CN114049035A - Automatic dispensing monitoring system and method based on Internet - Google Patents
Automatic dispensing monitoring system and method based on Internet Download PDFInfo
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- CN114049035A CN114049035A CN202111405365.9A CN202111405365A CN114049035A CN 114049035 A CN114049035 A CN 114049035A CN 202111405365 A CN202111405365 A CN 202111405365A CN 114049035 A CN114049035 A CN 114049035A
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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
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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
- B05C11/1005—Means for controlling supply, i.e. flow or pressure, of liquid or other fluent material to the applying apparatus, e.g. valves responsive to condition of liquid or other fluent material already applied to the surface, e.g. coating thickness, weight or pattern
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- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
- Y02P—CLIMATE CHANGE MITIGATION TECHNOLOGIES IN THE PRODUCTION OR PROCESSING OF GOODS
- Y02P90/00—Enabling technologies with a potential contribution to greenhouse gas [GHG] emissions mitigation
- Y02P90/30—Computing systems specially adapted for manufacturing
Abstract
The invention belongs to the field of lens dispensing machines, relates to a dispensing monitoring technology, and is used for solving the problems that the existing dispensing detection system can only detect the dispensing process and cannot reflect the final dispensing efficiency and effect through the detection result, in particular to an automatic dispensing monitoring system and method based on the internet, wherein the system comprises a monitoring platform, the monitoring platform is in communication connection with an effective rate detection module, an effect analysis module, a batch analysis module and a storage module, the efficiency detection module is used for detecting and analyzing the dispensing efficiency of a dispensing machine and detecting and analyzing the reason causing the unqualified efficiency when the dispensing efficiency is unqualified; according to the invention, the discharging quantity detects the dispensing efficiency, the discharging quantity directly feeds back the detection efficiency, and when the dispensing efficiency is unqualified, the feeding mechanism, the dispensing mechanism and the discharging mechanism are screened for faults through the quantity of fed workpieces and the feeding operation times.
Description
Technical Field
The invention belongs to the field of lens dispensing machines, relates to a dispensing monitoring technology, and particularly relates to an automatic dispensing monitoring system and method based on the Internet.
Background
The glue dispenser is mainly used for accurately dispensing, injecting, coating and dripping glue, paint and other liquids in a product process to each accurate position of a product, and can be used for realizing dispensing, line drawing, circular or arc-shaped;
the invention patent with publication number CN110773389A discloses a glue overflow real-time monitoring system of a glue dispenser, wherein an image acquisition module is arranged on the glue dispenser, the image acquisition module is used for acquiring glue output data information of a glue dispensing head, and an analysis processing module is used for comparing the glue output data information of the glue dispensing head with the data of the size of a glue target position, so that the glue output of the glue dispensing head of the glue dispenser is monitored, and once the glue output overflows, a worker is reminded to process the glue output; however, the detection system can only detect the dispensing process, and the dispensing effect and the dispensing efficiency are affected by many factors, so the process detection mode cannot reflect the final dispensing efficiency and effect;
in view of the above technical problems, the present application provides a dispensing detection system that derives the failure cause of the dispensing process from the dispensing result with the result as the guide.
Disclosure of Invention
The invention aims to provide an automatic dispensing monitoring system and method based on the internet, which are used for solving the problem that the existing dispensing detection system can only detect the dispensing process and cannot reflect the final dispensing efficiency and effect through the detection result.
The technical problems to be solved by the invention are as follows:
how to provide a dispensing detection system which uses results as guidance to deduce the failure cause of the dispensing process.
The purpose of the invention can be realized by the following technical scheme:
an automatic dispensing monitoring system based on the Internet comprises a monitoring platform, wherein the monitoring platform is in communication connection with an efficiency detection module, an effect analysis module, a batch analysis module and a storage module;
the efficiency detection module is used for detecting and analyzing the dispensing efficiency of the dispensing machine and detecting and analyzing the reason causing the unqualified efficiency when the dispensing efficiency is unqualified;
the effect analysis module is used for detecting and analyzing the dispensing effect of the workpiece to obtain a qualified ratio HG, comparing the qualified ratio HG with qualified thresholds HGmin and HGmax, and judging whether the dispensing effect detection result is qualified or not according to the comparison result.
