WO2007121953A1

WO2007121953A1 - Device for automatically applying or producing and monitoring a structure placed on a substrate with a determination of geometric dimensions and corresponding method therefor

Info

Publication number: WO2007121953A1
Application number: PCT/EP2007/003506
Authority: WO
Inventors: Bernhard Gruber
Original assignee: Quiss Gmbh
Priority date: 2006-04-21
Filing date: 2007-04-20
Publication date: 2007-11-01
Also published as: DE102006018558A1; DE102006018558B4

Abstract

The invention relates to a device and/or a method for automatically applying or producing and monitoring a structure placed on a substrate, for example an adhesive bead or welded joint. Said device comprises an application device, an illumination device which is fixed and transported with said application device, at least two cameras for detecting the applied structure, which are fixed and transported with the application device in an offset manner in relation to the illumination device and which lie opposite each other, and an image evaluation unit. The illumination device emits one or more light strips which have, respectively a continuous closed form, and which is/are projected around the application device onto the substrate and the applied structure, and the continuous light strips are detected by the cameras and the image evaluation unit such that the image evaluation unit determines at least one of the following characteristics of the applied structure; the width and/or the height, and/or the volume, and/or the position of the applied structure on the substrate.

Description

Device for automatically applying or generating and monitoring a structure applied to a substrate with determination of geometrical dimensions and a corresponding method therefor

The present invention relates to a device for automatically applying or generating and monitoring a structure applied to a substrate with determination of geometric dimensions of the applied structure and to a corresponding method therefor.

For the geometric determination of an applied structure or adhesive trace, a projected straight laser line has been used so far, which is recorded and checked by a camera. In this case, the laser line is substantially perpendicular to the course of the applied adhesive track and thereby the laser line is geometrically changed accordingly by the profile of the applied adhesive. However, this geometric change of the projected laser line is on the one hand due to the low scattering only partially or qualitatively difficult to detect.

In addition, the laser line is only a few tenths of a millimeter wide, so that even with high timing of the recording frequency of the camera according to the cycle time a certain cross section of the applied adhesive trace is inspected and until the next review of the applied adhesive trace according to the projected laser line a corresponding offset arises.

Furthermore, the sensor or the camera, which is arranged in the direction behind the line optics for the laser line, must be moved accordingly in the known straight laser line projection in order to always make the monitoring of the laser line can. Due to the tracking of the sensor it comes in the known systems to a cable salad when the line optics for the laser line and the sensor mounted behind it must be moved or rotated in accordance with the curve of the adhesive track relative to the robot arm.

Consequently, a continuous monitoring of the adhesive track with high quality by means of a straight laser line, in particular in a curvy course of the adhesive trace only partially possible.

It is therefore the object of the present invention to provide a device for automatically applying or generating and monitoring a structure applied to a substrate, preferably an adhesive bead, adhesive track, adhesive seam, sealing seam, foam profile, continuous profile, geometric profile, in particular triangular profile, or weld seam an improved detection of the geometry and / or the course of the applied structure and to provide a corresponding method for this purpose.

This object is achieved by device technology according to the features of claim 1 and procedurally according to the features of claim 16.

The invention is based on the idea that at least one circumferential light path is projected around the application device during the application of the application structure. The at least one projected circumferential light path makes it possible to monitor the applied structure at an angle of 360 °, irrespective of the travel path of the application device and, for example, an application nozzle, ie the circulating light path allows a complete inspection area around the application device or application nozzle , which can be described as a panoramic view. For this purpose, the at least two cameras detect the changes in the projected circumferential light path and the image evaluation unit connected to the cameras can use this to calculate the geometric dimensions of the applied structure. In particular, the width, the height, the volume and / or the position of the applied structure on the substrate can thus be determined in a simple and exact manner. For monitoring the applied structure, at least two cameras are required to always determine with at least one camera a partial surface of the inspection area or the applied structure, since possibly a partial area of the application nozzle for another camera may be hidden. Therefore, the two cameras are opposite each other and offset at the applicator or applicator nozzle attached. In particular, the circumferential light path strikes the applied structure, wherein the cameras can detect the deformation of the light path from an observation position which has a different angle to the light path, and can determine the deformation of the light path using suitable calculation methods. By advancing the application and monitoring device relative to the substrate or by advancing the substrate relative to the application and monitoring device, the applied structure can be detected three-dimensionally by the online monitoring.

According to a first aspect of the present invention, the device has an application device for applying or producing the applied structure, an illumination device which is mounted on the application device or a support structure of the application device, at least two cameras for optically detecting the applied structure, which face the illumination device offset on the applicator or the support structure of the applicator are mounted and mounted opposite each other, and an image evaluation unit for detecting the applied structure, which is connected to the cameras, the illumination device emits one or more light paths, each having a continuous self-contained shape and wherein the one or more circulating light paths around the applicator are projected onto the substrate and the deposited structure immediately after application or wherein the one or more circulating light paths projected onto the substrate and the applied structure are or are detected by the cameras and the image evaluation unit in online mode immediately after the application of the applied structure in such a way that the image evaluation unit detects the change in image quality projected circumferential light path or Light paths using calculation methods used to determine at least one of the following features of the applied structure: the width of the applied structure, which is determined in particular substantially perpendicular to the center line with respect to the course of the applied structure, and / or the height of the applied structure, and / or the volume of the applied structure, in particular with respect to the applied length of the application structure including the height, the width and the profile or the shape of the applied structure, and / or the position of the applied structure on the substrate.

