Abstract: This article introduces the Cartesian robot produced by the German company Beagle and its main features. On this basis, it mainly introduces several application cases in the nondestructive testing of workpieces.
Keywords: Cartesian coordinate robot CCD camera image processing feature extraction template matching
1. Task description:
In almost all modern mass production processes, the characters, symbols and labels printed on product packaging boxes must be beautifully printed without defects and errors. However, there will be some problems in actual production, such as some characters are missing, some characters are incomplete, and different characters are confused, such as 5 and 6, 6 and 9 are easy to print and mix. The character position is incorrect, the character font is incorrect or inconsistent, etc. To solve the above problems, you must choose an excellent image processing system and perform 100% reliable inspection on these characters and symbols to ensure a 100% pass rate and achieve true "zero defects". The characters and symbols to be recognized can be generated by the following methods: printing, coding, thermal transfer and laser engraving. This increases the difficulty of checking and identifying.
The inspected items can be discharged in a single row on the conveyor belt, or they can be discharged side by side as shown in Figure 1. The robot first stops the conveyor belt and moves the detection head above the first product, and the recognition system starts to automatically detect and recognize the first product. The robot then moves the detection head over the second product, and then the recognition system starts to automatically detect the second product, so that the last product in the row is recognized in sequence. Restart the conveyor belt to move the second row of products directly under the detection system, and start the automatic inspection and identification of the products in the line.
The text examined in Figure 2 is on transparent plastic. The robot first stops the conveyor belt and moves the detection head at a uniform speed. The recognition system automatically detects and recognizes the printed characters and symbols at several specific positions. The plastic restarts for a certain length, the robot moves in reverse, and the detection system starts the automatic inspection and identification of the products in the line.
Second, the system composition
The task here is the inspection of the product in Figure 2. The robot is a single-axis robot from the German company Baigra. Due to its small load and low moving speed, the model used is LM-P404 R-AT5. The effective stroke is selected as 1500 mm according to the task requirements. The driving motor is the stepper motor VRDM 3910 LWB from Begra. The robot control system selects the special industrial control computer TLCC of Bagra Company. TLCC controls TLC611 stepper motor driver through CAN bus. The image processing system uses the inspection system VE4000 OCV / 2 from Vision Experts GmbH of Germany. Figure 2 is a photo of the system in actual use. The following describes the Cartesian robot and detection system in more detail.
2.1 Introduction to Cartesian Robot
The company is one of the most famous robot suppliers in the world. It produces linear motion units / rails, stepper motors, AC servo motors, linear motors and multi-axis CNC systems in various specifications. Based on this, various specifications of linear guides, two-dimensional and three-dimensional standard robots, user-specific robots and production lines can be provided in a short time. These robots can be equipped with welding torches, general grippers or special tools to complete welding, handling, loading and unloading, packaging, palletizing, depalletizing, inspection, flaw detection, sorting, assembly, labeling, spraying, coding, ) A series of work such as spraying. Because all the components such as guide rails, drive motors, reducers and control systems of Begra are produced by ourselves, the overall performance of the robot is more excellent. For more than ten years, all the robots and production lines that have been shipped have been working normally. Deeply loved by new and old users in the industries of packaging machinery, printing machinery, mechatronics, automobiles, food, medicine and cosmetics production.
More than 120 experts and engineering technicians of Baigra have successfully developed and produced linear guides of various specifications, and on this basis, they have cooperated closely with users to develop universal and special robots. Robots and production lines.
One of the application areas is the detection of quality defects in product labels, etc.
In a rectangular coordinate robot, each axis mainly performs linear motion, and the direction of motion is usually perpendicular to each other, so it is called a rectangular coordinate robot. Cartesian robots can be divided into a variety of one-dimensional to multi-dimensional, each dimension is a motion axis, composed of a linear motion unit. A three-dimensional rectangular coordinate robot for painting consists of three linear motion units, and a palletizing robot is usually composed of several one-dimensional, two-dimensional and three-dimensional rectangular coordinate robots according to the application requirements. The main technical data of the Cartesian rectangular coordinate robot is the motion range of 0 to 18 meters; the load is 1 to 180 kilograms; the repeat positioning accuracy is 0.05mm; the speed of each axis can reach up to 5 meters / second.
