DE202012103130U1 - Industrial camera system - Google Patents

Abstract

Industrial camera system type 1 (2.1) with its own 1–2 CNC positioning drives for an integrated oscillating mirror or base is coupled with an industrial robot (11) or a CNC-controlled linear or rotary feed, in order to use its external machine movements to control the camera's field of view , outside or between complicated spatial structures, for example To expand car bodies (12) and / or to significantly shorten or even enable high-resolution, fast individual image recording sequences of technical elements such as joints and small edges.

Description

The invention relates to a modular system for industrial cameras for functional extension of a first and / or a second type of industrial camera for fully or partially automatic optical inspections.

There are still traditional visual inspections in production and logistics ( DIN EN 473, 970, 1330, 13018 . DIN 25435 etc.), some of which have quality risks, especially in multi-unit or hard-to-reach objects such as joints and miniature elements due to limited visual acuity, incompleteness, non-integrated logging, short cycle times, tight process tolerances, high-strength, critical materials, and bulky and expensive parts. Novel technical combinations of optics, image processing, robotics and drive technology are sought after and eligible for protection.

The motorized multi-spectral cameras from Carl-Zeiss Jena from the 1970s are known for earth-remote sensing. It builds on that Prof. Janaschek, TU Dresden with piezo actuators for image sensors auf in: Janaschek: System Design of Mechatronic Systems, Springer-Verlag 2010 , Furthermore, there are swivel and tiltable sockets for surveillance and studio cameras by SIEMENS, BOSCH, MOBOTIX, etc., sometimes referred to as a robot webcam, as well as hand-held scanners and constant oscillating oscillating mirror scanners for logistics and trade by DATALOGIC, LEUTZE, etc.

For innovative requirements and industrial value for money is an extremely fast and high-resolution camera system with integrated tilting mirror and its 2-axis CNC control for up to 50 recording positions / sec. from the publication DE 10 2005 029 901 A1 known. It is used for the biometric identification of faces and eyes for eg eGates and increasingly for the identification of parts and coding in logistics and production as well as for optical inspection of joints, cut edges, etc. Camera modules with integrated 2-axis CNC mirror or CNC Base adjustments are previously mounted stationary or are used on mobile or humanoid robots of navigation or inspection.

Since about 2006 VARIOPTIC, SAMSUNG et al. Liquid lenses with electronically controllable focus. Falling prices and better performance enhance the possibilities for fully or partially automated optical inspections in the industry.

The state of the art with devices and software for industrial image processing is documented, for example, in Fraunhofer Materials "Image Processing: Solutions for Machine Vision" www.vision.fraunhofer.de/de/index.html , in "image processing and laser metrology" ( http: //files.pepperl-fuchs.com/selector_files/navi/productInfo/doct / ... ), in COGNEX "VisionControl &SmartView" http://www.cognex.com/Products Services / VisionSystems and Microscan "firsts" http://files.microscan.com/deutsch/DE , For surface defects there are libraries and automatable classifications: eg www.cognex.com ; http://www.vision.fraunhofer.de/en/projects/ 240, 438 and 512.html ,

However, no comparable solution can be seen in the published materials for this patent application. Manufacturer of cameras and image evaluation systems such as Keyence, OMRON, Vision Components, IOSS, VITRONIC, IFM and others. offer high-quality code readers, high-speed and smart cameras, multi-camera systems, combinations of optics with ultrasound etc. in their websites, product directories and application examples, but obviously no camera system with such a fast moving field of view and a "tandem optics" for Overview and extreme details like the MODI GmbH Gummersbach.