Thus, according to the invention, for example, an adhesive trace can be applied and monitored online, wherein the adhesive trace can be detected independently of the direction of travel with a 360 ° inspection area around the application nozzle. As a result, the sensor or the cameras no longer need to be tracked, so that twisting or cable clutter between the sensor and the application device is avoided.

Further advantageous embodiments of the invention will become apparent from the dependent claims. Thus, it is advantageous if the application device has an application nozzle, around which a sensor head with the two cameras and the illumination device is mounted, wherein the application nozzle is fixedly or rotatably connected to the sensor head. If the application nozzle is rotatably connected to the sensor head, the cameras mounted laterally offset from the application nozzle on the sensor head can monitor each area of the circulating light path, since at least one of the two cameras can monitor each point of the circulating light path independently of the travel path. Of course, this also applies to an application nozzle fixedly arranged on the sensor head, since there is no relative movement between the cameras and the application nozzle.

Preferably, the two cameras are mounted opposite one another on the application device in such a way that both cameras realize at least part of the applied structure in the intersection region with the peripheral light path (s). or that at least one camera completely covers the applied structure in the intersection region with the peripheral light path (s). As a result, the device according to the invention can monitor the applied structure independently of the travel path of the application device at any time.

According to a preferred embodiment of the invention, the two cameras are mounted laterally on the application nozzle such that the intersection of the circulating light path with the applied structure is respectively monitored by the first and second camera such that the first camera is a side view of the intersection between the circulating light path and the applied structure and the second camera detect the opposite side view of the intersection between the circulating light path and the applied structure.

Another advantage of the invention lies in the fact that the beam path of the cameras is always aligned with the circulating light path, wherein in particular a laterally offset to the cameras mirror is provided such that the angle of incidence of the beam path of the cameras is changed to the orbiting light path. Thus, the applied structure can also be monitored from a more favorable flat angle, wherein the dimension of the device according to the invention is minimized or the cameras have only a small distance to the applicator. As a result, the diameter of the sensor head formed thereby is small, whereby even complex components can be provided with an application structure and monitored in the on-line process, without the sensor head coming into conflict with the substrate or component.

If the illumination device projects the one or more light paths in the form of a substantially circular light ring around the substrate and the applied structure, the determination of the geometric dimensions and the course of the applied structure can be calculated particularly easily by the image evaluation unit. If the substantially circular light ring has a width such that the light ring has a defined inner and outer diameter, in particular the intersections of the edge of the inner diameter and the applied structure and also the intersections of the edge of the outer diameter and the applied structure for monitoring be used. As a result, the geometrical dimensions and the course of the applied structure or adhesive trace can be calculated and recorded more precisely, since the intersections of the inner diameter and the outer diameter can each be used in an image analysis and thus be present twice. This thus results in a higher sampling frequency due to the scanning of the edges of the inner and outer diameters of the light ring. In addition, the scanning of the two edges of the inside and outside diameters increases the redundancy, because in the event that either the edge of the inside diameter or the outside diameter can not be scanned for any reason, the second edge can always be scanned and thus a monitoring of the applied structure or adhesive trace is made possible.

In accordance with a preferred embodiment of the invention, the illumination device transmits, in the form of a cone, an annular, circumferential light path to form a light cone on the substrate. The conical course of the circumferential light path also allows the acquisition of unfavorable in profile job structures, such as spherical profiles in which the base, ie the transition between the job structure and the substrate would not be illuminated in a direct incidence of light. According to a preferred embodiment, the conical shape converges or tapers in the direction of the substrate. This makes it possible for the circumferential light path or the circumferential light ring with a small radius to run around the application nozzle even with a larger dimension of the illumination device. Thus, the applied structure in the immediate vicinity of the application nozzle can be detected by the close-fitting light ring or the tight-fitting light path, so that the applied structure can be monitored immediately after application. A significant advantage is to be seen in that, in particular in the case of a pronounced curvature of the course of the adhesive track or the applied structure, it is always possible to detect each area of the applied structure without interruption in the online method. As a further advantage, a suitable regulation, in particular of the applied quantity or the metered quantity of the application nozzle, can also be achieved if the image evaluation unit calculates a height and / or width and / or a volume of the applied structure which is outside a predetermined reference range.

According to a further embodiment, the light paths or at least one light path are projected by the illumination device substantially in elliptical, polygonal or by lines in circumferentially closed form for detection on the substrate and the applied structure. Here also composite sections of different light lines or light paths can be used.

Furthermore, it is advantageous if the illumination device has a plurality of LED diodes, in particular 10 to 30 LED diodes, by which the circumferential light path is generated on the substrate and on the applied structure and which are operated in particular pulsed. Due to the pulsed operation of the LED diodes, a high-quality image acquisition and image evaluation can be achieved even with a fast feed or high travel. In particular, an LED illumination allows a suitable surface structure for the light path or a circular light ring, which has a suitable homogeneity of the surface. Furthermore, it is advantageous that the pulsed operation of the LED illumination or the flashing of the LEDs relative to extraneous light is relatively insensitive, which does not come from the lighting device and could affect the monitoring. Alternatively, however, laser diodes are also possible as a light source for the illumination device.

When the center or the center of the projected circumferential light path substantially coincides with the application nozzle of the applicator or the longitudinal axis of the Applicable nozzle, a global coordinate system for the cameras over the monitored area of the applied structure can be achieved in a simple manner.

