CN111229548A - Automatic tracking dispensing system based on assembly line - Google Patents
Automatic tracking dispensing system based on assembly line Download PDFInfo
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- CN111229548A CN111229548A CN202010185388.2A CN202010185388A CN111229548A CN 111229548 A CN111229548 A CN 111229548A CN 202010185388 A CN202010185388 A CN 202010185388A CN 111229548 A CN111229548 A CN 111229548A
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B05—SPRAYING OR ATOMISING IN GENERAL; APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
- B05C—APPARATUS FOR APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
- B05C5/00—Apparatus in which liquid or other fluent material is projected, poured or allowed to flow on to the surface of the work
- B05C5/02—Apparatus in which liquid or other fluent material is projected, poured or allowed to flow on to the surface of the work the liquid or other fluent material being discharged through an outlet orifice by pressure, e.g. from an outlet device in contact or almost in contact, with the work
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B05—SPRAYING OR ATOMISING IN GENERAL; APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
- B05C—APPARATUS FOR APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
- B05C11/00—Component parts, details or accessories not specifically provided for in groups B05C1/00 - B05C9/00
- B05C11/10—Storage, supply or control of liquid or other fluent material; Recovery of excess liquid or other fluent material
- B05C11/1002—Means for controlling supply, i.e. flow or pressure, of liquid or other fluent material to the applying apparatus, e.g. valves
- B05C11/1015—Means for controlling supply, i.e. flow or pressure, of liquid or other fluent material to the applying apparatus, e.g. valves responsive to a conditions of ambient medium or target, e.g. humidity, temperature ; responsive to position or movement of the coating head relative to the target
- B05C11/1021—Means for controlling supply, i.e. flow or pressure, of liquid or other fluent material to the applying apparatus, e.g. valves responsive to a conditions of ambient medium or target, e.g. humidity, temperature ; responsive to position or movement of the coating head relative to the target responsive to presence or shape of target
Abstract
The invention discloses an automatic tracking dispensing system based on a production line, which comprises: the device comprises an incoming material detection module, an image acquisition module, an image processing module, a track editing module, a motion control module, a speed acquisition module, a fluid control module and a rubber valve cleaning module. The glue coating operation is realized in a non-stop mode through the tracking glue dispensing flow under the control of the system, complex feeding and discharging actions are omitted, the mechanism of the whole equipment is simple and reliable, more importantly, redundant actions are omitted, only the core glue dispensing action is reserved, operation events are saved, the capacity is greatly increased, the core idea of lean production is also conformed, and the production efficiency is greatly improved. The system automatically tracks the position of a product, corrects the dispensing needle head in real time to follow the product, and can perform relative motion on the basis of the product according to a specific track taught in advance on the basis of synchronous following motion so as to achieve the function of uniformly coating glue on the product.
Description
Technical Field
The invention relates to the technical fields of intelligent manufacturing, equipment automation, fluid control and the like, in particular to an automatic tracking dispensing system based on a production line.
Background
In a conventional product dispensing process, if most products are to be dispensed, the following processes are basically required: carrying and feeding, carrying/mechanical positioning, visual positioning, gluing operation, carrying and discharging and the like; in the process, value is really generated, only the process of 'gluing operation' is adopted, and the rest processes are auxiliary processes and are unnecessary.
Currently, there are three general methods of dispensing in the industry, but each of them has its own disadvantages. For example:
1. and (3) manual dispensing: the labor cost is increased, the precision is poor, the proficiency of operators is completely depended on, and the yield is low;
2. desktop formula point gum machine: the requirement on the precision of the jig is high, and personnel are unstable;
3. a full automatic machine: high cost, requirements on the front and rear processes of the production line and poor flexibility.
Meanwhile, in the traditional dispensing operation, the jig/carrier is indispensable, so that if another product needs to be replaced for production, the production can be resumed only by stopping the machine, manually replacing the carrier, debugging the track and the like, the step is time-consuming and labor-consuming, and the production scene of small-batch, multi-batch and multi-type products cannot be met.
Disclosure of Invention
The technical scheme of the invention is as follows: the automatic tracking dispensing system based on the production line realizes non-stop control, automatically tracks the position of a product, corrects the dispensing needle head in real time to follow the product, and can carry out relative motion on the basis of the product and a specific track taught in advance on the basis of synchronous following motion so as to achieve the function of uniformly coating glue on the product. Moreover, the automatic tracking dispensing system solves the technical problems of carrier requirement, poor flexibility, necessity of static dispensing, no mixed line production and the like in the traditional dispensing operation.
The system comprises the following modules:
incoming material detection module: for detecting the actual arrival of a product at a certain location on the production line by means of one or more specific sensors.