Known are cameras without their own drives on robots and linear drives to "handle in the box or on the conveyor belt", for adaptive correction of the gripper position of KUKA, ABB, STÄUBLI, REISS, EPSON, FESTO, etc., for surface and attitude testing, for the casting inspection System CapaCam (Fraunhofer project 438 and Daimler), for all-round tests the PentaCam (5 stationary cameras in Fraunhofer project 134), super wide-angle and periscope cameras for boreholes and hollow bodies, eg Fraunhofer projects 234 and 607. Further examples are scanners for and data matrix codes, for visual inspection of soldered printed circuit boards, for welding seam tests with two cooperating robots from VIRO ( http://www.vitronic.com/industry/automotive/virowsi-2d-and-3d-weld-seam testing ), similar applications of the two-armed robot SDA10 from YASAKAWA-Motoman ( http://www.motoman.de/uploads/tx. catalog robot / SDA10D ), Conveyor and multi-robot synchronizations and automatic calibrations. Other robot-camera combinations are used for 3D measurements with fringe projections and stereo cameras as well as interferometric and holographic form testing (eg in http://www.vision. Fraunhofer. de / en / projects 397, 305, 202, 496.html ). Robots that can operate without a safety fence, eg from Universal Robots, KUKA, ABB and SCHUNK, are advantageous for automatic inspections.

So far, the applicant could find no example for the coupling of an industrial robot with a camera system with integrated CNC drives for movable mirrors according to document DE 10 2005 029 901 A1 or with a dome or pan camera, ie with the CNC drives in a rotatable and tiltable camera base.

Electric servo drives are decisive in terms of dynamics, positioning and concentricity precision, both in standard design with housing and shaft and also as flat torque motors, which work without a gearbox and offer a technical working space in the center. Examples are the flat KBM motors from Kollmorgen, the SCHUNK encapsulated ERS135 rotary module and classic rotary modules with a separate motor from Jenaer Antriebstechnik and ORIENTAL Motors: http://www.wikikollmorgen.eu/wiki/DanMoBilder/file/pdf_archiv/motoren/KBM-kollmorgen/2011-04/kbm_e.pdf ; http://www.schunk.com/schunk_files/attachments/ OM_AU_ERS-560V__EN.pdf ; http://www.jatgmbh.de/pdf_dt/mech/04_Rotatorische_ Systeme / 9_2 _HRT190_e.pdf ; http://www.orientalmotor.de/Products/Linear_rotary_actuators/Rotary_actuators/Hollow_ rotary_actuators_dg / , However, no example with industrial camera on torque motor for orbital workpiece orbit could be determined.

The product and company names used are the property of the companies concerned.

The object of the invention is to develop a modular, cost-effective and fast industrial camera system, which is suitable for partially and fully automatic visual checks and difficult accessibility, if necessary, performs additional and safety functions and uses modern image processing and handling technology.

Application goals are e.g. Car body shells, lightweight structures, pre-assembled hydraulic lines, girder constructions and similar objects with complicated, even unwieldy geometry and obstructed visibility of elements and details that can occur in large numbers or at long intervals, as well as collaboration workstations by humans and robots.

This object is solved by the features of the first patent claim. Advantageous embodiments emerge from the subclaims.