According to a further embodiment, the illumination device is mounted substantially annularly around the application nozzle, wherein outside the annular illumination device, the cameras are mounted diametrically opposite to the application nozzle. As a result, the entire apparatus can be made compact, and at the same time, a high quality of monitoring can be achieved.

In a particularly preferred embodiment of the invention, three or more cameras, in particular six cameras, are mounted concentrically and / or at a constant distance from each other around the application nozzle. When using three or more cameras, in particular six cameras, at least one camera has an optimum viewing angle on the adhesive track or structure applied. In online surveillance, therefore, the camera with the best viewing angle can be activated to optimize the quality of surveillance.

If the longitudinal axes of the cameras are inclined to the longitudinal axis or the beam path of the application nozzle in the viewing direction, wherein in particular the longitudinal axis or the beam path of the cameras intersect the longitudinal axis of the application nozzle substantially in the region of the substrate, then one achieves a defined height resolution, wherein the detected changes of Height levels of the adhesive trace or the adhesive profile are detected by the local deformation of the projected structure.

According to a further preferred embodiment, a calibration device is provided for determining each position of the cameras in the room and for determining the position of the cameras for the illumination device, in particular in the form of a calibration plate, thereby enabling the formation of a global, cross-camera coordinate system with high accuracy. In particular, it is thereby possible that the individual images of the various cameras can be processed and calculated by the image evaluation unit in a common global coordinate system. According to another aspect of the present invention there is provided a method of applying or generating and monitoring a structure deposited on a substrate, in particular for use with the apparatus of claims 1 to 15, the method comprising:

Providing an application device for applying or producing the applied structure, a lighting device which is attached to the application device or a support structure of the applicator, at least two cameras for optically monitoring the applied structure, which offset from the illumination device on the applicator or the support structure of Applicator device are mounted and mounted opposite each other, and an image evaluation unit for detecting the applied structure, which is connected to the cameras,

Emitting one or more light paths, each having an encircling self-contained shape, from the illumination device, wherein the one or more circumferential light paths around the application device are projected or projected onto the substrate and the applied structure immediately after application;

Detecting the projected one or more circumferential light paths immediately after application of the applied structure in online operation by the cameras and the image evaluation unit, wherein the changes of the projected circumferential light path or light paths are used by the image evaluation unit by means of calculation methods, thereby at least one of the following features determine the applied structure of the image evaluation unit:

the width of the applied structure, which is determined in particular substantially perpendicular to the center line with respect to the course of the applied structure, and or

the height of the applied structure,

and or

the volume of the applied structure, in particular with respect to the applied length of the application structure including the height, the width and the profile or the shape of the applied structure,

and or

the position of the deposited structure on the substrate.

According to a preferred embodiment of the method according to the invention, the light-section method with the projected circumferential light path is used for the evaluation of the images of the applied structure. Here, the light path or line of light is guided over the applied structure, wherein the deformation of the light path or line of light from the observation position of the individual cameras which have a different angle to the light path or light line, the curve or the geometry of the applied Structure can be determined.

It is particularly advantageous if the images of the cameras are recorded in a high-frequency and synchronous manner and processed with the image evaluation unit in such a way that the images of the individual cameras are processed substantially simultaneously during the application of the applied structure, wherein in particular only a part of the image is taken and is transmitted. As a result, the applied structure can be monitored in online mode such that the applied structure can be checked at a very small distance (for example every 1 to 3 mm) with regard to the shape and the profile, for example with a recording frequency of 200 Hz. According to a preferred embodiment, the applied structure is regulated according to a predetermined application amount of the applied structure, depending on the width and / or the height and / or the volume of the applied structure which has been determined by the image evaluation unit during the application. This allows the adaptation of the applied structure to a predetermined profile or a predetermined order quantity.

A further advantage is the fact that one or more light paths in the form of a substantially circular light ring are projected or projected onto the substrate and the applied structure, in particular by forming one or more light cones from the illumination device. If one or more light cones are projected onto the substrate, it is advantageous if the substantially circular light ring in each case has a width such that the light ring has a defined inner and outer diameter. Here, the intersections of the edge of the inner diameter and the applied structure as well as the intersections of the edge of the outer diameter with the applied structure are used for the monitoring, so that this leads to a doubling of the examination of the applied structure by the evaluation of the inner and outer diameter.

According to a further preferred embodiment of the invention, the intersection region between the circulating path and the applied structure is detected by three or more cameras, in particular six cameras, which are arranged concentrically or at a constant distance from each other around the application gland, wherein in each case one segment of the circulating path of is monitored by a camera, and wherein the orbiting path is detected by the cameras at an angle of 360 ° around the applicator to form a global coordinate system. When the course and / or height of the graft is controlled with respect to the substrate according to a predetermined tolerance, using an edge, a recess or the like of the substrate for controlling the gland in all directions, the application and monitoring of the applied Structure are made in accordance with a geometric shape or specification of the substrate or a component. This can be done, for example, by the seam tracking of two components, wherein on or at the seam of the two components, for example, an adhesive trace or a sealing seam can be applied and monitored.

Furthermore, it is advantageous if the teaching of the course and / or the profile of the applied structure is carried out by means of a physical reference structure, a CAD drawing or a corresponding electronic file which comprises the applied structure in relation to the substrate. It is preferably determined by means of the CAD drawing or the corresponding file which of the cameras is used in each case for detecting the applied structure in accordance with the course, so that the training of a reference structure can be carried out particularly simply and also the monitoring can be carried out in a simplified form.

