Current Dispensing Market Environment:
--What is Dispensing--
Dispensing:
Use different types of adhesives to complete sealing, insulation, thermal conductivity, and corrosion resistance. Then it can be applied in all kinds of products' manufacturing.
In the processing of dispensing, we can detect glue width, dispensing position, and continuity of glue-path to make products be stable and reliable.
--How Dispensing is--
However, in real production process, there is one influence on "dispensing precision" caused by actuator's physical property, environment, and material property, that is, it may appear some errors while dispensing, such as, overflow, breaking, etc. (like below graphic) Then, the whole product quality becomes worse.
At this time, we need to do some measurements, parameters will be "max glue width" , "min glue width" , "average width" , and others. Then, we can obtain one lower defective rate, that is, the cost caused by defects can be saved. Subsequently, enterprise production efficiency, quality, and economic efficiency all can be improved.
--Traditional Dispensing Detection Solution--
In traditional dispensing path detection, labor detection generally is used. Specifically, operators check and judge by naked-eyes and personal experience. Obviously, some problems will be produced, "low detection consistence", "low efficiency", "hard to operate in high-speed production line", even "visual fatigue" due to overtime detection, which means, corresponding "missed detection" and "detection error" risks are increased, and all these problems definitely influence the most important thing of the product, "quality" .
--Zmotion Dispensing Detection Solution--
Zmotion deeply knows above industry situation, developing one dispensing solution based on "VPLC7XX Vision Motion Controller". It supports detecting the width, position, path continuity by "ZVision Vision Processing Commands". And it can real-time give the feedback to lower structure for removing defect products. In this way, effectively promote production efficiency, products' precision, and quality, achieve complete dispensing components period control. Applications could be glue path detection and control for UV glue (include fluorescent agent) and other colored glue.
In addition, VPLC7XX vision motion controller supports CAD mapping, speed look-ahead, PSO, PWM, all kinds of interpolation (linear, circular, continuous, space...), etc. Through these, it can optimize the dispensing path planning and can control stable glue output, then make single/dual dispensing be smooth and stable. Moreover, different dispensing technology processes are simplified, in other words, it integrates "vision control" with "motion control". Specially suit to mass production and high-speed & high-precision dispensing.
Vision Motion Controller in Dispensing Glue-Path Detection
Automatic Dispensing + Vision Detection
--Traditional Glue Path Detection Problems--
Ø errors caused by labor inspection with high strength.
Ø hard to achieve real-time watch & feedback in large-scale automatic production line.
Ø hard to check small defects due to limited precision, and the cost of high-precision 2D imager is high.
--Zmotion Glue Path Detection Solution Optimization--
Ø 20DI: connect to sensors of origin, position limit, and switch signals, encoders, etc.
Ø 20DO: high-speed OUT connects to hard trigger IN of industrial camera and dispensing valve.
Ø EtherCAT: connect to EtherCAT drives for controlling other axes.
Ø 4 Single-Ended Pulse OUT: connect to pulse drives for controlling conveyor belt.
Ø RS232: connect to light source controller.
Ø EtherNET: Gigabit network port, connect to area-scan camera that supports Gige protocol to do vision positioning, vision detection.
(1) How to Control Motion & Vision
A. Motion Control
It can monitor the running speed on the belt by calculating and analyzing the encoder position, that is, do product's coordinate offset (on the belt) calculation, while the product is moving, its specific position can be determined. At last, system can keep adjusting the position to get the material by the robot through "position synchronous follow" function, which means it can synchronize with the real-time trajectory position of the product on the belt, then "OK" or "NG" products can be captured and put in corresponding material disk.
B. Vision Control
OK
NG: Breaking, Uneven...
Because there is on vision positioning before dispensing, vision detection mainly is "image preprocessing" , that is, it extracts the dispensing area outline, and creates dispensing detection template, then it can generate "measurement sub-region" based on "outline defect measurer" along with the dispensing path. Next, set needed parameters (ideal width, position offset range, width offset range, polarity detection, etc.), then measure corresponding point-pair in each sub-region, at last, judge and output NG/OK signal according to point-pair gap distance.
Ø Promote dispensing path detection precision and production efficiency, Reduce operation costs.
Ø Simplify parameter configuration and programming process by Zmotion Vision Dispensing & Debugging Software.
Ø Develop quickly in secondary software by Zmotion open API interfaces, including integration and customization.
Ø Save the cost & Reduce the space because vision and motion control are combined (no need extra IPC).
For High-Speed & High-Precision Applications, Specialized-Machine System, Medium & Large Production Line, etc.
an EtherCAT Vision Motion Controller based on x86:
√ run offline
√ rich motion control and vision control functions -- simplify configuration process a lot
√ high kernel data interaction speed -- reduce time and costs & improve efficiency
√ convenient to install and remove, small space occupied -- integrate with other control components (servo drive, sensor, etc.) without gap
√ vision & motion control solution: open IPC form real-time soft controller / soft PLC integrated vision + motion control