• 1) Sehr schnelle, selektive und zugleich hoch auflösende Bilder, vergrößerte Sichtfelder trotz kritischer Platzverhältnisse innerhalb von empfindlichen Objekten und/oder in kurzer Zeit zwischen benachbarten oder aufeinanderfolgenden Objekten z.B. Autokarosserien durch Befestigung einer Industriekamera mit eigenem CNC-Schwenkspiegel oder -sockel an einem Industrieroboter (vgl. 1 und 2) oder an einer maschinellen Linear- oder Rotationseinheit;
• 2) Erweiterung des Roboterkoordinatensystems um zusätzliche Nebenachsen in Gestalt der CNC-gesteuerten Bewegungsantriebe der Industriekamera für das Definieren, Ausführen und Rückmelden von Positionen, Orientierungen und Bewegungen (anders als Roboter mit einer Kamera ohne eigene Bewegungsantriebe);
• 3) Effektivere, zerstörungsfreie und automatisierte Qualitätssicherung durch teil- oder vollautomatisierte Sichtkontrollen von z.B. extrem langen Teilen oder vielgliedrigen Fügeverbindungen wie Schweiß- und Lötstellen, Pressfügeflächen (Niete, Clinch- oder Toxx-Punkte), Gewinde, Falze, Klebstoff-Raupen und -Überschüssen, einschließlich Erkennen von Poren, Rissen, Schweißperlen, Werkzeug-Abplatzern und deren Druckstellen sowie von sonstigen Fremdkörpern und Farbänderungen;
• 4) Mehrfach-Nutzung vorhandener Industriekameras und Scanner für Sicherheitsfunktionen zusätzlich zu üblichen Abstands- und Kraftsensoren für Arbeitsschutz und Selbstüberwachung, d.h. nicht nur Störungsmeldung „kein Teil“, „fehlerhafter Code“, sondern auch Erkennung von Fremdkörpern, von Händen im gemeinsamen Arbeitsraum etc. als unterstützende Funktionen zur Einhaltung der Vorschriften für Maschinen und Arbeitsplätze incl. der Vorschriften für kollaborierende Robotern nach DIN EN ISO 10218 und BG/BGIA-Empfehlungen U001/ 2009 betreffs aktiver und passiver Sicherheitseinrichtungen etc.;
• 5) Nutzung der Kamerasteuerung zur automatisch-adaptiven Fokussierung, z.B. einer Flüssigkeitslinse und deren Bildauswertung bzw. des industriellen Bildsensors zum Erkennen der Distanzen und Bewegungen von Fremdkörpern im Roboterarbeitsraum für den Arbeitsschutz und die Selbstüberwachung auf dem Weg der Geschwindigkeitsreduzierung des Roboters einer maschinellen Linear- oder Rotationseinheit für ein noch gefahrloses Fortsetzen und situationsabhängiges Stoppen;
• 6) Leistungsfähigkeit und Universalität einer optischen Inspektionsvorrichtung mit orbital umlaufender Kamera um ein zu inspizierendes Objekt; das Objekt kann von Hand, mit Roboter oder Förderband be- und entladen werden; die Vorrichtung ist an Formen und Maße der Objekte gut anpassbar, schützt vor Fremdlicht, gestattet zusätzliche Sensoren oder Wirkmodule, vermeidet Getriebe und deren Kosten und Geräusche, ermöglicht verschiedene Sichtfelder und erfüllt effektiv die Sicherheitsanforderungen;
• 7) Orbitaler Rotationsantrieb ohne Getriebe für Kamera, Optikmodul (13), sonstige Sensoren oder Wirkelemente allein unter Anwendung eines Hohlwellen- oder Torquemotors mit großem Durchlass im Vergleich zur axialen Höhe, mit minimalem Geräusch und mit präzisen Rundlaufeigenschaften (z.B. ohne Pulsation von Verzahnungen);
• 8) Ein oder mehrere mitbewegende Spiegel im festen oder variablen Winkel im Strahlengang der Kamera zur automatischen optischen Inspektion für koaxiales oder schräges Sichtfeld z.B. zur Sichtprüfung von mehr oder weniger konzentrischen Ringnuten, Innenverzahnungen, Bohrungen, Kanälen, unter Flanschen und Gehäusen, von unhandlichen oder schweren Objekten;
• 9) Die orbital rotierende Kamera kann ergänzt oder ersetzt durch andere Wirkelemente wie einen Markiermodul für Schreibstift, Tinte, Laser oder Prägenadel;
• 10) Automatische optische Innenraum-, Öffnungs- und/oder Zentrier-/Mechanik-Überwachung durch die Kamera selbst.

The solution according to the invention has the following application possibilities and advantages:

