inside the device base. The device base comprises a classifying assembly mounted on the installing plate. The controlling module is electrically connected to the classifying assembly. The carrying mechanism is mounted on the installing plate and comprises a carrying rail, a space-adjusting assembly and a conveyance assembly. The carrying rail has two guide-rail assemblies extending along a linear direction and arranged parallelly. The space-adjusting assembly is connected to the two guide-rail assemblies and drives the two guide-rail assemblies toward or away from each other. The conveyance assembly cooperates with the carrying rail to move a screw on the two guide-rail assemblies along the linear direction toward the classifying assembly. The controlling module is electrically connected to and controls the space-adjusting assembly and the conveyance assembly. The top visual-detection mechanism is mounted on the installing plate and comprises a top visual-detection camera and a top focal-length-controlling assembly. The top visual-detection camera is disposed over the carrying rail and faces toward the carrying rail. The top focal-length-controlling assembly is connected to the top visual-detection camera, is electrically connected to and controlled by the controlling module, and can adjust a focal length of the top visual-detection camera. The lateral visual-detection mechanism is mounted on the installing plate and comprises a lateral visual-detection camera and a lateral focal-length-controlling assembly. The lateral visual-detection camera is disposed at a side of the carrying rail and faces toward the carrying rail. The lateral focal-length-controlling assembly is connected to the lateral visual-detection camera, is electrically connected to and controlled by the controlling module, and can adjust a focal length of the lateral visual-detection camera. The controlling module is electrically connected to the top visual-detection camera and the lateral visual-detection camera and controls the top visual-detection camera and the lateral visual-detection camera to photograph the screw, so that the controlling module determines whether the screw is defective and discards a defective screw through the classifying assembly.
The screw detection device is configured to detect screws. A screw-feeding device feeds several screws onto the two guide-rail assemblies of the carrying rail of the carrying mechanism and lets the screws extend to be between the two guide-rail assemblies. The conveyance assembly drives the screws moving forward along the linear direction. When passing through the top visual-detection camera of the top visual-detection mechanism and passing through the lateral visual-detection camera of the lateral visual-detection mechanism, each one of the screws is photographed. The controlling module of the screw detection device detects and determines whether the screw is defective, and discards a defective screw through the classifying assembly.
In addition, the screw detection device has the following advantages:
1. Reducing errors: When using the screw detection device to detect screws of different sizes, by presetting the adjusting parameters of the controlling module, the controlling module controls the space-adjusting assembly to move the two guide-rail assemblies toward and away from each other, thereby adjusting a distance between the two guide-rail assemblies to correspond to the screws of different sizes. The controlling module controls the top focal-length-controlling assembly to adjust the focal length of the top visual-detection camera, and controls the lateral focal-length-controlling assembly to adjust the focal length of the lateral visual-detection camera, thereby letting the screw detection device automatically adjust to meet detection needs of screws of different sizes. Therefore, manual adjustments are unnecessary, increasing convenience and reducing time spent on adjustments, and effectively reducing errors caused by adjusting device, hence increasing detection accuracy.
2. Increasing detection amount: A conventional screw detection device uses a rotary disk to carry to-be-detected screws, so the screw-feeding device feeds screws onto the rotating rotary disk. However, due to an effect of centrifugal force, a rotational speed of the rotary disk is limited. On the other hand, because the two guide-rail assemblies of the carrying rail of the carrying mechanism are linear, the conveyance assembly of the carrying mechanism moves screws on the two guide-rail assemblies along the linear direction to process detection. So, compared to the conventional screw detection device, the screw detection device in accordance with the present invention does not need to consider the effect of centrifugal device, and hence a feeding speed of the screw-feeding device can be increased, thereby increasing the detection amount.
3. Lowering costs: As mentioned above, the distance between the two guide-rail assemblies can be adjusted through the space-adjusting assembly. Therefore, the carrying rail corresponds to screws of different sizes and rotary disks of different sizes are unnecessary to be prepared, and hence lowering the costs.
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When the screw 50 is moved to the detecting area and passes under the top visual-detection camera 31, the top visual-detection camera 31 photographs the screw 50 to take a photograph of the screw head of the screw 50. When the screw 50 is moved and passes in front of the lateral visual-detection camera 41, the lateral visual-detection camera 41 photographs the screw 50 to take a photograph of the thread segment of the screw 50. Then the top visual-detection camera 31 and the lateral visual-detection camera 41 respectively transmit photographic data to the controlling module 12 for the controlling module 12 to determine whether the screw 50 is defective.