Specifically, the material detection module includes:
the sensor hardware detects, and a sensor (including but not limited to an opposite light source/a reflective optical fiber/a metal proximity sensor/mechanical micro-motion induction and the like) is adopted to detect that the product reaches a photographing position and trigger photographing.
And (3) detecting camera software, continuously photographing camera images in real time, carrying out global image preprocessing analysis (a gray histogram tool and the like), comparing with an empty material state, and dynamically monitoring whether the product enters the visual field or not.
An image acquisition module: the system is used for monitoring and capturing image information of a product flowing on a production line in real time by one or more wide-angle cameras (large visual fields) to globally cover the flow area of the production line, wherein the image information comprises product type and product position information.
Specifically, the image acquisition module includes: a 2D camera control unit and a 3D camera control unit.
The 2D camera control unit includes:
the 2D camera acquires a large visual field, and the 2D camera is matched with a wide-angle lens/a telecentric lens, various light sources and the like to acquire a large visual field so as to capture a large-size product conveniently;
the 2D camera view cutting and 2D camera single-camera picture area cutting scheme can cut a single camera view into a plurality of independent views for independent monitoring;
and (3) combining the views of the 2D cameras, combining and splicing a plurality of view areas of the 2D cameras into one view through a software algorithm, obtaining a huge view, and monitoring and capturing in a larger range.
The 3D camera control unit includes:
3D image acquisition, by using fixed 3D line laser, directly scanning the product 3D that moves on the assembly line
And (4) generating a product contour map and specific position information by synthesizing the contour.
An image processing module: the type of the product and the coordinates and rotation angle of the center point of the product are determined using, but not limited to, a single/multiple template matching algorithm, while the image is combined with morphological analysis, fitting of geometric figures (e.g., points, lines, arcs).
Specifically, the image processing module includes:
the template establishing module unit can establish one or more templates aiming at product characteristics, and can perform preprocessing (operations such as effective area selection, interference information smearing, sharpening, contour deletion and the like) aiming at the templates so as to ensure that the obtained templates have excellent quality.
A template matching algorithm unit: the image processing is carried out by adopting a specific algorithm library, single template matching can be carried out, multi-template matching can be carried out, a plurality of same products can be matched in the same image, a plurality of different products can be matched, matching can be appointed to be carried out within a certain angle range, matching is carried out under the shielded part of the template, and the like.
And customizing an image processing algorithm, performing morphological analysis on the product on the basis of template matching, and fitting a specific geometric shape (such as a point, a line and a circular arc) according to the product characteristics so as to realize accurate positioning of the product.
A coordinate matching unit for associating the image coordinate system with the equipment motion coordinate system according to a five-point calibration method; and combining the incoming material model with the image coordinate system to determine the center point coordinate and the rotation angle of the current incoming material in the equipment motion coordinate system.
Before the template is established, the camera needs to be calibrated, distortion calibration is adopted in the scheme, the camera distortion calibration is realized through the calibration method, and pillow-shaped distortion and barrel-shaped distortion brought by a camera lens are corrected.
A track editing module: the gluing device is used for pre-editing and teaching a gluing track of a product, simulating and teaching a processing process of an incoming material model through a preset dispensing track or a manual operation track, and correcting the dispensing track according to coordinates and angles of incoming materials.
Specifically, the track editing module includes:
and the manual teaching unit moves the dispensing needle head through a manual operation program interface/handheld teaching box, and aligns the corresponding point positions through naked eyes to perform track editing.
And the image teaching unit is used for teaching a track by shooting a global picture of a product and selecting a corresponding point position in the image or sliding the mouse by the mouse.
And a DXF importing unit for forming a gluing track by importing a DXF file edited in advance (CAD edition).
And the track automatic identification unit adopts automatic image identification to form tracks (such as drawing shapes on white paper and automatic generation by photographing) through a product real object diagram or a simulation diagram.
The track splicing unit needs to synthesize multiple sections of tracks to form an integral track for products with larger sizes.
Before the control equipment moves, a motion coordinate system of the glue valve needle head needs to be calibrated, and three calibration points are selected through a three-point calibration method to teach a tool coordinate system corresponding to the glue valve needle head.
