1 Introduction
At present, the total global vision market is about 6-7 billion US dollars, which is growing at an annual growth rate of 8.8%. In China, this number currently seems a bit huge, but with the development of processing and manufacturing, China's demand for machine vision will continue to rise. Machine vision is to use machines to replace human eyes for measurement and judgment. The machine vision system refers to the machine vision products (that is, the image pickup device, divided into two types of CMOS and CCD) to convert the captured object into an image signal, and send it to a dedicated image processing system, according to the pixel distribution and brightness, color and other information, change Into a digital signal; the image system performs various operations on these signals to extract the characteristics of the target, and then controls the operation of the equipment on the spot according to the result of the discrimination. Here, automated machine vision systems provide solutions to problems in the medical device industry.
2 Defects of disposable injection needles
The disposable injection needle can be divided into two parts: the needle seat and the needle. The influence of the defect of the needle seat on the quality of the product can be neglected. There are two kinds of defects in the needle: First, the needle tip may produce burrs during the manufacturing process of the needle; Secondly, the needle may be inserted backwards during the automatic assembly process (the needle tip is inserted into the needle holder). Several defects affecting the needle are: needle burr and reverse insertion. Among them, the reverse insertion will not only have a direct impact on the quality of the product, but also seriously endanger human life. Figure 1:
3 Use machine vision to realize the automatic detection of the appearance defects of PET beverage bottles
With the increasing demand for disposable injection needles in the market and the requirements of customers for product quality, more and more medical device manufacturers use automated injection needle inspection systems to comprehensively inspect the appearance defects of disposable injection needles. This method replaces the traditional manual methods to improve production efficiency and product quality, and solves the false detection and missed detection caused by uncertain factors such as low efficiency, slow speed, and subjective constraints of the inspection personnel, and achieves better 100% of products are tested online.
3.1 Machine vision realizes the automatic detection scheme of appearance defects of disposable injection needles
This article uses the injection needle detection system developed by Hangzhou Huafeng Automation System Co., Ltd. for the detection of the appearance defects of disposable injection needles. The system takes Siemens image processor [3] as the core and combines with Siemens automation equipment to form a system with both simple digital signal interface and complex industrial network interface, allowing users to choose a system suitable for their working conditions. Convenient and save investment.
The basic detection process flow is shown in Figure 2, and the simple system framework is shown in Figure 3:
Working principle: First, the injection needle is sensed through the optical fiber sensor, and then the image processor is triggered to take a picture. After the image is collected, the image is processed by image analysis such as binarization, target positioning, measurement, and feature matching. The processing result is transferred to the PLC Carry out logic control and drive the rejecting device according to the current speed of the conveyor belt to accurately reject unqualified products. Considering the needs of current automated production, the current rejection method adopts the entire row of rejection. If a higher level of automation is required, a suction cup can be added to each needle seat.
System design features: This system uses Siemens embedded image processor, its integrated module, it is easy to design the system configuration and appearance according to the customer site environment and customer requirements. The appearance of the system uses all stainless steel materials, which meets the specifications of the medical device industry; the independent mechanical structure is easy to install at any position of the assembly line; through the connection of Siemens touch screen and PLC, it is easy for the operator to switch the procedures of different products online, and You can view the real-time detection data from the touch screen; according to the diversification of single-line products, the system uses a mechanical mechanism that can be adjusted by XYZ, allowing users to operate more flexibly.
4 Conclusion
The system has been successfully applied to the production line of a well-known domestic medical device company, the effect is very good, the rate of missed rejection is 0, the rate of false rejection is 99.99%. Not only meets the existing needs of users, but also reserves a lot for users Functions and upgrade space, these functions will play more roles in future inspection tasks, solve more problems for users, and save a lot of upgrade costs. Among the many factors that rely on the popularization and development of machine vision, there are technical and commercial levels, but the demand of the manufacturing industry is decisive. The development of the manufacturing industry has brought about an increase in the demand for machine vision; it also determines that machine vision will gradually develop in the direction of openness by collecting, analyzing, transmitting data, and judging actions in the past. Vision will be further integrated with automation. Demand determines products, and only products that meet demand have room for survival. This is an invariable law. The same is true of machine vision.
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