According to the method according to the invention, a calibration is carried out for the determination of each position of the individual cameras in the room and for the determination of the position of the cameras for the illumination device, wherein in particular the calibration for forming a global camera-overlapping coordinate system is carried out in particular by means of a calibration plate. Due to the global coordinate system, the image evaluation unit can process the images of the individual cameras in a particularly simple manner, it being sufficient for at least one camera to detect the applied structure. Preferably, the calibration is carried out together with the training course for the course and / or the geometry and / or the profile of the applied structure. Thus, calibration and teaching of the reference structure prior to application and over Afterwards, a large number of components can be provided with a job structure and at the same time monitored online.

Further advantageous embodiments are the subject of the dependent claims of the method according to the invention.

With reference to the following drawings, advantageous embodiments of the invention are shown purely by way of example.

Figure 1 shows the device according to the invention when applying and monitoring an adhesive trace in side view;

Figure 2 shows a perspective view of the device according to the invention of Figure 1;

Figure 3 is a bottom plan view of the device of Figures 1 and 2 according to the invention;

Figure 4 is a schematic view of the device of Figure 1 according to the invention;

Figure 5 shows the schematic structure of a device according to the invention when applying a trace of adhesive to a substrate;

FIG. 6 shows a section of a light ring of the device according to the invention, which is projected onto a substrate on a triangular profile;

FIG. 7 shows a perspective view of the light ring of FIG. 6 projected on the triangular profile; Figure 8 shows the application of an adhesive trace and the projected light ring;

Figure 9 shows a triangular profile with a circumferential traverse projected thereon;

FIG. 10 shows a further embodiment of FIG. 9;

Figure 11 is a schematic representation of the monitoring of a triangular profile according to the invention;

Figure 12 is another embodiment of monitoring a triangular profile;

FIG. 13 is another perspective view of FIG. 12;

Figure 14 shows an adhesive trace as an enlarged view;

Figure 15 shows further embodiments of traces of adhesive in cross section;

Figure 16 shows an embodiment of the device according to the invention with folding of the beam path;

FIG. 17 shows a flowchart relating to the method according to the invention;

FIG. 18 shows a representation with regard to the calibration of the device according to the invention;

FIG. 19 shows a further illustration with regard to the calibration of the device according to the invention.

1 shows a device according to the invention for the automatic application and monitoring of an adhesive trace 6 on a substrate or component. provides. The erfϊndungemäße device comprises an applicator 10, which has at its lower end an application gland 12, for example, to apply adhesive on a component. When applying the adhesive projects a lighting device 20, which is constructed for example of a plurality of LED diodes, at least one circumferential light path, preferably a light ring to the application gland 12 on the substrate and the applied adhesive trace. The illumination device 20 is attached to the applicator 10 and thereby travels with the applicator when applying the adhesive, when there is a relative movement between the substrate and the applicator. At least two cameras 31, 32 for optical detection of the adhesive track are in turn attached to the illumination device 20. The cameras 31, 32 are mounted laterally offset from the illumination device and aligned on the projected light ring close to the application gland 12. The cameras 31, 32 are connected to an image evaluation unit, not shown, which records and evaluates the images of the adhesive trace determined by the cameras in online operation, wherein the image evaluation unit uses the change of the projected light ring by means of appropriate calculation methods that from either the width and / or or the height and / or the volume of the adhesive trace can be determined and thus checked.

In the embodiment of Figure 1, the sensor head with the illumination device and the cameras is fixedly connected to the applicator 10, wherein at least one of the two cameras detects the intersection between the light ring and the adhesive trace, as will be explained in more detail below.

In Figure 2, the device according to the invention is shown in perspective. In this view, it is now apparent that preferably six cameras 31 to 36 are arranged concentrically around the application device 10. In such an arrangement of a plurality of cameras, the cutting area between the projected light ring and the adhesive track is detected by at least two cameras, which are preferably located in the circle segment, where the adhesive trace runs during application. if the Adhesive track takes a curved course, so another camera can be activated for evaluation to monitor the course of the adhesive trace. This applies to the entire circumference around the application device 10, depending on the course of the adhesive trace.

In Figure 3, the device of the invention is now shown from below. In the center of the device is the application gland 12, which is surrounded by the illumination device 20 in the form of an LED circular ring projector and attached to the applicator 10. The cameras 31 to 36 are arranged at a uniform distance and concentrically around the application gland 12 and aligned therewith.

Analogous to Figure 3, the structure of the device according to the invention in Figure 4 is shown schematically. It can be seen in particular that the cameras are offset laterally to the annular illumination device.