A motion control module: the motion control system is built, connected with each driving motor, combined with software and hardware, and matched with various motion models, the motion mechanism is controlled to move in a program expected mode;
specifically, the motion control module includes:
the motion following unit controls the motion mechanism to move in the same direction as the workpiece according to the motion speed of the workpiece and simultaneously carry out dispensing operation according to a preset dispensing track;
the interpolation motion unit simultaneously controls 2 and more than 2 shafts in the motion mechanism to carry out cooperative motion so as to realize motions such as linear interpolation, circular interpolation and the like;
a point-to-point (PTP) single-point motion unit enables each shaft of the motion mechanism to move independently respectively so as to meet the requirement of reaching a single point at the highest speed;
the board card control unit can carry various types of motion control cards of different brands to realize motion control; or the control mode without the board card realizes the control of the movement without the board card through the built-in upper computer system (Codesys) and the communication protocol (Ethercat).
A motion mechanism module: building a motion mechanism in various modes according to different motion models, carrying one or more dispensing valves on the motion mechanism, and matching the dispensing valves with a motion control module to enable the motion mechanism to drive the dispensing valves to complete specific motion;
specifically, the movement mechanism module includes:
the gantry type mechanism adopts a gantry type mechanism frame, and double Y-axes can be single motor power or double motor power.
The cantilever type mechanism adopts a cantilever type mechanism frame and single Y-axis single motor power.
The SCARA mechanical arm adopts a three/four-axis SCARA type mechanical arm mode to realize a movement mechanism.
The six-axis manipulator adopts a five/six-axis spatial manipulator mode to realize a movement mechanism.
The multi-module mechanism is combined with a gantry type or a frame type to form a plurality of sets of motion mechanisms in the same equipment, and the motion mechanisms operate independently.
A speed acquisition module: and measuring the distance from the shooting position to the glue dispensing operation position of the workpiece through a rotary encoder, and calculating the movement speed of the workpiece.
Specifically, the speed acquisition module includes:
the contact type speed acquisition unit is used for monitoring speed change by combining a rotary encoder and a roller, wherein the roller is installed by adopting a spring mechanism to be tightly attached to a motion assembly line, and encoder signals are fed back;
the non-contact speed acquisition unit monitors speed change through a non-contact sensor (such as laser/photoelectric sensing/metal sensing) and also through continuous image acquisition calculation of a camera.
A fluid control module: through the application of different types of dispensing valves and glue supply systems, the fluid glue is finely controlled.
Specifically, the fluid control module includes:
the glue supply unit adopts a supercharged high-capacity glue supply system and a pressure stabilizing device to realize stable glue supply.
The liquid level detection unit monitors the residual capacity of the glue water through different sensors (such as a liquid level sensor/a flow sensor and the like) and gives an alarm at a low liquid level;
the glue valve communication linkage unit realizes the real-time matching of the speed and the glue dispensing frequency by performing handshake communication on the motion assembly for controlling the glue dispensing and the glue dispensing valve controller, so that the final glue dispensing effect is consistent and uniform in width.
Because the glue valve type is various, can carry on and adapt to the glue valve of multiple different grade type, atomizing valve, piezoelectric valve, pneumatic valve etc to can the different glue of adaptation.
Glue valve cleaning module: in order to adapt to different glue valves, different kinds of glue cleaning modules are designed to realize the cleaning process of the needle head of the glue valve, so that the redundant glue residues of the needle head of the glue valve can not influence the glue dispensing of the next product;
specifically, the glue valve cleaning module includes:
and the coil material wiping unit adopts a dust-free cloth coil to perform wiping action.
The brush cleaning unit adopts a rotary brush and is matched with corresponding cleaning liquid to wipe the rubber valve.
And the air knife cleaning unit adopts a specific mechanism, and positive pressure air with different pressures passes through the mechanism to form an air knife so as to clean the rubber valve.
The invention has the advantages that:
1. the glue dispensing is tracked to realize glue coating operation in a non-stop mode, complex feeding and discharging actions are omitted, the mechanism of the whole equipment is simple and reliable, more importantly, redundant actions are omitted, only the core glue dispensing action is reserved, operation events are saved, the capacity is greatly increased, the core idea of lean production is also conformed, and the production efficiency is greatly improved.
2. Need not the carrier and can produce the operation, through visual identification product type, automatic switch corresponds the product formulation, can realize not shutting down, the production of many products mixed line, this has improved the adaptability of production line undoubtedly greatly, satisfies the pain point of mill's diversified product coproduction. The production efficiency of the production line can be greatly improved, the equipment reuse rate is greatly improved, and the efficiency of production line assets is fully exerted.
3. The production line capacity can be flexibly adjusted simply by adjusting the line speed. On the premise of not changing the existing production environment of the production line of a client, the production line can be transformed at the lowest cost, so that the automatic production is realized.
Drawings
The invention is further described with reference to the following figures and examples:
FIG. 1 is a block diagram of an automatic tracking dispensing system;
FIG. 2 is a diagram of an apparatus equipped with an automatic tracking dispensing system;
fig. 3 is a flow chart of the operation of the apparatus equipped with the automatic tracking dispensing system.