Further, the dispensing efficiency detection and analysis process comprises: marking the number of the workpieces output by the discharging mechanism of the dispenser in H1 minutes as GS, setting H1 as a set time constant, and comparing the number GS of the output workpieces with an output threshold value GSmin: if the number GS of the workpieces is larger than or equal to the output threshold value GSmin, the dispensing efficiency of the dispensing machine is judged to be qualified; and if the number GS of the workpieces is smaller than the output threshold value GSmin, determining that the dispensing efficiency of the dispenser is unqualified.
Further, the detection and analysis process for the reasons of the failure in efficiency comprises the following steps: marking the number of times of the feeding operation executed by the feeding mechanism of the dispenser in H1 minutes as a feeding execution number JS;
if the feeding and holding quantity JS is larger than the workpiece quantity GS, the bearing value of a feeding plate when the feeding mechanism executes feeding operation is obtained and marked as CZ, the workpiece weight is obtained and marked as GZ, a bearing threshold value CZmin is obtained through a formula CZmin = GZ multiplied by 0.85, the feeding operation execution times of which the bearing value CZ is smaller than the bearing threshold value CZmin are marked as invalid feeding times WJ, whether the numerical value of the invalid feeding times WJ is zero or not is judged, if the numerical value of the invalid feeding times WJ is zero, it is judged that the unqualified dispensing efficiency is caused by the fault of the discharging mechanism, and an efficiency detection module sends a discharging fault signal to a monitoring platform; if the numerical value of the invalid feeding times WJ is not zero, judging that the unqualified dispensing efficiency is caused by the fault of the feeding mechanism, and sending a feeding fault signal to the monitoring platform by the efficiency detection module;
if the number J of the receipt is advancedS is not more than the number GS of the workpieces, the dispensing efficiency of the dispensing mechanism is detected: marking workpieces processed by the glue dispensing mechanism within H1 minutes as workpieces i, i =1, 2, …, n, n is a positive integer, and n = GS, acquiring the time when the workpiece i is conveyed by the feeding mechanism to the glue dispensing mechanism and marking the workpiece i as JLi, acquiring the time when the workpiece i is output by the discharging mechanism and marking the workpiece i as CLi, and processing the workpieces by the formula
Obtaining an efficiency coefficient XL of the glue dispensing mechanism, and comparing the efficiency coefficient XL with an efficiency threshold value XLMin: if the efficiency coefficient XL is not smaller than an efficiency threshold value XLMin, the efficiency detection module sends a dispensing fault signal to the monitoring platform; and if the efficiency coefficient XL is smaller than an efficiency threshold value XLMin, the efficiency detection module sends an artificial check signal to the monitoring platform.
Further, the detection and analysis process of the dispensing effect includes: the method comprises the steps of shooting a gluing surface of a workpiece subjected to glue dispensing processing, amplifying a shot image to a pixel grid image, marking the obtained pixel grid image as a detection image, marking a pixel grid of the detection image as u, u =1, 2, …, wherein m is a positive integer, carrying out image processing on the detection image to obtain a gray value of the pixel grid u and marking the gray value as HDu, establishing a rectangular coordinate system by taking one corner of the detection image as an origin, obtaining a coordinate value of the pixel grid u in the rectangular coordinate system and marking the coordinate value as (Xu, Yu), wherein Xu is an abscissa value of a central point of the pixel grid u, and Yu is an ordinate value of the central point of the pixel grid u; the gray value HDu of the pixel bin u of the detected image is compared with a gray threshold HDmin: if the gray value HDu of the pixel grid u is greater than or equal to the gray threshold value HDmin, determining that the corresponding pixel grid is the dispensing pixel grid; if the gray value HDu of the pixel cell u is smaller than the gray threshold HDmin, the corresponding pixel cell is determined to be a blank pixel cell;
obtaining a standard dispensing image through a storage module and amplifying the standard dispensing image into a pixel grid image, marking the obtained pixel grid image as a contrast image, marking a gray value of a pixel grid of the contrast image as a gray standard value HBu, obtaining coordinate values of the dispensing pixel grid, finding a pixel grid corresponding to the dispensing pixel grid in the contrast image through the coordinate values, and marking the pixel grid as a standard pixel grid, obtaining a standard threshold value HBmin and HBmax of the standard pixel grid, wherein HBmin is a minimum standard threshold value, HBmax is a maximum standard threshold value, values of the standard threshold value HBmin and HBmax are calculated by a formula HBmin = t1 × HBu and a formula HBmax = t2 × HBu, wherein t1 and t2 are proportionality coefficients, ti =0.87, t2=1.15, and comparing the gray value HDu of the dispensing pixel grid with the standard threshold values HBmin and HBmax of the standard pixel grid:
if the HBmin is not more than HDu and not more than HBmax, judging that the dispensing effect of the dispensing pixel grids meets the processing requirement, and marking the corresponding dispensing pixel grids as qualified pixel grids;
if HDu is less than HBmin or HDu is more than HBmax, the dispensing effect of the dispensing pixel grids is judged not to meet the processing requirement, and the corresponding dispensing pixel grids are marked as error pixel grids;
the method comprises the steps of obtaining the number of dispensing pixel grids and marking as o, obtaining the number of qualified pixel grids and marking as q, marking the ratio of q to o as a qualified ratio HG, comparing the qualified ratio HG with a qualified threshold HGmin, and judging whether a dispensing effect detection result of a detected image is qualified or not according to the comparison result of the qualified ratio HG and the qualified threshold HGmin.
