CN107229291B - Synchronization method of online vision positioning system - Google Patents
Synchronization method of online vision positioning system Download PDFInfo
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- CN107229291B CN107229291B CN201710445927.XA CN201710445927A CN107229291B CN 107229291 B CN107229291 B CN 107229291B CN 201710445927 A CN201710445927 A CN 201710445927A CN 107229291 B CN107229291 B CN 107229291B
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Abstract
The invention discloses a synchronization method of an online visual positioning system, which comprises the steps that a camera trigger signal output from the visual positioning system triggers a camera to take a picture and is simultaneously sent to a servo control system to trigger the servo control system to be interrupted, the servo control system is communicated with a servo motor through a real-time bus to record the real-time position of the servo motor corresponding to the trigger moment of the camera, the absolute position of the servo motor is recorded by the servo control system at the moment that any camera takes a picture, and the real synchronization between a servo controller and the visual positioning system is realized. By the synchronization method, the rotation angle of the main shaft of the labeling machine required by 360-degree imaging is shortened, so that a positioning system needs a smaller installation space, the control errors of mechanical installation of a camera and a servo system are eliminated, the pre-positioning precision is improved, the whole system is more miniaturized, and the market application range of the positioning system is wider.
Description
Technical Field
The invention relates to an automatic production line, in particular to a synchronization method of an online vision positioning system.
Background
Manufacturers such as drinks and beverages often release containers with exquisite and unique designs when producing the products, and the products are matched with market promotion and brand display to meet the personalized requirements of terminal customers. For example, in the market today, there are more and more containers for beer, wine, liquor and beverages that have been provided with reliefs, branding, windows and other features. To enhance the aesthetic appearance of the product, it is desirable to apply the label in a specific location on the container, such as directly under the embossment or within a designated window. To meet this demand, vision-based positioning and aligning systems have emerged in labeling machines. Compared with the traditional mechanical positioning system, the system has the characteristics of high efficiency and good universality. Two positionings, pre-positioning and fine positioning, are usually required to improve the actual accuracy of the positioning alignment. The space required by the whole positioning system is relatively large. It is difficult to integrate the positioning system into existing small labelers. There is a need for a method that reduces the space required for the positioning system so that the positioning system can be more widely used in automated filling lines or other similar industries.
Disclosure of Invention
The invention aims to: the method for synchronizing the on-line visual positioning system is provided, and the rotating distance of a servo motor required by the positioning system is reduced by establishing a stronger synchronization process of the visual positioning system and a servo control system, so that the space required by a single positioning and aligning module is reduced.
The technical scheme of the invention is as follows:
a synchronization method of an online visual positioning system comprises the visual positioning system, a servo control system and a servo motor, wherein the visual positioning system shoots and images a positioning object on a production line, searches a characteristic position of the positioning object according to visual characteristics and sends a result to a servo controller, the servo controller controls the servo motor to drive the positioning object to rotate together by a certain angle according to the characteristic position result, and positioning and aligning of the positioning object are completed, and the synchronization method comprises the following steps:
the camera trigger signal output from the visual positioning system triggers the camera to take a picture on one hand and is simultaneously sent to the servo control system to trigger the servo control system to be interrupted, the servo control system is communicated with the servo motor through a real-time bus to record the real-time position of the servo motor corresponding to the camera trigger moment, and the absolute position of the servo motor is ensured to be recorded by the servo control system at the moment when any one camera takes a picture.
Preferably, the information transmitted by the visual positioning system and the servo motor to the servo control system further includes a camera trigger serial number and relative angle information.
Preferably, the method for shooting and imaging the positioning object on the production line by the vision positioning system comprises: the servo control system controls the servo motor to complete 360-degree rotation, the visual positioning system controls the cameras to shoot a plurality of pictures at the stage, and 360-degree panoramic shooting of a positioned object is achieved.
Preferably, after the vision positioning system captures the images, the vision positioning system performs image processing and feature search on each obtained image, determines feature reliability and feature position, finds out the image with the highest found feature reliability in all the images, and calculates the final angle of rotation of the servo motor according to the image feature position and the absolute positions of the servo motor and the positioning object tray during synchronous picture capturing.
Preferably, the visual positioning system sends the characteristic position result to the servo control system through a real-time industrial control bus according to a preset protocol in a preset time window.
Preferably, the servo control system drives the positioning object to rotate by a specified angle according to final angle information that the servo motor needs to rotate, so that the searched feature faces the right front.
Preferably, for the occasion with higher precision requirement, after the first positioning is completed, the online vision positioning system repeats the step of the first positioning to perform the second precision positioning.
