Market Application Background
The XPCIE1028 ultra-high-speed real-time motion control card, combined with dedicated screening machine debugging software provided by positive motion technology, can achieve an IO trigger detection speed of 15,000+ pcs/minute. With simple parameter settings and image acquisition hardware and vision processing software, fully automatic CCD vision screening can be quickly realized.
The XPCIE1028, equipped with the MotionRT7 real-time kernel, possesses multi-core parallel computing capabilities, enabling it to efficiently handle core tasks of automated equipment such as motion control and machine vision. It can solve problems such as slow data interaction speed between vision and motion control in traditional solutions, significantly improving the efficiency and accuracy of six-sided appearance inspection equipment and highly meeting the high-speed requirements of equipment CCD vision screening.
It is applicable to camera components, lithium battery components, magnetic materials, electronic components, plastic and rubber products, screws and nuts, electronic components, precision hardware parts and other fields.
01. Introduction to the XPCIE1028 Ultra-High-Speed Real-Time Motion Control Card
The XPCIE1028 is a PCI Express® bus motion control card developed by Positive Motion Technology specifically for high-speed visual screening equipment. It can control multiple stepper motors or digital servo motors, as well as multiple cameras and air inlets. It features position latching, multi-dimensional high-speed hardware position comparison output (PSO), synchronous following, precise triggering, and I/O control.
Functions of the XPCIE1028 motion control card
● Multi-channel hardware position comparison trigger efficiency can reach 15000+ pcs/min;
●Standard PCIe interface, enabling faster inter-core communication;
● 12 inputs and 16 outputs, including 8 high-speed inputs and 16 high-speed outputs;
●1-16 high-speed output ports, freely assignable to cameras and air outlets;
●Dedicated pulse output and encoder input interface;
●Supports development using multiple host computer programming languages.
02. Application of XPC IIE1028 Motion Control Card in Six-Sided Appearance Inspection Equipment
Six-sided appearance inspection solution based on XPCE1028
Materials are automatically arranged and conveyed to a uniformly rotating, highly transparent glass turntable via a vibratory feeder. Fiber optic sensors detect the workpiece material at the inlet. The high-speed latch input of the XPCIE1028 motion control card records the incoming material position, calculates the trigger nodes of the material passing through multiple detection cameras and the unloading mechanism, and then issues commands to trigger the detection cameras to take pictures at the corresponding positions. The camera trigger statistics and trigger results are actively reported. The industrial control computer finally calculates the material status and issues discharge data based on the status. The control card automatically arranges the materials according to the data and issues commands to blow the materials into the corresponding unloading boxes.
Six-sided visual inspection diagram
Machine vision inspection systems use CCD industrial cameras to convert the targets to be inspected into image signals, which are then transmitted to a dedicated image processing system. Based on pixel distribution and information such as brightness and color, the signals are converted into digital signals. The image processing system performs various operations on these signals to extract the target's features, such as area, quantity, position, and length. Then, based on preset tolerance ranges and other conditions, it generates output results, including dimensions, angles, number, pass/fail status, presence/absence, etc., thereby achieving automatic screening functionality.
Hardware solution 1 for XPCIE1028 six-sided appearance inspection (8 cameras + 8 rows)
Hardware solution 2 for XPCIE1028 six-sided appearance inspection (12 cameras + 4 rows)
Implementation of motion control
The six-sided appearance inspection system based on a motion controller/motion control card is more integrated, faster-responding, and more efficient than the traditional PLC + touch screen solution. Even when the glass turntable is moving rapidly, the system can instantly trigger shooting, illumination, and image processing of the material via visual imaging, thereby ensuring inspection accuracy while also increasing inspection and sorting capacity.
Motion control implementation principle diagram
●The XPCIE1028 motion control card controls the servo motor through a proprietary pulse + encoder feedback axis interface, enabling the turntable to rotate at a constant speed and recording the encoder feedback position in real time;
●The XPCIE1028 motion control card's high-speed input port connects to a fiber optic sensor to sense and record the material's position;
●The XPCIE1028 motion control card's high-speed output port can connect to 1-12 cameras for visual imaging to detect whether materials are qualified or unqualified;
●The high-speed output port of the XPCIE1028 motion control card can connect to 1-8 air blowing devices to promptly process and classify the results of visual inspection.
Implementation of a vision system
It mainly consists of core components such as a camera, lens, light source, light source controller, and image processing system. Depending on the speed of movement, the system has specific technical requirements for camera shooting response time, exposure time, lens aperture, pixels, and light source. Only when all conditions meet the current project's movement speed can the vision system effectively complete various product inspection tasks, including front-illuminated inspection, down-illuminated inspection, right-illuminated inspection, left-illuminated inspection, rear-illuminated inspection, and top-illuminated inspection.
03. Implementation of a solution for six-sided appearance inspection of the XPCIE1028 motion control card.
Solution hardware configuration
System Action Flow
(1) Loading of products to be inspected:
Depending on the type of material, a suitable vibratory feeder is selected to transport various loose parts to a high-transparency glass turntable, where the turntable rotates at a constant speed according to a certain set speed.
(2) Sensing materials and recording their positions:
When the sensor detects material, the high-speed latch port based on FPGA records the current position of the material.
(3) Camera triggers photo capture:
The position of each camera is calculated by the position latched by the high-speed latch port, and the position comparison output of the motion controller's internal hardware triggers the camera to perform visual aerial shooting.
(4) Visual system processing:
It performs visual inspection, measurement, and recognition functions on photographed material images and transmits OK, NG, or pending inspection signals to the motion control card.
(5) Air blowing screening:
Based on the results fed back to the motion control card by the vision system and the material position locked by the sensor, the position of the air blowing port is calculated. The position comparison output of the internal hardware of the motion control card controls the air blowing port to perform OK, NG or pending inspection screening.
04. Motion control and debugging tools for a six-sided appearance inspection automatic sorting machine
A complete and easy-to-use set of motion control screening and debugging tools
For the application of the XPCIE1028 motion control card in six-sided appearance inspection equipment, Zheng Motion Technology provides complete dedicated six-sided appearance inspection debugging software. With just simple parameter settings, combined with camera and vision processing software, fully automatic CCD six-sided appearance inspection and visual screening can be quickly realized, shortening the development cycle and reducing development costs.
● Reserve 1-12 camera output port numbers; each camera can have its output port, trigger time, and other parameters set individually.
● Reserve 1-8 air output port numbers; each solenoid valve can be individually configured with parameters such as output port and trigger time.
●Incoming materials are sensor-based for screening and size filtering;
●Motor parameter settings allow customers to freely configure parameters according to different models;
● Intelligent data detection, counting of qualified parts, unqualified parts, material loss, and material mis-blowing;
●IO status monitoring;
● The blowing range and blowing time can be freely set;
●Heartbeat interaction, a more secure mechanism.
05. Advantages of XPC IIE1028 in High-Speed Visual Screening for Six-Sided Appearance Inspection
●Motion control requires no programming and parameter settings are simple;
●Automatic size filtering reduces batch rejection rate;
●Heartbeat interaction enhances device safety;
●Provides a dedicated API function interface for screening machines;
● High-speed screening, multi-channel hardware position comparison trigger efficiency can reach 15000+ pcs/min.
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