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If the controlling module 12 determines that the screw 50 is a normal screw without any defect, then when the normal screw is moved to the discharging end 213 of the carrying rail 21, the controlling module 12 controls the air-spraying classifying element 133 to spray air, pushing the normal screw to leave the carrying rail 21 and fall into the second discharging slideway 132. If the controlling module 12 determines that the screw 50 is a defective screw, then when the defective screw is moved to the discharging end 213 of the carrying rail 21, the defective screw leaves the carrying rail 21, and falls into the first discharging slideway 131, thereby classifying the screws 50 into the normal screw and the defective screw.
A conventional screw detection device uses a rotary disk to carry to-be-detected screws, so the screw-feeding device feeds the to-be-detected screws onto the rotating rotary disk. However, due to an effect of centrifugal force, a rotational speed of the rotary disk is limited. On the other hand, because the two guide-rail assemblies 211 of the carrying rail 21 of the carrying mechanism 20 are linear, the conveyance assembly 23 of the carrying mechanism 20 moves screws 50 on the two guide-rail assemblies 211 along the linear direction to process detection. So, compared to the conventional screw detection device, the screw detection device in accordance with the present invention does not need to consider the effect of centrifugal device, and hence a feeding speed of the screw-feeding device can be increased, thereby increasing a detection amount.
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Additionally, the top back-light plate 35 is electrically connected to and controlled by the controlling module 12. The top fill-light element 342 and the top back-light plate 35 emit light to make the photograph of the screw 50 taken by the top visual-detection camera 31 clearer. The lateral back-light plate 45 is electrically connected to and controlled by the controlling module 12, and emits light to make the photograph of the screw 50 taken by the lateral visual-detection camera 41 clearer, thereby increasing detection accuracy.
The controlling module 12 controls the top focal-length-controlling assembly 32 to adjust the focal length of the top visual-detection camera 31, controls the top fill-light driving component 341 to move the top fill-light element 342 up and down, and controls the lateral focal-length-controlling assembly 42 to adjust the focal length of the lateral visual-detection camera 41. The controlling module 12 controls the pedestal-driving element 442 of the lateral camera-driving assembly 44 to move the lateral camera pedestal 441 up and down along the lateral base seat 43, thereby adjusting a height position of the lateral visual-detection camera 41.
When using the screw detection device to detect the screws 50 of different sizes, by presetting the adjusting parameters of the controlling module 12, the controlling module 12 automatically controls the carrying rail 21, the top visual-detection camera 31 and the lateral visual-detection camera 41 to meet detection needs of the screws 50 of different sizes. Therefore, manual adjustments are unnecessary, increasing convenience and reducing time spent on operations, and effectively reducing errors caused by adjusting device, hence increasing detection accuracy, and it is easier for manufacturers to determine whether a defective product is caused by errors of production.
Furthermore, the distance between the two guide-rail assemblies 211 can be adjusted through the space-adjusting assembly 22, so the carrying rail 21 can correspond to the screws 50 of different sizes, and rotary disks of different sizes are unnecessary, thereby lowering the costs. Besides, if one said screw detection device detects screws of a particular size, the controlling module 12 inside the device base 10 of said screw detection device records the adjusting parameters of the screws of the particular size. Then, the adjusting parameters can be provided to the controlling module 12 of another screw detection device for use. Therefore, different screw detection devices can share the adjusting parameters, so repeating detecting and recording is unnecessary, increasing convenience of use.
To sum up, the screw detection device is configured to detect the screws 50 of different sizes. By presetting the adjusting parameters of the controlling module 12, the controlling module 12 automatically controls the carrying rail 21, the top visual-detection camera 31 and the lateral visual-detection camera 41 to meet the detection needs of screws 50 of different sizes, and therefore manual adjustments are unnecessary. And by the linear carrying rail 21, the detection amount is increased.
Even though numerous characteristics and advantages of the present invention have been set forth in the foregoing description, together with details of the structure and features of the invention, the disclosure is illustrative only. Changes may be made in the details, especially in matters of shape, size, and arrangement of parts within the principles of the invention to the full extent indicated by the broad general meaning of the terms in which the appended claims are expressed.
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11196967 | Lee | Dec 2021 | B1 |
20050257599 | Kuo | Nov 2005 | A1 |
Number | Date | Country |
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207929596 | Oct 2018 | CN |
112330584 | Feb 2021 | CN |
213179866 | May 2021 | CN |
S62239008 | Oct 1987 | JP |
H0971310 | Mar 1997 | JP |
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Entry |
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CN213179866 with English translation; Inv: Wu; Pub. Date: May 2021 (Year: 2021). |
Number | Date | Country | |
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20250091091 A1 | Mar 2025 | US |