• 1) Very fast, selective and at the same time high-resolution images, enlarged fields of view despite critical space conditions within sensitive objects and / or in a short time between adjacent or successive objects eg car bodies by attaching an industrial camera with its own CNC tilting mirror or base to an industrial robot ( see. 1 and 2 ) or on a machine linear or rotary unit;
• 2) Extension of the robot coordinate system by additional minor axes in the form of the CNC-controlled motion drives of the industrial camera for defining, executing and confirming positions, orientations and movements (unlike robots with a camera without own movement drives);
• 3) More effective, non-destructive and automated quality assurance through partially or fully automated visual inspection of eg extremely long parts or multi-joint joints such as welds and solder joints, pressfoot surfaces (rivets, clinch or Toxx points), threads, folds, adhesive beads and excesses including the detection of pores, cracks, weld beads, tool chipping and their bruises as well as other foreign bodies and color changes;
• 4) Multiple use of existing industrial cameras and scanners for safety functions in addition to conventional distance and force sensors for occupational safety and self-monitoring, ie not only fault "no part", "faulty code", but also detection of foreign bodies, of hands in the common workspace, etc. as supporting functions for compliance with the regulations for machines and workplaces incl. the regulations for collaborative robots DIN EN ISO 10218 and BG / BGIA recommendations U001 / 2009 regarding active and passive safety devices, etc .;
• 5) Use of camera control for automatically adaptive focusing, eg a liquid lens and its image evaluation or the industrial image sensor for detecting the distances and movements of foreign objects in the robot workspace for work safety and self-monitoring on the way of reducing the speed of the robot of a machine linear or Rotation unit for a still safe continuation and situation-dependent stopping;
• 6) performance and universality of an optical inspection device with orbital rotating camera around an object to be inspected; the object can be loaded and unloaded by hand, with robot or conveyor belt; The device is well adaptable to the shapes and dimensions of the objects, protects against external light, allows additional sensors or active modules, avoids gearboxes and their costs and noises, allows different fields of view and effectively meets the safety requirements;
• 7) Orbital rotary drive without gear for camera, optical module (13), other sensors or active elements alone using a hollow shaft or torque motor with large passage compared to the axial height, with minimal noise and with precise concentricity (eg without pulsation of gears);
• 8) One or more moving mirrors in a fixed or variable angle in the beam path of the camera for automatic optical inspection for coaxial or oblique field of view eg for visual inspection of more or less concentric annular grooves, internal gears, holes, channels, under flanges and housings of bulky or heavy objects;
• 9) The orbital rotating camera can be supplemented or replaced by other active elements such as a marker module for pen, ink, laser or embossing needle;
• 10) Automatic optical interior, opening and / or centering / mechanical monitoring by the camera itself.

The invention will be explained in more detail with reference to embodiments and accompanying drawings.

Show it:

1 a longitudinal section through an industrial camera system for the function extension of a second type of industrial camera,

2 a three-dimensional exterior view of the industrial camera system acc. 3 .

3 an industrial robot with a type 1 industrial camera for visual inspection at the rear of a moving body and shortly thereafter at the front of an incoming body,

4 an industrial robot with a type 1 industrial camera for visual inspection within a body.

The 1 and 2 show a universal inspection device using an industrial camera system 1 with industrial camera type 2.2 placed in an unmarked housing with an optical module 3 is integrated. The optics module 3 is on a rotation module 4 attached in the manner of a turntable, with a torque motor 5 is driven directly. The torque motor 5 embodies a flat hollow shaft motor with through-hole 5.1 which extends along the longitudinal axis A. The torque motor 5 is on a base plate 6 attached. All encloses a telescopic housing 7 which comprises at least two telescopically substantially cylindrical wall sections 7.1 . 7.2 having, wherein the wall portion 7.1 with the base plate 6 is connected and the upper end of the wall portion 7.2 with a lid area 7.3 is completed, which has a central opening 7.4 having. At the lid area 7.3 is a replaceable ring cover 8th attached. Its opening diameter 8.1 and joining aid are to the object to be inspected 9 adapted or variably adjustable (in the example shown a tube with flange). The here tubular object 9 becomes with its towards the base plate 6 pointing end to a centering module 10 added. The centering module 10 does not rotate with the rotation module, but is detachably mounted on the base plate through the hollow shaft drive. If required, the centering module can be coupled with sealing and filling elements for the application of leakage test gas. In this case, the orbital rotating camera can be supplemented or replaced by a chemical or physical sniffer probe and / or microphone for flow noise. For continuous or cyclic continuous testing of long objects, the central passage of the torque motor and adapted outer centering elements can be used (not shown). The modular and adjustable optics, housing, centering and additional elements allow the desired performance, universality and process reliability.

Depending on the object to be inspected, the camera or rotation module used here may have additional light sources and / or mirrors which can be swiveled manually or mechanically, which is not necessarily required for the application described above (testing of a soldered connection pipe with flange).

The industrial camera is turned into an orbital rotation by means of a torque motor around the object to be tested 9 (here a tube with flange) offset. The object 9 is centered inside and outside the case 7 held manually or mechanically. The loading and unloading direction can be selected. The image information is forwarded to an evaluation and visualization unit (not shown) where it is analyzed, classified, visualized and stored.