Detailed Description
Example 1
Automatic tracking dispensing system based on assembly line includes: the system comprises a login module, an identity authentication module, a supplied material detection module, an image acquisition module, an image processing module, a track editing module, a motion control module, a speed acquisition module, a fluid control module and a rubber valve cleaning module.
The login module and the authentication module belong to common system operation modules and are used for login interface display, user name and password input, user authentication and the like. After proper operation, the system can be entered.
The specific functions of the incoming material detection module comprise:
the sensor hardware detects, and a sensor (including but not limited to an opposite light source/a reflective optical fiber/a metal proximity sensor/mechanical micro-motion induction and the like) is adopted to detect that the product reaches a photographing position and trigger photographing.
And (3) detecting camera software, continuously photographing camera images in real time, carrying out global image preprocessing analysis (a gray histogram tool and the like), comparing with an empty material state, and dynamically monitoring whether the product enters the visual field or not.
The image acquisition module has the specific functions of:
the 2D camera acquires a large visual field, and the 2D camera is matched with a wide-angle lens/a telecentric lens, various light sources and the like to acquire a large visual field so as to capture a large-size product conveniently;
the 2D camera view cutting and 2D camera single-camera picture area cutting scheme can cut a single camera view into a plurality of independent views for independent monitoring;
and (3) combining the views of the 2D cameras, combining and splicing a plurality of view areas of the 2D cameras into one view through a software algorithm, obtaining a huge view, and monitoring and capturing in a larger range.
And 3D image acquisition, namely directly scanning the 3D outline of the product moving on the production line by using fixed 3D line laser, and synthesizing to generate a product outline drawing and specific position information.
The image processing module has the specific functions of:
the template establishing module can establish one or more templates aiming at product characteristics, and meanwhile, preprocessing (operations such as effective area selection, interference information smearing, sharpening, contour deletion and the like) can be carried out aiming at the templates so as to guarantee that the obtained templates are excellent in quality.
The template matching algorithm adopts a specific algorithm library for image processing, can be used for single template matching, can also be used for multi-template matching, can match a plurality of same products in the same image, can also match a plurality of different products, can specify matching within a certain angle range, can perform matching under the shielded part of the template, and the like.
And customizing an image processing algorithm, performing morphological analysis on the product on the basis of template matching, and fitting a specific geometric shape (such as a point, a line and a circular arc) according to the product characteristics so as to realize accurate positioning of the product.
Coordinate matching, namely associating an image coordinate system with an equipment motion coordinate system according to a five-point calibration method; and combining the incoming material model with the image coordinate system to determine the center point coordinate and the rotation angle of the current incoming material in the equipment motion coordinate system.
Before the template is established, the camera needs to be calibrated, distortion calibration is adopted in the scheme, the camera distortion calibration is realized through the calibration method, and pillow-shaped distortion and barrel-shaped distortion brought by a camera lens are corrected.
The track editing module has the specific functions of:
and manual teaching, namely moving the dispensing needle head through a manual operation program interface/a handheld teaching box, and carrying out track editing by aligning corresponding point positions through naked eyes.
And image teaching, namely, selecting a corresponding point position in an image by a mouse or sliding the mouse to teach a track by shooting a global picture of a product.
DXF import, which is to form a glue trace by importing a previously edited DXF file (CAD edit).
And the track automatic identification unit adopts automatic image identification to form tracks (such as drawing shapes on white paper and automatic generation by photographing) through a product real object diagram or a simulation diagram.
Track splicing, for a product with a larger size, a plurality of sections of tracks need to be synthesized to form an integral track.
Before the control equipment moves, a motion coordinate system of the glue valve needle head needs to be calibrated, and three calibration points are selected through a three-point calibration method to teach a tool coordinate system corresponding to the glue valve needle head.
The motion control module has the specific functions of:
the movement following is realized, the movement is carried out according to the movement speed of the workpiece and the same direction of the workpiece by controlling the movement mechanism, and meanwhile, the dispensing operation is carried out according to the preset dispensing track;
interpolation movement, namely simultaneously controlling 2 or more than 2 shafts in a movement mechanism to perform cooperative movement so as to realize linear interpolation, circular interpolation and other movements;
point-to-point (PTP) single-point movement, each shaft of the movement mechanism moves independently respectively, so as to meet the requirement of reaching a single point at the highest speed;
the board card control mode can carry various types of motion control cards of different brands to realize motion control;
the control mode of the no board card realizes the control of the no board card motion by a built-in upper computer system (Codesys) and a communication protocol (Ethercat).
