Application of six-side appearance detection and high-speed vision screening can be achieved by XPCIE1028 super-speed real-time motion control card and specified sifting debug software provided by Zmotion, in this way, 15000 + pcs / min IO trigger detection speed can be realized. Specifically, simple parameters setting matches with image acquisition hardware and vision processing software to reach full automatic CCD visual screening rapidly.
When XPCIE1028 motion control card is used with MotionRT7 real-time kernel, there is the multi-core parallel operation ability, which means it can process automatic equipment's core task of motion control and machine vision effectively, and achieve high-speed data interaction between vision and motion control. Then, in six-side appearance detection, efficiency and precision are improved, also CCD visual screening high-speed requirement is met.
XPCIE1028 and MotionRT7 can be applied widely, and they are mainly used in camera parts, lithium battery parts, magnetic materials, electronic components, plastic rubber products, screws and nuts, precision hardware and other fields.
Let's see what the six-side appearance visual detection is.
XPCIE1028 motion control card is a kind of PCI Express@R bus motion control card that is developed by Zmotion for high-speed vision filter.
XPCIE1028 can control multiple step motors or digital servo motors, including multiple cameras and blowing port. In addition, it supports position latch, multi-dimensional high-speed hardware position comparison output PSO, synchronous follow, precise trigger and IO control, etc.
multiple hardware position comparison trigger efficiency can reach 15000 + pcs / min
standard PCIe interface for data interaction, higher velocity.
12 inputs (8 high-speed) and 16 high-speed outputs.
1-16 are high-speed outputs that can allocate cameras and blow ports freely.
there are specialized pulse outputs and encoder inputs.
developed by several kinds of host computer programming languages.
--how the six-side appearance vision detection solution is--
Firstly, materials are sorted automatically and output through vibration disk to high transparent glass turntable that rotates in constant speed, then fiber optic sensor feels workpiece in the entry position, and high-speed latch input port of XPCIE1028 records the incoming position, at the same time, it calculates the position trigger nodes of detection cameras and unloading mechanism where the material passed, then sends the command to trigger detection camera to take the picture at corresponding position, also actively reports the trigger times and results. Finally, IPC counts materials' states, and it sends out data according to this kind of state, then motion control card will blow materials into corresponding unloading box according to automatic sorting data and command.
Machine vision detection system uses CCD industrial cameras to convert the detected target into image signal, and sends it to specialized image processing system. That is, pixel distribution, lightness, color and other information are converted to digital information. Then, image processing system do all kinds of operations for these signals to extract target's features, such as, square, number, position, length, etc., and then generates output results according to preset tolerance range and other conditions to achieve auto-screening, like, size, angle, number, qualified/unqualified, with/without, etc.
--how motion control is--
Compare to traditional PLC + HMI solution, this six-side appearance visual detection system based on motion controller / motion control card is more integrated, the response is faster and efficiency is higher. When glass turntable is moving at high-speed, system can photo, light and image process instantly through visual fly-shooting, then it can ensure the detection precision, at the same time, detection and sorting production performance are improved.
XPCIE1028 motion control card controls servo motor through specialized pulse + encoder feedback axis interfaces to achieve constant speed rotation for turntable and to real-time record encoder feedback position (MPOS).
XPCIE1028 motion control's high-speed input connects to fiber optic sensor to sense and record materials' position.
XPCIE1028 motion control's high-speed outputs can connect to 1-12 cameras to do visual fly-shooting, then to detect materials are qualified or not.
XPCIE1028 motion control's high-speed outputs also can connect to 1-8 blowing equipment, then to sort detected results in time.
--how vision system is--
It is composed by camera, lens, light source, light source's controller and image processing system. Different motion speed requires specified technologies for camera shooting response time, exposure time, lens aperture, pixel, light source, etc. That is, only when all conditions meet current project motion speed, visual system can complete each item's detection tasks effectively, including front light detection, bottom light detection, right light detection, left light detection, back light detection, top light detection, etc.
(1) Solution Hardware Configuration
(2) Solution Action Process
--loading materials--
According to materials types, select corresponding vibration disk to transfer each type materials to high transparent glass turntable. And the turntable rotates at one certain constant speed that is set.
--sense materials & record position--
When sensor senses the material, high-speed latch ports based on FPGA will record materials' current position.
--trigger camera to take the photo--
Through the position latched by high-speed latch port, calculate each camera's position. Then, camera is triggered by motion controller internal hardware position comparison output to do visual fly-shooting.
--vision system processing--
To do vision detection, measurement, identification for pictured material's photo, and then transfer "OK", "NG" or the signal to be detected to motion controller.
--blow screening--
According to the result from motion control card feedbacked by vision system, calculate blow port's position through material position latched by sensor. Then, control card inside hardware position comparison output controls the blow port, and do OK, NG or to be detected screening.
(3) Motion Control Debug Tool
--a full set of motion control filtering debug tool | easy to use--
For the application six-side appearance detection device of XPCIE1028, Zmotion technology provides complete specialized debug software, simple parameters configuration with camera and visual processing software can rapidly achieve full-automatic CCD six-side appearance detection visual filtering. It can be seen development period can be shortened and development cost can be reduced.
reserve 1-12 camera output No., each camera can set output, trigger time and other parameters independently.
reserve 1-8 blow output No., each solenoid valve can set output, trigger time and other parameters independently.
sense and screen incoming materials, filter the size.
set motor parameters freely according to different cards.
AI data detection, like, the number of qualified / unqualified, material loose, material wrong-blowing, etc.
watch IO state.
set blowing range and time freely.
data interaction with safety.
(4) Solution & Application Advantages For You
without programming for motion control, easy to set parameters.
automatically filtering for size.
data interaction with safer device operation.
provide specified API function interface for screening machine.
high-speed filtering, multiple hardware position comparison trigger efficiency can reach 15000 + pcs / min.
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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...)
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