Further, the comparison process of the qualification ratio HG and the qualification threshold HGmin includes:
if the qualification ratio HG is smaller than the qualification threshold HGmin, judging that the dispensing effect detection result of the corresponding detection image is unqualified, and sending a rework signal to the monitoring platform by the effect analysis module;
and if the qualification ratio HG is greater than or equal to the qualification threshold HGmin, judging that the dispensing effect detection result of the corresponding detection image is qualified, and sending a detection qualification signal to the monitoring platform by the effect analysis module.
Further, the batch analysis module is used for performing batch quality analysis on the workpieces which are subjected to effect detection analysis: setting a timer and a counter, triggering the counter to count down when the batch analysis module receives the rework signal, wherein the count down time is H2 minutes, resetting the timer to count down when the batch analysis module receives the rework signal again within the count down time period, the count down time is H2 minutes, and the counting number of the counter is increased by one; if the batch analysis module does not receive the rework signal in the countdown time period, resetting the counter and the counter at the same time when the next batch analysis module receives the rework signal, wherein the countdown time of the timer is H2 minutes, and the technical frequency of the counter is reset to zero; when the counting times of the counter is three, the batch analysis module sends batch unqualified signals to the monitoring platform, and the monitoring platform stops the glue dispensing mechanism to operate after receiving the batch unqualified signals.
The automatic dispensing monitoring method based on the Internet comprises the following steps:
the method comprises the following steps: the efficiency detection module detects and analyzes the dispensing efficiency of the dispensing machine, detects and analyzes whether the dispensing efficiency is qualified or not according to the dispensing efficiency detection and analysis result, and simultaneously inspects the reason causing the unqualified efficiency when the dispensing efficiency is unqualified;
step two: the effect analysis module detects and analyzes the dispensing effect of the workpiece to obtain a qualified ratio, compares the qualified ratio with a qualified threshold value, and judges whether the dispensing effect of the coating surface of the workpiece meets the processing requirement or not according to the comparison result of the qualified ratio and the qualified threshold value;
step three: the batch analysis module is used for carrying out batch quality analysis on the workpieces which are subjected to effect detection and analysis, and when the batch analysis module continuously receives a rework signal to cause continuous resetting of the timer, the batch analysis module sends a batch of unqualified signals to the monitoring platform, and the stop point glue mechanism runs.
The invention has the following beneficial effects:
1. the efficiency detection module detects the dispensing efficiency through the discharge quantity, the discharge quantity directly feeds back the detection efficiency, when the dispensing efficiency is unqualified, the feeding mechanism, the dispensing mechanism and the discharge mechanism are subjected to fault screening through the quantity of fed workpieces and the feeding operation times, so that the reason of unqualified efficiency is quickly locked, the maintenance efficiency is accelerated, compared with the mode that the existing dispensing monitoring system can only detect the dispensing process, the efficiency detection module feeds back the detection efficiency through the discharge result, derives the operation state of each process by taking the efficiency detection result as a guide, and can directly lock the structure with abnormal operation when the abnormality occurs;
2. the effect analysis module is used for shooting an image of the coating surface of the workpiece, comparing the image with a standard image by adopting an image processing technology, judging the dispensing effect of the dispensing pixel grids by detecting whether the gray value of the pixel grid of the image is in the gray range of the pixel grid of the standard image, feeding back the dispensing effect of the whole detection image by qualified comparison, and converting the dispensing condition of the coating surface of the workpiece into image comparison, so that the dispensing effect detection result is more visual and accurate;
3. the batch analysis module monitors workpieces which are continuously unqualified in dispensing, timely feeds back and stops the dispenser to operate when the timer is continuously reset in a countdown time period, detects equipment and re-detects the workpieces with qualified effect in the same batch, avoids the phenomenon that unqualified workpieces flow out due to detection errors in the workpieces in the same batch, and further ensures the accuracy of effect detection results.