The motion mechanism module specifically includes:
the gantry type mechanism adopts a gantry type mechanism frame, and double Y-axes can be single motor power or double motor power.
The cantilever type mechanism adopts a cantilever type mechanism frame and single Y-axis single motor power.
The SCARA mechanical arm adopts a three/four-axis SCARA type mechanical arm mode to realize a movement mechanism.
The six-axis manipulator adopts a five/six-axis spatial manipulator mode to realize a movement mechanism.
The multi-module mechanism is combined with a gantry type or a frame type to form a plurality of sets of motion mechanisms in the same equipment, and the motion mechanisms operate independently.
The speed acquisition module has the specific functions of:
acquiring a contact speed, namely combining a rotary encoder and a roller, wherein the roller is tightly attached to a motion assembly line by adopting a spring mechanism, and monitoring speed change by encoder signal feedback;
the non-contact speed acquisition can monitor the speed change through a non-contact sensor (such as laser/photoelectric sensing/metal sensing and the like) and also through the calculation of continuously collecting images by a camera.
The fluid control module includes specific functions:
the glue supply control adopts a supercharged high-capacity glue supply system and a pressure stabilizing device to realize stable glue supply.
Liquid level detection and alarm, namely monitoring the residual capacity of the glue through different sensors (such as a liquid level sensor/a flow sensor and the like), and alarming at low liquid level;
the glue valves are in communication linkage, and the motion assembly for controlling glue dispensing and the glue dispensing valve controller are in handshake communication, so that the speed and the glue dispensing frequency are matched in real time, and the final glue dispensing effect is consistent and uniform in width.
Because the glue valve type is various, can carry on and adapt to the glue valve of multiple different grade type, atomizing valve, piezoelectric valve, pneumatic valve etc to can the different glue of adaptation.
The specific functions of the glue valve cleaning module comprise:
and (4) wiping the roll material by adopting a dust-free cloth to roll the roll material, and performing wiping action.
The brush is cleaned by rotating the brush and matching with corresponding cleaning liquid to wipe the rubber valve.
And (3) air knife cleaning, namely adopting a specific mechanism, and forming an air knife by passing positive pressure air with different pressures through the mechanism so as to clean the rubber valve.
Example 2:
the system is mainly implemented in a cantilever type motion structure building mode, and other motion structure building modes including but not limited to gantry type/cantilever type/joint type Scara/six-axis manipulator/spider hand/multi-module mixed structures and the like are all regarded as the scope of the patent.
The matched equipment model of the system comprises: welding frame, belt transmission line, XYZW four-axis motion platform, gluey valve, vision supervisory equipment (2D camera, 3D camera), sensing original paper etc..
Based on the structure, the operation flow steps of the equipment carrying the system comprise:
the method comprises the following steps: incoming material sensing
The sensor detects the incoming material and triggers shooting to acquire the image information of the incoming material, and real-time uninterrupted triggering of image acquisition can also be adopted.
The sensor triggering means that: and when the product reaches the photographing position, triggering to photograph. In general, sensors include, but are not limited to: a correlation light source, a reflection optical fiber, a metal proximity sensor and a mechanical micro-motion sensor.
Real-time uninterrupted touch means: and continuously photographing the camera images in real time, carrying out global image preprocessing analysis (a gray histogram tool and the like), comparing with an empty material state, and dynamically monitoring whether the incoming material enters the visual field.
Step two: image acquisition
One or more cameras are used for shooting products moving on the production line, acquiring contour images of incoming materials and recording position information. The material shape is generally fitted by a 2D picture and a 3D profile by combining a 2D camera and 3D line laser scanning.
The specific process of image acquisition comprises two substeps:
A. constructing a proper optical system, selecting a proper light source combination and installation angle according to the incoming material characteristics and the background environment, selecting a proper high-resolution camera lens (an 8mm wide-angle lens is adopted in the model to obtain a large visual field range of 400 x 400 mm), and adjusting proper camera parameters (an exposure value, a gain value and the like) to obtain a high-quality original image with uniform brightness;
B. distortion correction of the camera lens itself.
The camera calibration method provided by the invention is roughly divided into two steps:
the method comprises the following steps of firstly, obtaining corrected internal and external parameters of a camera for a calibration action; the method is realized by adopting a Sudoku calibration method based on a Halcon algorithm library, a float glass calibration plate with the thickness of 120mm by 120mm is adopted, 7 dots with the thickness of 7 x 7 are uniformly distributed on the float glass calibration plate, and the printing process precision of each dot is 1 um. The calibration process comprises the steps of moving a calibration plate in the field of view of a camera, uniformly distributing 9 positions, respectively taking phases and calculating.