Preferably, the shooting imaging stage of the second accurate positioning coincides with the tail time of the positioning object completing the positioning and correcting stage driven by the servo motor of the first positioning.
The invention has the advantages that:
1. the synchronization method of the online visual positioning system provided by the invention has the advantages that the hardware trigger signal of the camera of the visual positioning system is directly introduced into the servo control system through the circuit, the real-time position of the servo motor when being photographed is stored by utilizing the interrupt signal of the hardware, the position of the servo motor is known at any time when the visual positioning system photographs, and the real synchronization between the servo controller and the visual positioning system is realized.
2. By the synchronization method, the rotation angle of the main shaft of the labeling machine required by 360-degree imaging is shortened, so that a positioning system needs smaller installation space.
3. The closed-loop system constructed by the synchronization method eliminates the control errors of the mechanical installation of the camera and the servo system, improves the pre-positioning precision, can omit a fine positioning module for a plurality of applications, enables the whole system to be more miniaturized, can also be applied to a small-sized labeling machine, and enables the market application range of the positioning system to be wider.
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The invention is further described with reference to the following figures and examples:
FIG. 1 is a diagram of a non-synchronized visual positioning system applied to a rotary labeling machine;
FIG. 2 is a control curve of a servo motor angle and a labeler spindle angle without synchronization;
FIG. 3 is a schematic diagram of the hardware connection between the camera and the servo controller of the positioning system of the present invention;
FIG. 4 is a control curve of the servo motor angle and the labeler spindle angle with synchronization according to the present invention;
FIG. 5 is a control curve of the servo motor angle and the labeling machine spindle angle with synchronization and omitting the fine positioning and centering process of the present invention.
Detailed Description
The online visual positioning system is applied to the labeling machine, and can realize the positioning and straightening functions through the matching with a servo motor of the labeling machine. The system is realized in three steps, wherein the first step is the shooting of 360-degree images, the second step is the image signal processing and searching of characteristic positions, and the third step is the control of the rotation of a servo motor through the searched result to drive the container to rotate to a desired position. And for the occasion with higher precision requirement, a fine positioning module can be added to shoot the image again and control the servo system to position and align.
As shown in fig. 1, a schematic view of a visual positioning system applied to a rotary labeler. First, the containers enter the labeling machine through the left-hand feed star. After entering the labeling machine, the tray is controlled to be compressed and fixed through the upper end fixing nozzle and the lower end servo motor. The tray rotates from point a to point B for a total of six stages, as shown in fig. 1 and 2:
1. the servo motor accelerates to a certain speed v;
2. the servo motor keeps the speed v to rotate at a constant speed; a plurality of cameras shoot a plurality of pictures at the stage, and 360-degree panoramic shooting is realized on the container;
3. the servo motor decelerates, and finally the speed is reduced to 0;
4. stopping the servo motor after rotating a specified angle according to the result of the positioning system;
5. keeping the state of no rotation, and shooting the image again by the fine positioning module;
6. and the servo motor stops after rotating a specified angle according to the result of the positioning system.
After the six stages, the tray rotates to a point A to a point B along with the main shaft of the labeling machine. In the whole process, the positioning system transmits the calculated result to the servo control system in a bus mode twice. In addition, there is no direct synchronization mechanism between the positioning system and the servo control system. The position of the servo motor must be known at the point in time (segment 2, segment 5) when the camera takes an image. Segment 2 must be a constant velocity segment and segment 5 does not rotate, otherwise the angle actually required to rotate cannot be obtained according to the result of image processing. The main shaft rotation angle alpha of the labeling machine in the whole process needs a large space and is difficult to integrate into a small labeling machine. And the final positioning precision can be directly influenced by the errors of the installation position of the camera, the calibration errors and the like.
As shown in fig. 3, the synchronization method of the present invention is to directly connect the hardware trigger of the camera to the servo control system through a circuit, and the hardware trigger camera signal output from the visual positioning system directly enters the servo control system. Since the servo control system communicates with the servo motor through a real-time bus by a self-contained protocol, and the information transmitted to the servo control system by the visual positioning system and the servo motor also comprises a camera trigger serial number and relative angle information, the position of the servo motor connected with the servo controller at any time is known. The camera trigger signal triggers the camera to take a picture on one hand, and triggers the servo control system to be interrupted at the same time, and records the real-time position of the servo motor of the corresponding container at the moment. By means of the synchronization mechanism, it is ensured that the absolute position of the servo motor is recorded by the servo control system when any one camera takes a picture. Compared with an asynchronous positioning system, the mechanical installation error of a camera and the rotation error of a servo motor in a photographing section cannot influence the final positioning error. And because the position of the motor at any moment is known, the system can take pictures at any moment, and does not need to be in a constant speed section or when the motor does not rotate.