Drawings
In order to more clearly illustrate the embodiments of the present invention or the technical solutions in the prior art, the drawings used in the description of the embodiments or the prior art will be briefly described below, it is obvious that the drawings in the following description are only some embodiments of the present invention, and for those skilled in the art, other drawings can be obtained according to the drawings without creative efforts.
FIG. 1 is a block diagram of a system according to a first embodiment of the present invention;
FIG. 2 is a block diagram of a system according to a second embodiment of the present invention;
fig. 3 is a flowchart of a method according to a third embodiment of the present invention.
Detailed Description
The technical solutions of the present invention will be described clearly and completely with reference to the following embodiments, and it should be understood that the described embodiments are only a part of the embodiments of the present invention, and not all of the embodiments. All other embodiments, which can be derived by a person skilled in the art from the embodiments given herein without making any creative effort, shall fall within the protection scope of the present invention.
Example one
As shown in fig. 1, an internet-based automatic dispensing monitoring system includes a monitoring platform, a monitoring platform communication connection effective rate detection module, an effect analysis module, and a storage module;
the efficiency detection module is used for detecting and analyzing the dispensing efficiency of the dispensing machine: marking the number of the workpieces output by the discharging mechanism of the dispenser in H1 minutes as GS, setting H1 as a set time constant, and comparing the number GS of the output workpieces with an output threshold value GSmin: if the number GS of the workpieces is larger than or equal to the output threshold value GSmin, the dispensing efficiency of the dispensing machine is judged to be qualified; if the number GS of the workpieces is smaller than an output threshold value GSmin, and the number of the workpieces output by the dispensing machine in unit time does not meet the efficiency requirement, determining that the dispensing efficiency of the dispensing machine is unqualified, and detecting and analyzing the reasons causing the unqualified efficiency, wherein the reasons causing the unqualified efficiency comprise a feeding mechanism fault, a discharging mechanism fault, a dispensing mechanism fault and other reasons, and other reasons need manual detection by detection personnel;
the detection and analysis process for the reasons of the unqualified efficiency comprises the following steps: marking the number of times of the feeding operation executed by the feeding mechanism of the dispenser in H1 minutes as a feeding execution number JS;
if the feeding and holding quantity JS is larger than the workpiece quantity GS, acquiring a load bearing value of a feeding plate when a feeding mechanism executes feeding operation and marking the load bearing value as CZ, acquiring the workpiece weight and marking the workpiece weight as GZ, acquiring a load bearing threshold value CZmin through a formula CZmin = GZ multiplied by 0.85, marking the feeding operation execution times of which the load bearing value CZ is smaller than the load bearing threshold value CZmin as invalid feeding times WJ, wherein the invalid feeding times WJ are used for reflecting whether actual workpiece input does not exist when the feeding mechanism executes feeding operation or not, judging whether the numerical value of the invalid feeding times WJ is zero or not, if the numerical value of the invalid feeding times WJ is zero and the actual feeding number is larger than the actual discharging number, judging that the dispensing efficiency is unqualified and is caused by the fault of the discharging mechanism, and sending a discharging fault signal to a monitoring platform by an efficiency detection module; if the numerical value of the invalid feeding times WJ is not zero, the phenomenon that feeding operation is executed and no workpiece is input into the dispensing mechanism exists, the dispensing efficiency is judged to be unqualified and caused by the failure of the feeding mechanism, and the efficiency detection module sends a feeding failure signal to the monitoring platform;
if the feeding quantity JS is not larger than the workpiece quantity GS, the actual feeding quantity and the actual discharging quantity do not meet the efficiency requirement at the same time, and the dispensing condition of the dispensing mechanism is detected: marking workpieces processed by the glue dispensing mechanism within H1 minutes as workpieces i, i =1, 2, …, n, n is a positive integer, and n = GS, acquiring the time when the workpiece i is conveyed by the feeding mechanism to the glue dispensing mechanism and marking the workpiece i as JLi, acquiring the time when the workpiece i is output by the discharging mechanism and marking the workpiece i as CLi, and processing the workpieces by the formula
Obtaining an efficiency coefficient XL of the glue dispensing mechanism, wherein the efficiency coefficient is a numerical value of reaction glue dispensing efficiency, the higher the numerical value of the efficiency coefficient is, the lower the efficiency of the glue dispensing mechanism is, and the efficiency coefficient XL is compared with an efficiency threshold value XLMin: if the efficiency coefficient XL is not smaller than an efficiency threshold value XLMin, judging that the dispensing efficiency is unqualified and is caused by the failure of a dispensing mechanism, and sending a dispensing failure signal to a monitoring platform by an efficiency detection module; if the efficiency coefficient XL is smaller than an efficiency threshold value XLMin, judging that the dispensing efficiency is unqualified and caused by other factors, and sending a manual inspection signal to a monitoring platform by an efficiency detection module; when efficiency is unqualified when gluing in the point, through quantity and the feeding operation number of times to feeding work piece to feed mechanism, mechanism and discharge mechanism carry out the trouble screening to quick locking efficiency unqualified reason, accelerate maintenance efficiency, compare in the mode that present monitoring system that glues only can detect to the process of gluing, this application feeds back detection efficiency through ejection of compact result, and use efficiency testing result to derive the running state of each process as the direction, can directly lock the unusual structure of operation when unusual.