In the 3 and 4 is an industrial robot 11 for the inspection of vehicle bodies 12 in the body shop 3 coupled with an industrial camera type 2.1 1 with integrated CNC swivel mirror shown. 3 illustrates the automatic visual inspection of joints at the rear 4 12.1 a moving body 12 and shortly thereafter at the front 5 12.2 an incoming body 12 during a short time in which the industrial robot 11 moves in synchronism with the speed of the conveyor belt, not shown here. Here, the axes of movement of industrial robots overlap 11 and camera system (principle online) for the Maintaining an optimal focus distance without or with a liquid lens in the camera lens. The possible fast camera image sequence and the mobility of the industrial robot also allow different viewing angles in indentations of individual clinching points for recognizing tool impressions for early warning wear indication and, for example, on rebate and solder joints with different side lights for detecting the bending and arching quality.

The camera-robot combination works here between two moving objects for the short-term inspection of many points at the rear and front of both objects. The parking position of the industrial robot is preferably located without collision outside the assembly line.

Not shown is the possible visual inspection with the robot-camera network in the front and rear wheel arches, which is feasible depending on the car and robot in drive or standstill of the conveyor belt and as the general use of rigid cameras on industrial robots to the prior art belongs.

4) shows the same industrial robot 11 with the same moving camera system of an industrial camera type 2.1 (not visible here) inside a body 12 during the conveyor belt standstill (conveyor belt is not shown). Here can the industrial robot 11 certain holding positions, from which only the very fast industrial camera type 2.1 operates with minimal moving masses and space requirements. The additional CNC-controlled motion axes in the camera system type 2.1 significantly expand the field of view with less bulky robot movements and collision risks, and with less car model dependency of robot programming. It is thus possible in the narrow and sensitive interior with minimal robot movements by the camera system type 2.1 with own movement axes in shortest time many points of the interior of the body 12 to inspect.

QUOTES INCLUDE IN THE DESCRIPTION

This list of the documents listed by the applicant has been generated automatically and is included solely for the better information of the reader. The list is not part of the German patent or utility model application. The DPMA assumes no liability for any errors or omissions.

Cited patent literature

• DE 102005029901 A1 [0004, 0009]

Cited non-patent literature

• DIN EN 473, 970, 1330, 13018 [0002]
• DIN 25435 [0002]
• Prof. Janaschek, TU Dresden with piezo actuators for image sensors auf in: Janaschek: System Design of Mechatronic Systems, Springer-Verlag 2010 [0003]
• www.vision.fraunhofer.de/en/index.html [0006]
• http: //files.pepperl-fuchs.com/selector_files/navi/productInfo/doct/ ... [0006]
• http://www.cognex.com/Products Services / [0006]
• http://files.microscan.com/english/DE [0006]
• www.cognex.com [0006]
• http://www.vision.fraunhofer.de/en/projects/ 240, 438 and 512.html [0006]
• http://www.vitronic.com/industry/automotive/virowsi-2d-and-3d-weld-seam inspection [0008]
• http://www.motoman.de/uploads/tx. catalogrobot / SDA10D [0008]
• http://www.vision. Fraunhofer. de / en / projects 397, 305, 202, 496.html [0008]
• http://www.wikikollmorgen.eu/wiki/DanMoBilder/file/pdf_archiv/motoren/KBM-kollmorgen/2011-04/kbm_e.pdf [0010]
• http://www.schunk.com/schunk_files/attachments/ OM_AU_ERS-560V__DE.pdf [0010]
• http://www.jatgmbh.de/pdf_dt/mech/04_Rotatorische_ Systeme / 9_2 _HRT190_e.pdf [0010]
• http://www.orientalmotor.de/Products/Linear_rotary_actuators/Rotary_actuators/Hollow_ rotary_actuators_dg / [0010]
• DIN EN ISO 10218 [0015]

Claims (14)

