Obviously, products are made and developed rapidly towards diversity and precision due to upgrade of consumption. Then, for complex curve trajectory processing, it requires higher precision, including appearance detection, polishing, and dispensing technology control. In this kind of fierce market competition, enterprise must promote technology to meet market's requirements actively.

Here, let's talk about XYR motion control in curve appearance quality detection.

XYR motion control plays an important role in production manufacture. It can be applied in mobile phone, tablet computer, square battery, etc., like, appearance defect detection, polishing, curve dispensing, square battery appearance detection, battery top cover laser welding.

As we all know, in the curve processing process, a series of quality problems may appear, such as, scratches, defects, dirty, etc. Then, nowadays vision defect solutions use several 2D area scan cameras and motion control cards to do position detection. However, the solution structure is complex and it is hard to debug, that is, in the aspects of efficiency, image quality and data interaction speed, it is a challenge to meet requirements. What's more, the cost of copy in bulk for 3D vision detection is high.

Therefore, XYR motion control is used. And Zmotion applies typical XYR structure well.

XYR means (XY+R) joint motion control algorithm, it can achieve that XY motion axes will change with product position and angle in real-time in the axis R rotation process, then it can ensure XY end processing points are consistent with surface position and attitude of processed object all the time, that is, XYR synchronous motion can be realized, and speed in scale production can be reached.

As it is mentioned above, there are many problems in curve detection, then Zmotion develops one curve appearance solution based on VPLC711 XYR motion control and line scan camera.

This solution combines high-precision single turntable XYR joint algorithm with rapid path planning function. And it adjusts XY position in real-time to compensate position offset, then the surface distance from focus of line scan camera to detected sample is consistent, which means XYR synchronized motion is achieved and high-quality image is obtained. Following, it is convenient to detect product's curve in full-side and appearance in plane part, then production efficiency and quality both can be promoted.

Please note:  In the whole detection process:

(1) camera center line always is perpendicular to product surface (camera center line in curve is perpendicular to tangential direction forever).

(2) the distance between camera and product keeps the same, in any position, L1=L2.

VPLC711 machine vision motion controller integrates machine vision function and motion control function in one control platform, so it can reduce the entire cost and enhance interaction velocity at the same time. In addition, you could rapidly build projects that relate to vision and motion control, the whole project development process is simplified.

Then let's see some details of this solution.

video showing

a. 20DI: connect to sensors (origin, position limit), switch signals, etc.

b. 20DO: high-speed outputs connect to line-scan camera for hardware trigger input

c. EtherCAT: connect to EtherCAT bus driver to control XYR motion

d. EtherNET: 1000M interface connects to area-scan camera and line-scan camera with Gige protocol to achieve vision positioning, rotation center confirmation, trajectory correction, curve image continuous acquisition, etc.

--VPLC711 hardware introduction--

VPLC711 vision motion controller integrates vision and motion, which replaces traditional IPC + vision software + motion control , its hardware wiring is more convenient and the cost is lower.

VPLC711 matches with Zmotion motion control real-time kernel MotionRT7, then it supports kernel interaction, and the instruction calling speed is up to us level, and the processing and detection efficiency are improved.

--VPLC711 features--

motion control: 6-64 axes (pulse + EtherCAT bus)

vision: real-time kernel MotionRT7 is built in, the third-party vision software also is valid

IN & OUT: 20 general inputs (10 are high-speed) and 20 high-speed outputs

multi-core parallel operation: process core tasks of automatic equipment in motion control and machine vision effectively

PSO : multi-dimensional position synchronous output PSO, precisely control dispensing and laser energy in the continuous processing process

Open IPC real-time soft controller / soft PLC: integrate motion control + machine vision solution flexibly

(1) Motion Control

When it is detecting curve appearance by XYR, XYR axes drive product to do continuous motion, at the same time, line-scan camera is fixed at the lateral position to take pictures for metal frame.

Above shows the whole detection process: 

it controls image acquisition time space precisely through 2D hardware comparison output PSO, that is, it ensures that graphics can be sampled with equal-space in the curve. Then through multi-axis linkage, achieve dynamic adjustment of the distance between line scan camera and material imaging, and keep the camera perpendicular to the product surface, then images are clear.

(2) Vision Processing

a. use 2D area-scan camera to determine product's rotation center point and correct the position.

b. capture product's image (length, width and 4 curve angle) through line-scan camera.

c. detect appearance defects.

(1) trajectory follow control

High-precision single turntable XYR joint algorithm is used, then in the rotation process, XY axes can follow with processing trajectory rotation position and angle in real-time, that is, the position synchronizes automatically in the X and Y directions, then it can always ensure a consistent vertical angle and distance from the line scan camera or tool to any position on the product to ensure high-quality inspection and processing.

(2) hardware comparison output PSO

2D hardware comparison output PSO function controls line-scan camera to capture image at high-speed and with equal-space, precise synchronization of vision shooting and product motion trajectory can be achieved, and object to be detected also can be shot at constant speed in the arc and corner position. At last, image superposition and distortion can be avoided, then high-quality images can be obtained.

(3) rapid path planning

Rapid path planning is used to determine processing trajectory data, and correct product drawing coordinate system and mechanical coordinate system. In this way, it can be used in applications that needs to change form quickly.

a. support 2D CAD mapping, DXF/PLT/AI formats all can be imported.

b. support length, width, chamfer radius and parameters configuration

Zmotion Solution Advantages:

a. uniform API function interface, all kinds of PC host computer languages are valid.

b. vision and motion are integrated, and the hardware wiring is more convenient, the cost is cheaper.

c. support S curve acceleration / SS curve jerk continuity, the motion control is smoother.

d. use high-precision XYR single rotation table joint algorithm to realize XYR joint motion control easily.

e. support hardware position comparison output PSO function to trigger image acquisition in high-speed and equal-space, and it is also valid in curve applications.

f. use motion control real-time kernel to achieve core interaction, the command calling speed reaches us level, then the processing efficiency is promoted.

That's all, thank you for your reading -- VPLC711 XYR Motion Control Solution | Curve Appearance Detection

For more information, please pay close attention to "Support"  and   "Download" , and there are other platforms about Zmotion - Youtube   &   LinkedIn   &   Twitter    &   Tiktok    &   Facebook,  including technical information (development environment, routine code), product showing, company development, etc.

Hope to meet you, talk with you and be friends with you.  Welcome!

This article is edited by ZMOTION, here, share with you, let's learn together.

ZMOTION: DO THE BEST TO USE MOTION CONTROL.

Note: Copyright belongs to Zmotion Technology, if there is reproduction, please indicate article source. Thank you.

Zmotion Technology focuses on development of motion control technology and general motion control products, it is a national high and new technology enterprise. Due to its concentration and hard work in motion control technology, ZMOTION already become one of the fastest growing industrial motion control companies in China, and is also the rare company who has managed core technologies of motion control and real time industrial control software completely. Here, Zmotion provides motion controller, motion control card, vision motion controller, expansion module and HMI. In addition, there is one program software developed by Zmotion -- ZDevelop. It is a good choice for you to program and compile. And program through upper computer, there is PC manual.

Zmotion Technology provides motion control card, motion controller, vision motion controller, expansion module and HMI. ( more keywords   for Zmotion: EtherCAT motion control card, EtherCAT motion controller, motion control system, vision controller, motion control PLC, robot controller, vision positioning...)

Have a good day, best wishes, see you next time.