In the following, the device according to the invention and the method according to the invention will now be explained according to FIG. The schematically illustrated cameras 31 to 36 are mounted together with the illumination device 20 on the applicator 10, as previously shown. The substantially annular illumination device 20 is constructed, in particular, from a multiplicity of LED diodes, for example 20 LED diodes. These LED diodes together project a circumferential light path onto the component and the adhesive track immediately after application through the application gland. It is particularly advantageous in this case if the illumination device projects a tapering cone of light directly around the application gland, whereby a circular light ring 21 is formed on the component. As a result, the light ring 21 can move very close to the application gland in order to also be able to monitor a path-like course of the adhesive trace with small radii. According to FIG. 6, the section area between the light ring 21 and the adhesive track 6 is now shown on the component. In order to evaluate the change in the light ring through the adhesive track 6, the light-section method is used in particular, with corresponding evaluation methods of the image evaluation unit calculating the changes in the height level of the adhesive track or the adhesive profile due to the local deformation of the projected light paths. As shown in FIG. 6, the light ring has an inner diameter 211 and an outer diameter 212, which results in an edge between the light path of the inner diameter 211 and the adhesive trace 6 and the outer diameter 212 and the adhesive profile 6. As a result, the edge of the inner diameter as well as the edge of the outer diameter with the adhesive profile 6 can be used for the calculation of the height or the width and the volume in each evaluation. In the light-section method, the light path 21 is thus guided over the adhesive profile 6, wherein the object curvature can be determined by the image evaluation unit from each observation position of the cameras, which have a different viewing angle from the light path. However, this object curvature or the surface course is determined only exactly at the line position or the edge. By advancing the object or by the relative speed between the applicator and the component, the object or the adhesive profile can be detected in three dimensions. For this purpose, a high image recording frequency is necessary, wherein the inner and outer diameter of the light ring 21 and the resulting two edges, so to speak, doubles the recording frequency for the image evaluation unit.

According to Figure 7, a further perspective is shown, which represents the deformation of the light ring by the adhesive profile 6 and can be detected by the cameras from corresponding angles.

FIG. 8 shows a section showing the application gland 12, which applies an adhesive profile 6 to a substrate or component 11. As can be seen from the course of the adhesive profile, the application device 10 travels in the image plane top right. Due to the light cone, which is projected onto the substrate 11 and the adhesive track 6 in the form of the light ring 21, the adhesive profile 6 can be detected immediately after application by the cameras with the aid of the deformation of the light ring 21.

As an alternative to the light ring 9, for example, a circumferential self-contained polygon 22 are shown in Figure 9, which is composed of a plurality of straight lines of light. In this case, the adhesive profile 6 can also be detected in the region of an intersection of two straight lines. However, as shown in Fig. 10, the adhesive profile can be detected even without intersecting two straight lines or other lines with respect to the height. It is particularly advantageous that, due to the resulting circulating light paths, the sensor or the cameras and also the illumination device do not have to be rotated.

As an alternative not shown, it is of course also possible to monitor a plurality of light rings or a plurality of concentrically circulating, self-contained light paths for determining the profile or the course of an applied structure or adhesive trace.

FIG. 11 shows how, for example, a substantially triangular adhesive profile 6 is detected by two cameras 31, 32. For example, a camera can detect the one side half of the adhesive profile 6 and the other camera the corresponding other side of the adhesive profile 6 for the detection at a pick-up point, which is particularly advantageous in geometrically complex shapes. As shown in FIG. 11, the cameras 31, 32 detect the point of intersection between the light ring (not shown in FIG. 11) and the adhesive trace 6 at successive points, depending on the recording frequency, at correspondingly short intervals. At a high recording frequency of about 200 Hz, the adhesive profile 6 can be checked at small intervals of a few millimeters. According to Figure 12, an embodiment is shown schematically, wherein analogous to Figure 11, three cameras 31 to 33 can check the adhesive profile 6 in the online process simultaneously. The parallel evaluation of the three cameras 31 to 33 is shown in FIG. 13, wherein the adhesive profile 6 is detected and checked at short intervals. Figure 14 shows the exemplary adhesive profile 6 as an enlarged view, wherein the tip 9 of the adhesive track 6 and the foot points 7 and 8 are shown. Due to the convex shape of the adhesive track 6, the foot points 7, 8 would not be visible at the same time with only one camera, but this can be overcome by monitoring with two or more cameras.

Further embodiments of traces of adhesive are shown in FIG. 15, wherein the adhesive tracks 61 and 62 are deformed with respect to an idealized triangular profile. Furthermore, such deformations can only be detected by at least two cameras with the aid of the projected-on light ring.

FIG. 16 schematically shows only one camera 31 and the application gland 12 of the device according to the invention in order to explain the folding of the beam path of a camera. To this end, offset relative to the camera 31 and the application gland 12, a mirror 40 is provided, which is also fixedly attached to the applicator 10 so that it can always be moved with the corresponding camera. As a result of the folding of the beam path, it can be seen from FIG. 16 that the angle at which the camera looks at the area of the substrate 11 around the application gland 12 becomes shallower. This is advantageous for the evaluation of the cutting area between the light ring and an applied adhesive trace, without increasing the distance of the camera from the application gland 12.

According to FIG. 17, it is shown how, for example, the image evaluation unit is provided and the entire check is carried out. Initially, a teach-in run is made from a reference structure, whereby the image sequence of the reference structure is used for the parameterization. Alternatively, the teaching of the course and / or the profile of the adhesive track by means of a CAD drawing or a corresponding electronic file which has information regarding the adhesive trace in relation to the component. During an inspection run, the applied structure to be checked is then compared with the course of the reference structure according to the illustrated scheme, and the resulting result of the check is output. The image recording of the individual cameras can be made high-frequency and synchronous. In order to achieve a high image recording frequency with comparatively low data transmission rates, only a strip of the images of the cameras is recorded and transmitted. With regard to the online monitoring during application with high-frequency evaluation, reference is also made to WO 2005/063406 of the applicant.

Furthermore, according to FIGS. 18 and 19, the calibration for the device according to the invention and for the method according to the invention will be explained. The calibration of the cameras with the illumination device establishes a logical and physical connection between the individual cameras.