2.2 Machine Vision System
Machine vision is to make the machine have some functions of human eyes and brain, and automatically do tasks such as shape measurement, print quality defect recognition and product appearance quality recognition. Machine vision systems are usually used in the detection and identification of fully automated, efficient, highly reliable and non-contact, mass production processes. Common vision systems generally include the following parts: light source, lens, CCD camera, frame grabber, image processing software, monitor, communication / input / output unit, etc. There are also many smart cameras with lens, CCD camera, high-speed CPU, memory, commonly used image processing software, communication port and / input and output unit. CCD camera has color camera and black and white camera, this article only introduces CCD black and white camera.
First, the CCD camera converts the captured object into a gray-scale image signal, which is first amplified and then digitized into a digital image. Digital images are stored in a two-dimensional matrix. For example, each digital image of the smart camera VC2028 of Vision Components GmbH is a two-dimensional matrix of 640 * 480. Each element of the matrix is ​​called a pixel, and its value is usually 0 ~ 255. The pixel value 0 ~ 255 corresponds to the darkest and brightest part of the target. Image processing software is to extract the characteristics of the target in the image based on the information such as pixel distribution and brightness change in the image, such as: area, length, number, position, etc., and then compare and match with the stored template, and finally give the result, such as: Angle, offset, number, pass / fail, yes / no, etc.
2.2.1 System hardware configuration
In this article, the CCD camera uses the intelligent camera VC2028 of German Vision Components GmbH. Its configuration is as follows: CCD chip is Sony 1/2 â€640 * 480 dots, 25 frames per second image, memory configuration is 16MB SDRAM, 2MB Flash Eprom, 8bit overlay, CPU is TMS 320 C62XX, speed is 1200MIPS (1200 hundred per second 10,000 commands). VC2028 can transmit position data to PC through its own RS232 port. VC2028 also comes with 4 digital input ports and 4 digital output ports. Choose the corresponding lens according to the field of view and height.
2.2.2 The function of the identification system
The detection system is the E4000OCV / 2 system of German Vision Experts GmbH. It consists of an intelligent CCD camera VC2028 and patent recognition software. It can detect various symbols, such as printed symbols, inkjet symbols, thermal transfer, laser engraving, etc. . You can be 100% guaranteed to find all the following problems: the entire missing characters, some missing characters, some characters are incomplete, confusion between different characters, such as 5 and 6; 6 and 9 are mixed, the character position is wrong, the character font is wrong or Not consistent. The system can recognize a variety of symbols. When the contrast between the symbol to be recognized in the image and the background changes, such as a problem with the lighting system or even a certain regular texture in the image background, it will not affect the normal operation of the system. The system is also very flexible. It can detect only 10 products per minute and 100,000 products per hour.
It can detect 300 characters at the same time, and can detect the symbol set containing 10 fonts at the same time. It can detect up to 100,000 products per hour. Each image can have 400 symbols, and simultaneously detect symbols in 10 different fonts. The detected object can be rotated, real-time dynamic detection in motion, automatic detection data is given, there are self-test and external signal to start the company, the detected symbol can be reduced and enlarged, and the position data of the symbol is given.
No programming experience is required for the operator, and very complex inspection tasks can be set up in minutes. The operator only needs to define the window of the area to be detected with the manual operator, tells the test system all the symbols to be recognized by teaching method and enters several parameters through the operation menu. The operator can fully master the system after a few hours of training.
3. Conclusion:
This article mainly introduces the Cartesian robot of German Beglar company and the E4000O CV / 2 inspection system of German Vision Experts GmbH company. The E4000 OCV / 2 inspection system from Vision Experts GmbH, Germany, is assembled on a single-axis Cartesian robot of Bagra, and has been used successfully by many users for text symbol inspection. The system is very reliable, and the following problems can be found 100%: the entire missed characters, some missed characters, some incomplete characters, confusion between different characters, incorrect character positions, incorrect or inconsistent fonts. This detection system has largely replaced a similar system in the United States in Europe and has become the most reliable system in the European and American markets.
With the rapid development of high-volume fully automated production and many products that need to be 100% tested in many production links, such rectangular robots and image processing systems will have a broader market prospect and development potential!
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