And secondly, correcting the image, and performing distortion correction on the acquired original image according to the correction parameters obtained in the first step to restore a corrected real image picture.
Step three: image processing
The acquired image is matched with a plurality of preset product characteristics by a single/multi-template matching algorithm, simultaneously combining morphological analysis with images, fitting geometric figures (such as points, lines and arcs) and the like so as to determine the current incoming material type and the coordinates and the rotating angle of the central point of the incoming material.
First, a template is established and determined
The modeling and model matching are specifically divided into three substeps:
A. establishing a template as a preparation work, shooting an incoming material image through a camera, selecting one or more characteristic areas according to incoming material characteristics, and establishing the template;
B. and (3) template matching, namely after the template is established, adjusting the position and the posture of the template, carrying out matching processing on the image data of the existing product, and observing the matching effect, wherein if the matching effect is not ideal (the matching score does not reach the preset score), the template needs to be taught again, or template parameters are adjusted (the matching score is adjusted or the angle of the template is adjusted), so that the template is optimized.
C. For products without obvious features or incoming materials with pure template matching accuracy not meeting requirements, the method can select the mode of further positioning and identifying the products by combining images with morphological analysis, fitting geometric figures (such as points, lines and arcs) and the like after template matching.
Second, the coordinate system is related
Establishing an image coordinate system based on the position image of the incoming material, randomly selecting five calibration points on the image, associating the image coordinate system with an equipment motion coordinate system according to a five-point calibration method, and determining the pixel proportion. And combining the incoming material model with the image coordinate system to determine the center point coordinate and the rotation angle of the current incoming material in the equipment motion coordinate system.
Step four: track editing
Automatically switching product formulas according to the determined product types and calling corresponding preset tracks; and correcting the preset track according to the determined center coordinates and the rotation angle, determining a track starting point (namely a needle drop point), and then moving the needle head of the glue valve to enter the position above the point for waiting.
In this step, template trajectory teaching is required, and as a preliminary work, various methods (including, but not limited to, manual teaching, image teaching, DXF import, trajectory automatic recognition, trajectory stitching, and the like) may be adopted.
Manual teaching: the dispensing needle head is moved through a manual operation program interface/handheld teaching box, and the track editing is carried out by aligning the corresponding point positions through naked eyes.
Image teaching: by shooting the global picture of a product, the mouse selects a corresponding point position in the image or slides the mouse to teach a track.
And (3) DXF import: the gluing trace is formed by importing a pre-edited DXF file (CAD edit).
Automatic track identification: the track is formed by automatic image recognition through a product real object diagram or a simulation diagram (such as a shape drawn on white paper and automatically generated by photographing).
Track splicing: for products with larger size, the multi-segment tracks need to be combined to form an integral track.
Step five: equipment pre-running
The rubber valve needle head enters the position above the needle falling point to wait, the speed change is monitored through the combination of the rotary encoder and the roller wheel by means of signal feedback of the encoder, and the position information fed back by the rotary encoder, the position information recorded when a product is triggered to shoot and the running speed of incoming materials are compared and calculated in real time.
Step six: tracking dispensing
When the product enters the gluing area, the needle head of the glue valve is moved to enter the initial point of the track, the product and the current product move in the same direction, meanwhile, the glue valve is controlled to finish gluing operation by performing superposition relative motion with the product according to the corrected track.
The method comprises the following specific steps:
firstly, five-point calibration, namely randomly selecting five calibration points on an image, establishing a relationship between an image coordinate system and a motion coordinate system by a five-point calibration method, and simultaneously determining a pixel proportion;
secondly, three-point calibration is carried out, the dispensing needle head is enabled to point to one point in the space at three different postures, and a tool coordinate system corresponding to the needle head is taught through the calibration method;
and thirdly, calibrating the following movement, and enabling the movement mechanism and the product to follow in the same direction by combining the feedback speed of the encoder according to the movement coordinate relation established in the first step. But if the remaining displacement distance of the incoming material on the production line does not meet the distance required by the gluing operation, the product is not glued.
Step seven: tracking dispensing
When the product is coated with glue, the glue valve cleaning module is started by returning to the cleaning position, and the next incoming material is cleaned; and if the next incoming material is not available or cannot be coated due to insufficient distance, the coating is not carried out.
Certainly, the rubber valve cleaning module can be started after a plurality of incoming materials are coated with rubber at each time and then the rubber valve needle head is cleaned, and the machining efficiency can be improved through reasonable planning.
The embodiments are merely illustrative of the principles and effects of the present invention, and do not limit the invention. Any person skilled in the art can modify or change the above-mentioned embodiments without departing from the spirit and scope of the present invention. Accordingly, it is intended that all equivalent modifications or changes which can be made by those skilled in the art without departing from the spirit and technical concepts disclosed herein be covered by the appended claims.