Calibration is performed in three stages, with Phase 1 determining the position of each of the individual cameras in the room. Then in phase 2, the determination of the position of the camera is made to the illumination device. In principle, the two calibrations of phase 1 and 2 are already sufficient to perform three-dimensional measurements.

However, it is only through the calibration that measurements in a global and cross-camera coordinate system are possible. In contrast, conventionally, a coordinate system is made with respect to a camera image.

In the third phase, the calibration is adapted to the individual geometry and surface of the component to be tested and the verification of the calibration parameters. This third phase can be integrated into the teach-in or teach-in run. Usually, this third phase will be carried out as soon as the Sensor, which includes the cameras and the lighting device is mounted on the applicator.

According to FIG. 18, the first phase of the calibration is explained in more detail. Here, the distance and the geometric arrangement of the dot marks on the calibration plate 50 are known to each other. Furthermore, the location of the calibration plate is known. Likewise, the size of the dot marks is known, which, however, can be designed differently. Alternatively, crosses, circles, Liπiengitter or similar structures can be used. Particularly advantageous are the point markings shown, which represent filled small circular markings.

By means of the arrangement of FIG. 18, the position of the camera and thus of the CCD chip for the calibration plate 50 is determined. Thus, the location of the cameras in space is determined when the location of the calibration plate 50 is predetermined or known in the room. Furthermore, this determines the position of the individual cameras relative to one another, and finally the inclination of the individual cameras relative to one another is determined or determined.

This first phase calibrates to a universally valid world coordinate system. Here, the plane calibration plate 50 is firmly connected to a calibration. The holder can be designed as a tube and has a locking nose or index marking in order to insert the sensor in a clearly defined position in a repeatable manner.

In phase 2, the position of the cameras for lighting or lighting device is determined. This is shown by way of example according to FIG. 19. For this purpose, the pattern or the shape of the circulating light path, which projects the illumination device onto the calibration plate, is viewed with all the cameras and each camera takes an image of this scene. FIG. 19 shows the light cone which is projected by the illumination device in the form of a light ring 21 onto the calibration plate. This light ring 21 will now be used by each camera depending on its position. seen distorted in the room. The cameras 31 and 32 see the light ring 21 as a compressed in one direction ellipse. Alternatively, if a projected square were seen by the individual cameras, each camera would detect a corresponding trapezium due to the lateral offset. However, the image evaluation unit which calculates the calibration values knows the ideal shape of the illustrated light ring 21. Therefore, it is possible for the image evaluation unit to calculate the position of the individual cameras based on the type of distortion of the pattern or light ring 21 on the calibration plate. For calibration, the eccentricity of the ellipse and the ratio of the two major axes of the ellipse are used in the present case.

In this second phase is now calibrated to the sensor coordinate system, the origin of which represents, for example, the center of the light ring 21 projected onto the calibration plate. Alternatively, however, the tip of the resulting cone can also be used as the origin of the coordinates if the rays of illumination are extended beyond the calibration plate. However, in both phases it is assumed that the illumination with its symmetry axis is perpendicular to the calibration plane. If a deformation of the ideal circular shape is detected, then the type, size or nature of the deformation can be used to deduce the three-dimensional shape of the light section.

As already mentioned, the single-arm run can also coincide with the third phase of the calibration. Thus, the training course is also used to determine the camera assignment, ie which cameras perform the 3D evaluation during the test run. In general, the nozzle of the applicator will not be aligned exactly perpendicular to the substrate but will be slightly skewed. With the aid of the calibration procedure in the second phase and the evaluation based thereon, it can be calculated in which angle to the component the nozzle is aligned. This essentially forms the third phase of the calibration, which generates a data record which determines and describes the geometry of the substrate surface. The data is then available to calculate the 3D data posed. When teaching in particular a history list is deposited, which contains the data for the travel and the travel time of the applicator, which also data on the direction and the 3D cross-section of the adhesive track are provided.

During the test run, the applied adhesive trace is now tested in relatively small sections. In this case, short sections are detected three-dimensionally with a high recording frequency, for example every 1 to 3 mm. Subsequently, the subsections can be combined by means of the image evaluation unit to the entire applied adhesive trace.

In the following, not further embodiments of the invention will be explained.

The device according to the invention and the method according to the invention can be used in various joining methods, such as the application of adhesive seams or sealing seams, the positionally accurate application of foams, soldering and welding. Welding may involve arc welding and laser welding, whereby, on the one hand, the weld is checked and, on the other hand, a guide may also be provided based on the edge of the components to be welded. Furthermore, endless profiles with a corresponding 3D shape can be generated and checked. Such endless profiles can be produced as a strand or by plastic extrusion.

According to the method according to the invention, volume sections can be determined via the 3D profile of the adhesive in order to readjust the adhesive quantity in real time during the test run. Alternatively, the applied total volume can be measured over several inspection runs and the order quantity can be readjusted or controlled on the basis of these values. Furthermore, a compressible material or a foam can be generated and monitored, which is constructed from a fluid or enclosed gas bubbles, which only after the order reach the actual volume. As a result, the volume of the order structure can be measured or checked only a short time after the order.

In addition, the 3D data determined according to the invention can be fed into a 3D CAD system and further processed in the desired manner. Such 3D data can be determined by the device according to the invention due to the all-round view of the cameras and the illumination in the form of a circulating path.

For evaluating the data, the device according to the invention can use, for example, dual processor cores of physically existing or even virtual multicore systems, wherein during the test runs an evaluation is carried out on the basis of stored or actual images with the same or modified test parameters in order to determine the effects of changes in the test parameters or to capture and evaluate changes in the environment.