The effect analysis module is used for detecting and analyzing the dispensing effect of the workpiece, and the detection and analysis process of the dispensing effect comprises the following steps: the method comprises the steps of shooting a gluing surface of a workpiece subjected to glue dispensing processing, amplifying a shot image to a pixel grid image, marking the obtained pixel grid image as a detection image, marking the pixel grid of the detection image as u, u =1, 2, …, wherein m and m are positive integers, carrying out image processing on the detection image to obtain a gray value of the pixel grid u and marking the gray value as HDu, wherein the image processing technology is a technology for processing image information by using a computer, mainly comprises image digitization, image enhancement and restoration, image segmentation, image identification, gray level transformation and the like, a rectangular coordinate system is established by taking one corner of the detection image as an origin, and coordinate values of the pixel grid u in the rectangular coordinate system are obtained and marked as (Xu, Yu), wherein Xu is an abscissa value of the center point of the pixel grid u, and Yu is an ordinate value of the center point of the pixel grid u; the gray value HDu of the pixel bin u of the detected image is compared with a gray threshold HDmin: if the gray value HDu of the pixel grid u is greater than or equal to the gray threshold value HDmin, determining that the corresponding pixel grid is the dispensing pixel grid; if the gray value HDu of the pixel cell u is smaller than the gray threshold HDmin, the corresponding pixel cell is determined to be a blank pixel cell;
obtaining a standard dispensing image through a storage module and amplifying the standard dispensing image into a pixel grid image, marking the obtained pixel grid image as a comparison image, marking a gray scale value of a pixel grid of the comparison image as a gray standard value HBu, obtaining coordinate values of the dispensing pixel grid, finding a pixel grid corresponding to the dispensing pixel grid in the comparison image through the coordinate values and marking the pixel grid as a standard pixel grid, obtaining standard threshold values HBmin and HBmax of the standard pixel grid, wherein HBmin is a minimum standard threshold value, HBmax is a maximum standard threshold value, values of the standard threshold values HBmin and HBmax are calculated by a formula HBmin = t1 × HBu and a formula HBmax = t2 × HBu, the standard threshold values HBmin and HBmax form a standard range, and judging whether a dispensing effect of the dispensing pixel grid meets a processing requirement by whether the gray scale value of the dispensing pixel grid is in the standard range, wherein t1 and t2 are proportionality coefficients, and t2= 0.87, t2=1.15, comparing the gray value HDu of the dispensing pixel grid with the standard threshold values HBmin, HBmax of the standard pixel grid:
if the HBmin is not more than HDu and not more than HBmax, judging that the dispensing effect of the dispensing pixel grids meets the processing requirement, and marking the corresponding dispensing pixel grids as qualified pixel grids;
if HDu is less than HBmin or HDu is more than HBmax, the dispensing effect of the dispensing pixel grids is judged not to meet the processing requirement, and the corresponding dispensing pixel grids are marked as error pixel grids;
obtaining the number of dispensing pixel grids and marking as o, obtaining the number of qualified pixel grids and marking as q, marking the ratio of q to o as a qualified ratio HG, and comparing the qualified ratio HG with a qualified threshold HGmin: if the qualification ratio HG is smaller than the qualification threshold HGmin, judging that the dispensing effect detection result of the corresponding detection image is unqualified, and sending a rework signal to the monitoring platform by the effect analysis module; if the qualification ratio HG is larger than or equal to the qualification threshold HGmin, the dispensing effect detection result corresponding to the detection image is judged to be qualified, the effect analysis module sends a detection qualification signal to the monitoring platform, and the dispensing condition of the coating surface of the workpiece is converted into image comparison, so that the dispensing effect detection result is more visual and accurate.
