As we all know, dispensing is used for  product sealing, insulation, heat conduction, corrosion resistance , etc., and then it is applied in all kinds of products' production and manufacturing, such as, 3C Consumer Electronics, Automotive New Energy, Photovoltaics, Semiconductor, and so on.

And today, we mainly share "Dispensing Application on Loudspeaker" with you here. For loudspeaker production, voice coil is a very important component. Therefore, dispensing influences the speaker directly. However, it is hard to meet market high requirements of "good quality and enough quantity" for traditional dispensing solutions. And for this kind of market background,  Zmotion Technology develops one "Vision Dispensing Solution". Let's see them in details.

--Traditional Dispensing Solution--

For traditional dispensing solution, it uses labor or small and medium-sized semi-automatic dispensing machines, which means many operations need to be done by manual, like, loading and unloading, even dispensing manually. Obviously, this  "not automated" solution can't do mass production. Especially when products are with different specifications,  a series of extra operations are needed frequently , for example, off the machine, then change the model tool.  In this way, production efficiency is low and the precision also is not high.

--Zmotion Technology Vision Dispensing Solution--

For Zmotion dispensing solution, it is mainly for dispensing of belt line following through  VPLC vision motion controller. Even if it needs filling internal, middle, and external coil of speakers with different specifications, there are  many functions of Zmotion solution that can  make dispensing position more precise . And it can achieve dispensing path planning, then can be used in applications that need mass production, high efficiency, and stability, but no need fixtures.

In addition, this solution can make sure smooth dispensing processing trajectory, and can control dispensing output stably. Because it supports  PSO (position synchronization output),  PWM, speed look-ahead functions. At the same time, it can realize dispensing trajectory of point, line, circle, and arc. For continuous segments, switch on and off dispensing in advance also is valid, including teach by manually, and teach for camera. It can be seen traditional problems can be avoided easily in this Zmotion "vision dispensing solution".

--Main Functions of Main Interfaces--

24DI: connect to sensors (origin, position limit), and switch signals.

12DO: (high-speed OUT) connect to hard trigger IN of industrial camera

EtherCAT:  connect to EtherCAT driver to control other axes

6 Pulse Axes:  connect to XYZ pulse driver, encoder, and belt axis

RS232: connect to light source controller

EtherNET: 1000M ethernet, connect to area matrix camera that supports Gige protocol to achieve vision positioning and correction.

--Machine Vision--

For machine vision, this solution uses  "template matching" function, that is, recognizing motion objects that are on the belt line and in shooting view. Before this, it needs to preset features, like, shape, size, Mark point. Then, it can identify motion contour that meets the set requirements, and make it arrive processing position, at this time, dispensing head will automatically dispense them one by one.

--Motion Control--

A. Determine Dispensing Position

It calculates and analyzes the encoder position, also watches running speed on belt line in real-time, then does coordinates offset calculation for adjusting dispensing head position, through this series of operations, dispensing position can also be determined while product is moving.

B. Make Dispensing Uniform

It uses PSO and PWM functions to control dispensing precisely. Because PSO function can control dispensing output in period and with equal space, PWN function can adjust the glue flow, which ensures there is no glue accumulation in corner, namely, dispensing can be stable and even.

C. Synchronize Dispensing Position

System can adjust the dispensing head position continuously through position synchronization follow function, and then it can synchronize product's real-time trajectory position on belt line.

Step 1: Feeding

Put the product on the assembly belt.

Step 2: Vision Shooting

Use camera to take the photo through sensor signal, you could select hard trigger or soft trigger. Another is connected to controller latch IN, then it can real-time watch encoder position on assembly line while shooting.

Step 3: Template Matching & Coordinates Correction & Sorting

Match the templates and correct the coordinates for images that to be shot to confirm the actual processing position, at the same time, sort, and process products according to optimized sequence.

Step 4: Correct Workpiece Position

Do position correction for recognized image, and then get the dispensing processing trajectory.

Step 5: Process Dispensing Mold

When the product arrives, dispensing mold moves from standby position, then down to processing position and dispense preset trajectory after synchronized with belt. Completed, off the dispensing valve, and cancel the follow action.

Step 6: Return & Restart

When dispensing completes, dispensing mole returns to standby position. If there is next product, mold directly adjusts the return path and process it again.

--Difficulties of Traditional Dispensing Solution--

A.  hard to achieve mass production, then hard to realized market needs.

B.  high consumable operating  costs and  long time on tool changing and dispensing parameters matching.

C. hard to achieve online soft manufacturing because hard to integrate semi-automated dispensing machines with current production line.

D.  low integration of hardware and software due to separate development of motion control and vision, then not easy to develop.

E.  low dispensing consistence causes glue can't be processed as specified design, such as, round, dotted line, arc, etc.

--Advantages of Zmotion Vision Dispensing Solution--

A. traditional dispensing technology optimization

support on or off glue in advance, corner deceleration, and hardware comparison output functions to ensure precise spraying, then cut down materials waste and operating cost.

B. cost and space optimization

vision and motion control are combined, which means no need extra IPC, then cost is saved and space is reduced.

C. automation degree improvement

adjust belt speed automatically according to dispensing speed, then realize free dispensing with multi-position.

D. production efficiency promotion

keep moving for belt line while dispensing, which means no need to pause or stop, then enhance whole efficiency.

E. mass production

no need many labors and no need much time, suit to unmanned workshop and application that needs high automation degree.

F. flexibility & easy to install

install equipment easily, and no need complex disassembly and assembly process, which means it can change production line conveniently and easily.

As it was mentioned above, VPLC vision motion controller is used.

--What is VPLC Vision Motion Controller--

VPLC vision motion controller is a kind of EtherCAT vision controller that is based on Linux system , it can run offline, and there are rich vision and motion control functions built in. That is, simplify vision and motion control configuration process in a great extent. In addition, fast data interaction reduces time and cost obviously.

Even if it integrates vision and motion, small space is enough, and easy to install & dismantle. What's more, it can integrate other control components, like, servo driver, sensor, encoder, control valve, etc. In this way, an end to end vision motion control solution can be provided fully.

--VPLC516E Vision Motion Controller--

VPLC516E supports 16-32 axis motion control. There are 16 digital inputs and 16 digital outputs. Among them, 2 are high-speed inputs for latch, 2 high-speed outputs for PWM and PSO. And it is with 4 single-ended pulse outputs, and the speed can reach 500KHz.

--VPLC532E Vision Motion Controller--

VPLC532E supports up to 32-axis motion control. There are 24+6 digital inputs and 12+6 digital outputs. Among them, 4 are high-speed inputs for latch, 4 high-speed outputs for PWM and PSO. And it is with 6 high-speed pulse axes + encoder feedback, and the speed can reach 10M.

Zmotion provides one vision dispensing development and debug software that is easy to use. This software makes visual interface, rich vision, and motion control functions together. It only needs to set basic parameters, that is, build vision dispensing project. Then, project development period can be shortened a lot, and development cost can be reduced.

--Vision Dispensing Software Functions--

A. Full Functions

support dispensing trajectory be point, line, circle, arc, continuous segment, array.

support on and off dispensing in advance.

support manual teach and camera teach...

B. Machine Vision Correction

recognize and dispense, spray automatically through vision correction function when product is put in any position and angle.

C. Simple Interface Operation

easy and convenient to edit and debug.

support teaching and inching in vision image.

That's all, thank you for your reading -- Vision Motion Controller Application on Speaker Following Dispensing

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.

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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...)

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