Industrial Camera System Type 1 ( 2.1 ) with own 1-2 CNC positioning drives for an integrated swivel mirror or base is equipped with an industrial robot ( 11 ) or a CNC-controlled linear or rotary feed coupled to the external machine movements, the camera field of view inside, outside or between complicated spatial structures such as car bodies ( 12 ) and / or to significantly shorten or even enable high-resolution, fast frame acquisition sequences of technical elements such as joints and small edges. Industrial camera system according to claim 1, characterized in that the internal CNC movement axes of the camera system type 1 ( 2.1 ) are additively coupled to the higher-level robot or feed control in such a way that the camera system type 1 ( 2.1 ) works with its internal CNC motion axes either at robot standstill (offline) or during robot motion (online), which preserves the high performance image resolution capabilities and very fast frame sequences. Industrial camera system according to claim 1, characterized in that the internal CNC control system of the camera system type 1 ( 2.1 ) is coupled with the higher-level robot or feed control in such a way that free CNC axis functions from the robot or feed control for the movements of the internal tilt mirrors or sockets in the camera system type 1 ( 2.1 ), which simplifies the programming, simulation and management of the images and their shooting positions and auxiliary light control. Industrial camera system according to claim 1, characterized in that the mechanical and electronic connections between the industrial camera type 1 ( 2.1 ) and the industrial robot ( 11 ) or the CNC-controlled linear or rotary feed at standstill (offline) analog robotic gripper change are decoupled and the industrial camera type 1 ( 2.1 ) operates in one or more consecutive stationary image pickup positions or waits outside in a parked position. Industrial Camera System Type 2 ( 2.2 ) With a gearless, directly driven rotary module for orbital rotation or reversing about the center located workpiece / object that passes axially or is fixed and this is by hand, with robot or conveyor belt loading and unloaded. Industrial camera system according to claim 5, characterized in that said machine inspection, identification or treatment device has the following features: a) base plate ( 6 ) with a mechanical rotary drive, wherein between base plate ( 6 ) and rotational drive no or a transmission is arranged, b) optical module ( 3 ) for inspection or identification operations with orbital motion type 1 or 2 industrial camera ( 2.1 . 2.2 ) whose inclination, height, radius, focus and additional elements can be adjusted as required, c) one or more modular centering and / or fixing modules ( 5.1 ) which are adaptable to dimensions and shape of the workpiece / object to be inspected ( 9 ) and to the loading and unloading principle, d) a housing ( 7 ), e) an operating and control module. Industrial camera system according to claim 5 or 6, characterized in that the housing ( 7 ) is telescopic and the inspection objects can be safely loaded and unloaded manually or mechanically if necessary. Industrial camera system according to one of claims 5 to 7, characterized in that the housing ( 7 ) at least one dimensionally variable ring cover ( 8th ) has for loading and unloading. Industrial camera system according to one of claims 1 to 8, characterized in that the industrial camera system type 2 ( 2.2 ) as an optical sensor is supplemented by other physical and / or chemical sensors eg for leak test gas, sound or magnetism. Industrial camera system according to one of claims 1 to 9, characterized in that the industrial camera type 1 ( 2.1 ) or Type 2 ( 2.1 ) as an optical sensor is complemented by an active module such as colored pencil, inkjet, embossing needle, laser or micro-flame. Industrial Camera System Type 1 ( 2.1 ) or Type 2 ( 2.2 ) according to claim 1 or 5, characterized in that it has a liquid lens for manual, for preprogrammed or for automatically adaptive focus, ie sharpness and field of view adjustment. Industrial camera system according to claim 11, characterized in that with this an additional safety-related use of the controlled focusing of the liquid lens is feasible and its image analysis for the automatic stopping or reducing of mechanical movements or currents by using a wide-angle focusing for a large-scale risk Detection alternating with high-resolution telephoto focusing for detailed detection of surfaces, defects, codes, fonts, edges, foreign objects and the like. Industrial camera system according to claim 11 or 12, characterized in that with this an additional safety-related use of the controlled focusing of the liquid lens and its image analysis as occasionally prescribed second, redundant hazard detection system for mechanical feeds or flows, for robots without shut-off guards or in collaborating Work processes is feasible. Industrial Camera System Type 1 ( 2.1 ) according to claim 1, characterized in that the recording sensor in the industrial camera system with its own 1-2 CNC positioning drives for an integrated swivel mirror or base directly in the invisible spectral range or indirectly with a transmission, ie infrared or polarization filter works for the Recognition of edges, positions, number of parts, surface details, defects and speeds despite poor visibility, eg on workpieces such as rolled, warm beams on roller conveyors, tables or slides.

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