Example two
As shown in fig. 2, monitoring platform still communication connection has batch analysis module, and monitoring platform receives after rework signal and the qualified signal of detection will rework signal and detect qualified signal and send to batch analysis module, and batch analysis module is used for carrying out quality analysis in batches to the work piece of accomplishing effect detection and analysis: setting a timer and a counter, triggering the counter to count down after the batch analysis module receives the rework signal, wherein the count down time is H2 minutes, H2 is a set time constant, if the batch analysis module receives the rework signal again in the count down time period, the timer is reset to count down, the count down time is H2 minutes, and the counting frequency of the counter is increased by one; if the batch analysis module does not receive the rework signal in the countdown time period, resetting the counter and the counter at the same time when the next batch analysis module receives the rework signal, wherein the countdown time of the timer is H2 minutes, and the technical frequency of the counter is reset to zero; when the counting times of the counter is three, the batch analysis module sends batch unqualified signals to the monitoring platform, the monitoring platform stops the operation of the dispensing mechanism after receiving the batch unqualified signals, and the batch analysis module is arranged to timely feed back and stop the operation of the dispensing mechanism when the timer is continuously reset in a countdown time period, detect equipment and detect workpieces with qualified effects in the same batch again, so that the phenomenon that unqualified workpieces flow out due to detection errors in the workpieces in the same batch is avoided.
EXAMPLE III
As shown in fig. 3, an internet-based automatic dispensing monitoring method includes the following steps:
the method comprises the following steps: the efficiency detection module detects and analyzes the dispensing efficiency of the dispensing machine, detects and analyzes whether the dispensing efficiency is qualified or not according to the dispensing efficiency detection and analysis result, and simultaneously inspects the reason causing the unqualified efficiency when the dispensing efficiency is unqualified;
step two: the effect analysis module detects and analyzes the dispensing effect of the workpiece to obtain a qualified ratio, compares the qualified ratio with a qualified threshold value, and judges whether the dispensing effect of the coating surface of the workpiece meets the processing requirement or not according to the comparison result of the qualified ratio and the qualified threshold value;
step three: the batch analysis module is used for carrying out batch quality analysis on the workpieces which are subjected to effect detection and analysis, and when the batch analysis module continuously receives a rework signal to cause continuous resetting of the timer, the batch analysis module sends a batch of unqualified signals to the monitoring platform, and the stop point glue mechanism runs.
An automatic dispensing monitoring system based on the Internet is characterized in that when the system works, an efficiency detection module is adopted to detect and analyze the dispensing efficiency of a dispensing machine, and when the dispensing efficiency is unqualified, the reason for the unqualified efficiency is checked; the effect analysis module detects and analyzes the dispensing effect of the workpiece to obtain a qualification ratio, compares the qualification ratio with a qualification threshold, reflects the proportion of qualified pixel grids in dispensing pixel grids through the qualification ratio, and judges whether the dispensing effect of the coating surface of the workpiece meets the processing requirement or not according to the comparison result of the qualification ratio and the qualification threshold.
The above formulas are all numerical values obtained by normalization processing, the formula is a formula obtained by acquiring a large amount of data and performing software simulation to obtain the latest real situation, and the preset parameters in the formula are set by the technical personnel in the field according to the actual situation.
In the description herein, references to the description of "one embodiment," "an example," "a specific example" or the like are intended to mean that a particular feature, structure, material, or characteristic described in connection with the embodiment or example is included in at least one embodiment or example of the invention. In this specification, the schematic representations of the terms used above do not necessarily refer to the same embodiment or example. Furthermore, the particular features, structures, materials, or characteristics described may be combined in any suitable manner in any one or more embodiments or examples.
The preferred embodiments of the invention disclosed above are intended to be illustrative only. The preferred embodiments are not intended to be exhaustive or to limit the invention to the precise forms disclosed. Obviously, many modifications and variations are possible in light of the above teaching. The embodiments were chosen and described in order to best explain the principles of the invention and the practical application, to thereby enable others skilled in the art to best utilize the invention. The invention is limited only by the claims and their full scope and equivalents.