Claims (12)
1. Automatic tracking dispensing system based on assembly line, the assembly line operation of the continuous pay-off of cooperation, its characterized in that: the method comprises the following steps:
incoming material detection module: detecting/monitoring the actual position of incoming material on the production line through one or more sensors and triggering the image acquisition action of the incoming material;
an image acquisition module: monitoring or capturing image information of incoming materials on a production line in real time through one or more image acquisition devices;
an image processing module: establishing a template based on the contour image information of the incoming material, and fitting a template model of a corresponding product through a model matching algorithm and a morphological analysis method; based on the position image of the incoming material, associating an image coordinate system with an equipment motion coordinate system by a five-point calibration method, and determining the coordinate and the angle of the current incoming material in the equipment motion coordinate system;
a track editing module: simulating teaching of a processing process is carried out on the incoming material model through a preset dispensing track or a manual operation track, and the dispensing track is corrected according to the coordinates and the angle of incoming materials;
a motion control module: the motion mechanism built by the motion components realizes combined action under various motion models by respectively controlling the drive of each motion component;
a speed acquisition module: feeding back the operation position and the movement speed of the incoming material at any moment after the incoming material is acquired from the image through contact or non-contact sensing;
a fluid control module: the control of fluid glue during dispensing is realized by selecting the type of a dispensing valve and monitoring the pressure and the liquid level of a glue supply system;
glue valve cleaning module: the rubber valve needle head is cleaned by controlling the rubber valve cleaning device, so that the residual rubber on the rubber valve needle head is ensured not to influence the next processing process.
2. The flow-line based automated tracking dispensing system of claim 1, wherein: the incoming material detection module detects whether incoming materials reach a trigger position through a sensor to trigger an image acquisition action.
3. The flow-line based automated tracking dispensing system of claim 2, wherein: the sensors include, but are not limited to: a correlation light source, a reflection optical fiber, a metal proximity sensor and a mechanical micro-motion sensor.
4. The flow-line based automated tracking dispensing system of claim 1, wherein: the incoming material detection module dynamically monitors whether incoming materials enter an image acquisition visual field through image sensing to trigger image acquisition actions.
5. The flow-line based automated tracking dispensing system of claim 1, wherein: the image acquisition module comprises a 2D camera matched with a wide-angle lens or a telecentric lens and a fixed 3D line laser scanner.
6. The flow-line based automated tracking dispensing system of claim 5, wherein: the image acquisition module comprises a 2D camera control unit and a 3D camera control unit;
the 2D camera control unit is used for independently monitoring by cutting a 2D camera shooting picture area into a plurality of independent views; or a plurality of 2D camera shooting pictures are merged and spliced into a visual field for large-scale monitoring;
the 3D camera control unit generates a product outline image and position information by synthesizing the 3D outlines of the moving incoming materials on the direct scanning production line.
7. The flow-line based automated tracking dispensing system of claim 1, wherein: the image processing module includes: the system comprises a camera calibration unit, a template establishing unit, a template matching unit and a coordinate matching unit;
the camera calibration unit realizes camera calibration by a distortion calibration method and corrects pincushion distortion and barrel distortion brought by a camera lens;
the template establishing unit is used for selecting one or more areas containing characteristic points as template characteristics to establish one or more templates according to the characteristic points of the products on the contour image of the incoming material;
the template matching unit is used for matching according to the template, and reestablishing the template or adjusting the parameters of the template if the matching value of the template and the product is lower than a set value; after template matching, fitting an incoming material model based on the template and the profile image of the incoming material by combining a morphological analysis method;
the coordinate matching unit is used for associating an image coordinate system with an equipment motion coordinate system according to a five-point calibration method; and combining the incoming material model with the image coordinate system to determine the center point coordinate and the rotation angle of the current incoming material in the equipment motion coordinate system.
8. The flow-line based automated tracking dispensing system of claim 1, wherein: the track editing module comprises: the system comprises a manual teaching unit, an image teaching unit, a file importing unit, a track identifying unit and a track splicing unit;
the manual teaching unit moves the dispensing needle head through a manual operation program interface/a handheld teaching box, and tracks of corresponding point positions are edited through naked eyes;
the image teaching unit selects corresponding point positions or sliding tracks in the images for teaching through the global images of the current incoming materials;
the file import unit is used for forming a gluing track by importing a pre-edited file;
the track recognition unit adopts image automatic recognition to form a track through a product real object diagram or a simulation diagram;
the track splicing unit is used for synthesizing by leading in multiple sections of tracks to form an integral track.