According to a further embodiment of the invention, the height of the adhesive nozzle can be readjusted to the sheet during the application, as in addition to the information about the 3D structure to be tested and information about the environment of the working area of the applicator device present. As a result of the arrangement of the cameras and the illumination, in principle the entire working area of the tool can be monitored three-dimensionally, so that, for example, a sheet edge or workpiece edge can be determined in the advance direction and the tool can be readjusted in each spatial direction during the application process and the test.

Another application is in the case of "assembly in motion." Here, as the test object or conveyor moves, the environment must be continually monitored to guide the tool with high precision during an assembly process, such as bolting with a Screw robot while the component moves on the conveyor belt, or even the application of sealants, while the body shell moves on.

According to a further embodiment, the present invention can also be used for the fully automatic repair of adhesive beads. Since the missing volume is measured according to the invention by the 3D detection, the exact volume of the adhesive in the bead can be refilled.

To check the volume flow, a corresponding measuring device may be provided in the application device. The measurement is not carried out by optical means, but with the aid of the image processing system according to the invention it is possible to compare the volume flow or the volume measured by optical means with the volume measured by the applicator and if necessary to draw corresponding conclusions.

Thus, an apparatus and a method for automatically applying or generating and monitoring a / on a substrate applied structure is described, preferably a bead of adhesive, adhesive trace, adhesive seam, sealing seam, foam profile, continuous profile, geometric profile, in particular triangular profile or weld. For this purpose, an application device for producing or applying the application structure, an illumination device which is attached to the application device or a support structure of the applicator, at least two cameras for optically detecting the applied structure, which is offset from the illumination device at the applicator or the support structure of the applicator are mounted and mounted opposite each other, and an image evaluation unit for detecting the applied structure, which is connected to the cameras. In this case, the illumination device emits one or more light paths, each of which has an encircling, self-contained shape, and wherein the one or more circulating light paths around the application device touch the substrate and the light path. and the structure projected immediately after the application is or are projected, and wherein the one or more circumferential light paths projected onto the substrate and the applied structure are detected by the cameras and the image evaluation unit in such an on-line operation immediately after application of the applied structure in that the image evaluation unit uses the change of the projected circumferential light path or light paths by means of calculation methods to determine at least one of the following features of the applied structure: the width of the applied structure, which is determined in particular substantially perpendicular to the center line with respect to the course of the applied structure, and / or the height of the applied structure, and / or the volume of the applied structure, in particular with respect to the applied length of the job structure including the height, the width and the profile or the shape of the aufg provided structure, and / or the position of the deposited structure on the substrate.

Claims

claims

1. A device for automatically applying or generating and monitoring a structure applied to a substrate, preferably a / a bead of adhesive, adhesive trace, adhesive seam, sealing seam, foam profile, continuous profile, geometric profile, in particular triangular profile, or weld, which

an application device for applying or producing the applied structure,

an illumination device, which is attached to the application device or a support structure of the application device,

at least two cameras for optically detecting the applied structure, which are mounted opposite the illumination device at the applicator device or the support structure of the applicator device and are mounted opposite one another,

and an image evaluation unit for recognizing the applied structure, which is connected to the cameras,

wherein the illumination device emits one or more light paths, each having an encircling self-contained shape, and wherein the one or more circumferential light paths around the application device are projected onto the substrate and the applied structure immediately after application,

and wherein the one or more circulating light paths projected onto the substrate and the applied structure are processed on-line by the cameras and the image display immediately after the application of the applied structure. unit is detected such that the image evaluation unit uses the change of the projected circumferential light path or light paths by means of calculation methods in order to determine at least one of the following features of the applied structure:

the width of the applied structure, which is determined in particular substantially perpendicular to the center line with respect to the course of the applied structure,

and or

the height of the applied structure,

and or

the position of the deposited structure on the substrate.

2. Device according to claim 1, characterized in that the application device has an application nozzle, around which a sensor head with the two cameras and the illumination device is mounted, wherein the application nozzle is fixedly or rotatably connected to the sensor head.

3. Apparatus according to claim 1 or 2, characterized in that the two cameras are mounted opposite each other to the applicator, that both cameras capture at least part of the applied structure in the intersection with the or the orbiting light paths or that at least one camera applied Structure completely captured in the intersection with the orbiting light paths.

4. Device according to one of claims 1 to 3, characterized in that the two cameras are mounted laterally on the application nozzle that the intersection of the circumferential light path is monitored with the applied structure each of the first and second camera such that the first Camera detects a side view of the intersection region between the circumferential light path and the applied structure and the second camera detects the opposite side view of the intersection region between the circumferential light path and the applied structure.

5. Device according to one of claims 1 to 4, characterized in that the beam path of the cameras is always aligned with the circumferential light path, wherein in particular a laterally offset from the cameras mirror is provided such that the angle of incidence of the beam path of the cameras on the rotating Light path is changed.

6. Device according to one of claims 1 to 5, characterized in that the illumination device projects the one or more light paths in the form of a substantially circular light ring on the substrate and the applied structure.

7. The device according to claim 5, characterized in that the substantially circular light ring has a width such that the light ring has a defined inner and outer diameter, wherein the intersections of the edge of the inner diameter and the applied structure and also the intersections of the edge of Outside diameter and the applied structure can be used for monitoring.