Claims (7)
1. An automatic dispensing monitoring system based on the Internet comprises a monitoring platform, and is characterized in that the monitoring platform is in communication connection with an efficiency detection module, an effect analysis module, a batch analysis module and a storage module;
the efficiency detection module is used for detecting and analyzing the dispensing efficiency of the dispensing machine and detecting and analyzing the reason causing the unqualified efficiency when the dispensing efficiency is unqualified;
the effect analysis module is used for detecting and analyzing the dispensing effect of the workpiece to obtain a qualified ratio HG, comparing the qualified ratio HG with qualified thresholds HGmin and HGmax, and judging whether the dispensing effect detection result is qualified or not according to the comparison result.
2. The system and method for automatic internet-based dispensing monitoring of claim 1, wherein the dispensing efficiency detection analysis process comprises: marking the number of the workpieces output by the discharging mechanism of the dispenser in H1 minutes as GS, setting H1 as a set time constant, and comparing the number GS of the output workpieces with an output threshold value GSmin: if the number GS of the workpieces is larger than or equal to the output threshold value GSmin, the dispensing efficiency of the dispensing machine is judged to be qualified; and if the number GS of the workpieces is smaller than the output threshold value GSmin, determining that the dispensing efficiency of the dispenser is unqualified.
3. The internet-based automatic dispensing monitoring system of claim 2, wherein the cause detection and analysis process for the failure in efficiency comprises: marking the number of times of the feeding operation executed by the feeding mechanism of the dispenser in H1 minutes as a feeding execution number JS;
if the feeding and holding quantity JS is larger than the workpiece quantity GS, the bearing value of a feeding plate when the feeding mechanism executes feeding operation is obtained and marked as CZ, the workpiece weight is obtained and marked as GZ, a bearing threshold value CZmin is obtained through a formula CZmin = GZ multiplied by 0.85, the feeding operation execution times of which the bearing value CZ is smaller than the bearing threshold value CZmin are marked as invalid feeding times WJ, whether the numerical value of the invalid feeding times WJ is zero or not is judged, if the numerical value of the invalid feeding times WJ is zero, it is judged that the unqualified dispensing efficiency is caused by the fault of the discharging mechanism, and an efficiency detection module sends a discharging fault signal to a monitoring platform; if the numerical value of the invalid feeding times WJ is not zero, judging that the unqualified dispensing efficiency is caused by the fault of the feeding mechanism, and sending a feeding fault signal to the monitoring platform by the efficiency detection module;
if the entering quantity JS is not larger than the quantity GS of the workpieces, the dispensing efficiency of the dispensing mechanism is detected: marking workpieces processed by the glue dispensing mechanism within H1 minutes as workpieces i, i =1, 2, …, n, n is a positive integer, and n = GS, acquiring the time when the workpiece i is conveyed by the feeding mechanism to the glue dispensing mechanism and marking the workpiece i as JLi, acquiring the time when the workpiece i is output by the discharging mechanism and marking the workpiece i as CLi, and processing the workpieces by the formula
Obtaining an efficiency coefficient XL of the glue dispensing mechanism, and comparing the efficiency coefficient XL with an efficiency threshold value XLMin: if the efficiency coefficient XL is not smaller than an efficiency threshold value XLMin, the efficiency detection module sends a dispensing fault signal to the monitoring platform; and if the efficiency coefficient XL is smaller than an efficiency threshold value XLMin, the efficiency detection module sends an artificial check signal to the monitoring platform.