9. The flow-line based automated tracking dispensing system of claim 1, wherein: the motion control module includes: the motion tracking unit, the interpolation motion unit, the single-point motion unit and the board card control unit are connected with the interpolation motion unit;
the motion following unit controls the motion assembly to perform glue dispensing operation according to a preset glue dispensing track in cooperation with the motion speed and the motion direction of the supplied materials;
the interpolation motion unit controls a plurality of motion assemblies in different running directions to perform coordinated motion to realize interpolation motion;
the single-point motion unit is used for independently controlling the motion assemblies in different running directions to quickly reach a target point;
and the board card control unit is used for adapting to a motion control card or realizing board-free motion control through a built-in upper computer system and a communication protocol.
10. The flow-line based automated tracking dispensing system of claim 1, wherein: the speed acquisition module comprises: a contact type speed acquisition unit and/or a non-contact type speed acquisition unit;
the contact type speed acquisition unit is arranged by a rotary encoder and a roller, the roller is tightly attached to the motion assembly line through a spring mechanism, and the rotary encoder feeds back the signal of the assembly line and the speed change of incoming materials;
the non-contact speed acquisition unit continuously acquires the incoming material position images through the camera to calculate the speed change of the assembly line and the incoming material.
11. The flow-line based automated tracking dispensing system of claim 1, wherein: the fluid control module includes: the glue supply unit, the liquid level monitoring unit and the glue valve communication linkage unit are arranged on the glue supply unit;
the glue supply unit realizes stable glue supply through a booster-type glue supply system and a pressure stabilizing device;
the liquid level monitoring unit monitors the residual capacity of the glue through a liquid level sensor or a flow sensor and gives an alarm at a low liquid level;
the glue valve communication linkage unit realizes real-time matching of the tracking speed and the glue dispensing frequency by enabling the motion control module to carry out handshake communication with the glue dispensing valve controller.
12. The flow-line based automated tracking dispensing system of claim 1, wherein: the glue valve cleaning module comprises: the device comprises a coil material wiping unit, a hairbrush cleaning unit and an air knife cleaning unit;
the coil stock wiping unit adopts a dust-free cloth tape to wipe the rubber valve;
the brush cleaning unit adopts a selected brush and is matched with cleaning liquid to wipe the rubber valve;
the air knife cleaning unit adopts air knives formed by different pressure gases in a plurality of directions to clean the rubber valve.
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| CN202010185388.2A CN111229548A (en) | 2020-03-17 | 2020-03-17 | Automatic tracking dispensing system based on assembly line |
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| CN202010185388.2A CN111229548A (en) | 2020-03-17 | 2020-03-17 | Automatic tracking dispensing system based on assembly line |
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| CN111921788A (en) * | 2020-08-07 | 2020-11-13 | 欣辰卓锐（苏州）智能装备有限公司 | High-precision dynamic tracking dispensing method and device |
| CN112289131A (en) * | 2020-09-23 | 2021-01-29 | 深圳市轴心自控技术有限公司 | Track path teaching method based on 2D picture and dispensing equipment |
| CN112289132A (en) * | 2020-09-23 | 2021-01-29 | 深圳市轴心自控技术有限公司 | Track path teaching method based on 3D model and dispensing equipment |
| CN112295843A (en) * | 2020-09-28 | 2021-02-02 | 深圳市轴心自控技术有限公司 | Track single-point position frequency conversion control glue discharging method |
| CN112517324A (en) * | 2020-11-17 | 2021-03-19 | 中国第一汽车股份有限公司 | Automatic robot gluing path generation device and method |
| CN112691852A (en) * | 2021-01-14 | 2021-04-23 | 珠海市运泰利自动化设备有限公司 | Automatic dispensing control system |
| CN112893007A (en) * | 2021-01-15 | 2021-06-04 | 深圳市悦创进科技有限公司 | Dispensing system based on machine vision and dispensing method thereof |
| CN113000301A (en) * | 2021-02-26 | 2021-06-22 | 广东利元亨智能装备股份有限公司 | Dispensing system and dispensing control method |
| CN113198686A (en) * | 2021-04-07 | 2021-08-03 | 深圳市鑫龙邦科技有限公司 | Special point gum machine in COB lamp area |
| CN114798299A (en) * | 2022-07-01 | 2022-07-29 | 江苏特创科技有限公司 | Cold head silicone grease cleaning and smearing device for CPU water cooling heat dissipation |
| CN115318554A (en) * | 2022-08-09 | 2022-11-11 | 深圳市盛发源自动化设备有限公司 | Visual online automatic following dynamic dispenser and control method thereof |
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