8. Device according to one of claims 5 or 6, characterized in that the illumination device emits a cone-shaped circularly circulating light path to form a light cone on the substrate, wherein the conical shape converges in particular in the direction of the substrate.

9. Device according to one of claims 1 to 5, characterized in that the one or more light paths are projected by the illumination device substantially in elliptical, polygonal or by lines in circumferentially closed form for detection on the substrate and the applied structure.

10. Device according to one of the preceding claims, characterized in that the illumination device has a plurality of LED diodes, in particular ten to thirty LED diodes, by which the circumferential light path on the substrate and the applied structure is generated and which in particular pulsed operate.

11. Device according to one of claims 1 to 10, characterized in that the center or the center of the projected circumferential light path substantially coincides with an application nozzle of the applicator.

12. Device according to one of claims 1 to 11, characterized in that the illumination device is mounted around the applicator nozzle substantially annular, and wherein outside the annular illumination device, the cameras are mounted diametrically opposite to the application nozzle.

13. Device according to one of claims 1 to 12, characterized in that three or more cameras, in particular six cameras, are mounted concentrically and / or at a constant distance from one another around the application nozzle.

14. The device according to at least one of the preceding claims, characterized in that the longitudinal axes or the beam path of the cameras are inclined to the longitudinal axis of the application nozzle in the viewing direction, in particular the longitudinal axes or the beam path of the cameras intersect the longitudinal axis of the application nozzle substantially in the region of the substrate.

15. Device according to one of the preceding claims 1 to 14, characterized in that a calibration device is provided for the determination of each position of the cameras in the room and for determining the position of the cameras for illuminating means, in particular in the form of a calibration plate.

16. A method for applying or generating and monitoring a structure applied to a substrate, preferably a / a bead of adhesive, adhesive, adhesive, sealing seam, foam profile, continuous profile, geometric profile, in particular triangular profile, or weld, in particular for use for the device according to the claims 1 to 15, which has the following steps:

Emitting one or more light paths, each having an encircling self-contained shape, from the illumination device, wherein the one or more circumferential light paths around the application device are projected or projected onto the substrate and the applied structure immediately after application; Detecting the projected one or more circumferential light paths immediately after application of the applied structure in online operation by the cameras and the image evaluation unit, wherein the changes of the projected circumferential light path or light paths are used by the image evaluation unit by means of calculation methods, thereby at least one of the following features determine the applied structure of the image evaluation unit:

and or

the height of the applied structure,

and or

the position of the deposited structure on the substrate.

17. The method according to claim 16, characterized in that the light section method with the projected circumferential light path is used for the evaluation of the images of the applied structure.

18. The method according to claim 16 or 17, characterized in that the images of the cameras recorded high-frequency and synchronous and processed with the image evaluation unit such that the images of the individual cameras during the application of the applied structure are processed substantially simultaneously, in particular, in each case only one strip of the image is taken and transmitted.

19. The method according to any one of claims 16 to 18, characterized in that the applied structure in dependence on the width and / or the height and / or the volume of the applied structure, which has been determined by the image evaluation unit during the application, according to a prescribed order quantity of the applied structure is regulated.

20. The method according to any one of claims 16 to 19, characterized in that the cutting area of the circumferential light path with the applied structure is in each case monitored by the cameras such that a first camera a side view of the intersection between the circulating light path and the applied structure and a second camera detects the opposite side view of the intersection between the circumferential light path and the applied structure.

21. The method according to any one of the preceding claims 16 to 20, characterized in that the one or more light paths are projected in the form of a substantially circular light ring from the illumination device to the substrate and the applied structure or projected.

22. The method according to claim 21, characterized in that the substantially circular light ring has a width such that the light ring has a defined inner and outer diameter, wherein the intersections of the edge of the inner diameter and the applied structure and also the intersections of the edge of Outside diameter and the applied structure can be used for monitoring.

23. The method according to any one of claims 16 to 21, characterized in that the one or more light paths of the illumination device is projected or projected substantially in elliptical, polygonal or by lines circumferentially closed form for detection on the substrate and the applied structure.

24. The method according to any one of the preceding claims 16 to 23, characterized in that the cutting area between the revolving web and the applied structure of three or more cameras, in particular six cameras is detected, which concentrically and / or at a constant distance from each other to the application nozzle each one segment of the circulating light path is monitored by a camera, and wherein the circulating path is detected by the cameras at an angle of 360 ° around the application device to form a global coordinate system.

25. The method according to any one of the preceding claims 16 to 24, characterized in that the course and / or the height of the application nozzle relative to the substrate is controlled according to a predetermined tolerance range, for which purpose an edge, recess or the like of the substrate for the regulation of the application nozzle is used in all spatial directions.

26. The method according to any one of the preceding claims 16 to 25, characterized in that the teaching of the course and / or the profile of the applied structure by means of a physical reference structure, a CAD drawing or a corresponding electronic file is made, which the applied structure in Relation to the substrate comprises.

27. The method according to claim 26, characterized in that it is determined by means of the CAD drawing or the corresponding file which of the plurality of cameras is used for the detection of the applied structure according to the course in each case.

28. The method according to any one of the preceding claims 16 to 27, characterized in that a calibration for the determination of each position of the individual cameras in the room and for the determination of the position of the cameras is made to the illumination device, in particular the calibration to form a global cross-camera Coordinate system is carried out in particular by means of a calibration plate.

29. The method according to claim 28, characterized in that the calibration is carried out together with the training course for the course and / or the geometry and / or the profile of the applied structure.