4. The internet-based automatic dispensing monitoring system of claim 2, wherein the detection and analysis process of dispensing effect comprises: the method comprises the steps of shooting a gluing surface of a workpiece subjected to glue dispensing processing, amplifying a shot image to a pixel grid image, marking the obtained pixel grid image as a detection image, marking a pixel grid of the detection image as u, u =1, 2, …, wherein m is a positive integer, carrying out image processing on the detection image to obtain a gray value of the pixel grid u and marking the gray value as HDu, establishing a rectangular coordinate system by taking one corner of the detection image as an origin, obtaining a coordinate value of the pixel grid u in the rectangular coordinate system and marking the coordinate value as (Xu, Yu), wherein Xu is an abscissa value of a central point of the pixel grid u, and Yu is an ordinate value of the central point of the pixel grid u; the gray value HDu of the pixel bin u of the detected image is compared with a gray threshold HDmin: if the gray value HDu of the pixel grid u is greater than or equal to the gray threshold value HDmin, determining that the corresponding pixel grid is the dispensing pixel grid; if the gray value HDu of the pixel cell u is smaller than the gray threshold HDmin, the corresponding pixel cell is determined to be a blank pixel cell;
obtaining a standard dispensing image through a storage module and amplifying the standard dispensing image into a pixel grid image, marking the obtained pixel grid image as a contrast image, marking a gray value of a pixel grid of the contrast image as a gray standard value HBu, obtaining coordinate values of the dispensing pixel grid, finding a pixel grid corresponding to the dispensing pixel grid in the contrast image through the coordinate values, and marking the pixel grid as a standard pixel grid, obtaining a standard threshold value HBmin and HBmax of the standard pixel grid, wherein HBmin is a minimum standard threshold value, HBmax is a maximum standard threshold value, values of the standard threshold value HBmin and HBmax are calculated by a formula HBmin = t1 × HBu and a formula HBmax = t2 × HBu, wherein t1 and t2 are proportionality coefficients, ti =0.87, t2=1.15, and comparing the gray value HDu of the dispensing pixel grid with the standard threshold values HBmin and HBmax of the standard pixel grid:
if the HBmin is not more than HDu and not more than HBmax, judging that the dispensing effect of the dispensing pixel grids meets the processing requirement, and marking the corresponding dispensing pixel grids as qualified pixel grids;
if HDu is less than HBmin or HDu is more than HBmax, the dispensing effect of the dispensing pixel grids is judged not to meet the processing requirement, and the corresponding dispensing pixel grids are marked as error pixel grids;
the method comprises the steps of obtaining the number of dispensing pixel grids and marking as o, obtaining the number of qualified pixel grids and marking as q, marking the ratio of q to o as a qualified ratio HG, comparing the qualified ratio HG with a qualified threshold HGmin, and judging whether a dispensing effect detection result of a detected image is qualified or not according to the comparison result of the qualified ratio HG and the qualified threshold HGmin.
5. The internet-based automatic dispensing monitoring system of claim 4, wherein the comparison of the qualification ratio HG with the qualification threshold HGmin comprises:
if the qualification ratio HG is smaller than the qualification threshold HGmin, judging that the dispensing effect detection result of the corresponding detection image is unqualified, and sending a rework signal to the monitoring platform by the effect analysis module;
and if the qualification ratio HG is greater than or equal to the qualification threshold HGmin, judging that the dispensing effect detection result of the corresponding detection image is qualified, and sending a detection qualification signal to the monitoring platform by the effect analysis module.
6. The internet-based automatic dispensing monitoring system of claim 5, wherein the batch analysis module is configured to perform batch quality analysis on the workpiece subjected to the effect detection analysis: setting a timer and a counter, triggering the counter to count down when the batch analysis module receives the rework signal, wherein the count down time is H2 minutes, resetting the timer to count down when the batch analysis module receives the rework signal again within the count down time period, the count down time is H2 minutes, and the counting number of the counter is increased by one; if the batch analysis module does not receive the rework signal in the countdown time period, resetting the counter and the counter at the same time when the next batch analysis module receives the rework signal, wherein the countdown time of the timer is H2 minutes, and the technical frequency of the counter is reset to zero; when the counting times of the counter is three, the batch analysis module sends batch unqualified signals to the monitoring platform, and the monitoring platform stops the glue dispensing mechanism to operate after receiving the batch unqualified signals.
7. An automatic dispensing monitoring method based on the Internet is characterized by comprising the following steps:
the method comprises the following steps: the efficiency detection module detects and analyzes the dispensing efficiency of the dispensing machine, detects and analyzes whether the dispensing efficiency is qualified or not according to the dispensing efficiency detection and analysis result, and simultaneously inspects the reason causing the unqualified efficiency when the dispensing efficiency is unqualified;
step two: the effect analysis module detects and analyzes the dispensing effect of the workpiece to obtain a qualified ratio, compares the qualified ratio with a qualified threshold value, and judges whether the dispensing effect of the coating surface of the workpiece meets the processing requirement or not according to the comparison result of the qualified ratio and the qualified threshold value;
step three: the batch analysis module is used for carrying out batch quality analysis on the workpieces which are subjected to effect detection and analysis, and when the batch analysis module continuously receives a rework signal to cause continuous resetting of the timer, the batch analysis module sends a batch of unqualified signals to the monitoring platform, and the stop point glue mechanism runs.
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