By adopting the synchronization method, the sections 1, 2 and 3 can be synthesized into one section, as long as the servo motor completes 360-degree rotation in the section, the visual positioning system controls a plurality of pictures to be shot at the stage, and 360-degree panoramic shooting is realized on a positioned object. And the 5 th secondary shooting section can be directly placed at the tail of the 4 th section. The relative positions of the servo motor and the labelling machine spindle after using this synchronization method are shown in fig. 4. The whole positioning section is reduced from 6 sections to 3 sections, so that the mechanical size of the module is saved. In addition, because the control error in the servo control section is not influenced by mechanical installation errors, the space is saved, and the precision of the first positioning and aligning module is improved.
In many applications, a subsequent fine positioning module can be omitted, and the steps of taking a picture of the container again and correcting the pre-positioning and aligning are not needed. The whole process can be further reduced to 2 segments as shown in fig. 5. The volume of the whole system and the required installation space are greatly reduced.
A comparison of a positioning system without synchronization and a positioning system with synchronization is shown in table 1.
Table 1: comparison with and without synchronization
At present, the system of the invention is successfully applied to a modular beer bottle high-speed labeling machine to complete the positioning test of the glass bottle. The system can process 72000 bottles per hour at the highest, the positioning precision can reach +/-1.5 mm, and the alignment accuracy can reach 99.9%. The system can also be applied to (but is not limited to) labeling production lines of PET bottles, wine and other high-concentration alcoholic beverages as well, and replaces the mechanical positioning or manual labeling process.
The above embodiments are merely illustrative of the technical ideas and features of the present invention, and the purpose of the embodiments is to enable those skilled in the art to understand the contents of the present invention and implement the present invention, and not to limit the protection scope of the present invention. All modifications made according to the spirit of the main technical scheme of the invention are covered in the protection scope of the invention.
Claims (5)
1. The utility model provides a synchronous method of online visual positioning system, online visual positioning system includes visual positioning system, servo control system and servo motor, visual positioning system shoots the formation of image to the location object on the production line, seeks the characteristic position of location object according to the visual characteristic to send the result to servo controller, servo controller controls servo motor according to the characteristic position result and drives the location object and rotate certain angle together, accomplishes the location of location object and puts upright or upright, its characterized in that, synchronous method is:
the camera trigger signal output from the visual positioning system triggers the camera to take a picture on one hand and is simultaneously sent to the servo control system to trigger the servo control system to be interrupted, the servo control system is communicated with the servo motor through a real-time bus, and the information transmitted to the servo control system by the visual positioning system and the servo motor also comprises a camera trigger serial number and relative angle information; the servo control system records the real-time position of the servo motor corresponding to the triggering moment of the camera, and ensures that the absolute position of the servo motor is recorded by the servo control system at the moment when any camera shoots a picture;
the method for shooting and imaging the positioning object on the production line by the visual positioning system comprises the following steps: the servo control system controls the servo motor to complete 360-degree rotation, and the visual positioning system controls the cameras to shoot a plurality of pictures at the stage that the servo motor completes 360-degree rotation, so that 360-degree panoramic shooting is realized on a positioned object;
after the vision positioning system shoots images, image processing and feature searching are carried out on each obtained image, feature reliability and feature positions are determined, the image with the highest feature reliability in all the images is found out, and the final angle of the servo motor needing to rotate is calculated according to the image feature positions and the absolute positions of the servo motor and the positioning object tray when the images are shot synchronously.
2. The method of claim 1, wherein the vision positioning system sends the characteristic position result to the servo control system via a real-time industrial control bus according to a preset protocol in a preset time window.
3. The method of claim 1, wherein the servo control system drives the positioning object to rotate by a predetermined angle according to the final angle information of the servo motor to be rotated, so that the searched feature faces forward.
4. The method of claim 3, wherein for an application requiring high accuracy, the on-line vision positioning system repeats the positioning step once to perform a second accurate positioning after the first positioning.
5. The synchronization method of on-line visual positioning system as claimed in claim 4, wherein the second stage of the precise positioning for shooting and imaging is time-overlapped with the end of the first stage of positioning where the servo motor drives the positioning object to complete the positioning and aligning.
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| CN109343419A (en) * | 2018-11-14 | 2019-02-15 | 无锡信捷电气股份有限公司 | Camera and servo synchronization control system and method |
| CN109302591A (en) * | 2018-11-27 | 2019-02-01 | 嘉兴学院 | A kind of servo control system of view-based access control model monitoring |
| CN113104338B (en) * | 2021-04-01 | 2023-01-03 | 江苏新美星包装机械股份有限公司 | Rotary labeling machine and positioning labeling method |
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