Market Application Background: Dispensing uses different types of adhesives to achieve functions such as sealing, insulation, thermal conductivity, and corrosion resistance in products, and is widely used in the manufacture of various products. In dispensing processing, the reliability and stability of product performance can be ensured by detecting the width of the adhesive, the dispensing position, and the continuity of the adhesive path.
In actual production processes, the precision of dispensing is often affected by various factors such as the physical characteristics of the actuator, environmental factors, and material properties. Occasional dispensing errors, such as glue overflow or breakage, may occur during the dispensing process, affecting the quality of the product. It is necessary to control these parameters by measuring the maximum, minimum, and average width of the glue, thereby reducing the defect rate, preventing defective products from proceeding to the next processing step, reducing unnecessary costs, and improving the company's production efficiency, quality, and economic benefits.
Limitations of traditional adhesive circuit testing methods:
Traditional glue circuit inspection is usually done manually, relying mainly on the operator's subjective judgment and visual inspection. This results in inconsistent inspection results, low efficiency, and difficulty in adapting to high-speed production lines. Furthermore, prolonged labor can cause eye fatigue, increasing the risk of missed or incorrect inspections and affecting the stability of product quality in mass production.
Positive motion technology solutions:
To address the aforementioned industry pain points, Zheng Motion Technology has launched an application solution based on the VPLC7 series machine vision motion control integrated machine. The solution uses RTVision vision processing instructions to detect the glue width, dispensing position, and glue path continuity, effectively improving production efficiency, accuracy, and product quality. It can provide real-time feedback to lower-level mechanisms to reject defective products, achieving complete cycle control of dispensing processing components. It is suitable for glue path detection and control of UV glue containing fluorescent agents and other colored glues.
The VPLC7 series machine vision and motion control all-in-one machine also supports CAD drawing import, speed look-ahead, PSO, PWM and various interpolation functions (linear, circular, continuous trajectory, spatial interpolation), optimizes dispensing path planning and controls the stable output size of glue dots, ensures the smoothness and stability of single/dual station dispensing processing, and further simplifies the development of integrated "vision + motion control" projects in various dispensing processes or manufacturing environments. It is especially suitable for mass production and high-speed, high-precision dispensing processing environments.
01. Solution for dispensing and adhesive path detection using a machine vision motion control integrated machine
Schematic diagram of automated dispensing + vision inspection process
Pain points of traditional adhesive circuit testing solutions
Manual inspection is intensive and prone to fatigue errors.
• It is difficult to achieve real-time monitoring and feedback for large-scale automated production lines.
• Limited detection accuracy makes it difficult to detect minute defects, and high-precision two-dimensional imagers are expensive.
Design of a positive motion adhesive circuit detection solution
·20DI: Connects to origin, limit, and other sensors, as well as switch signals, encoders, etc.
·20DO: High-speed output port for connecting to hard-trigger input of industrial cameras and dispensing valves.
• EtherCAT interface: Connects to the EtherCAT bus driver to control the movement of other axes.
• 4-channel single-ended pulse output: Connects to a pulse driver to control the conveyor belt.
• RS232 communication interface: connected to the light source controller
• Ethernet interface: Gigabit Ethernet port, for connecting area scan cameras supporting the Gigabit protocol to achieve visual positioning and detection applications.
01. Implementation Process of Motion Control and Machine Vision
(1) Motion control
By calculating and analyzing the encoder position and monitoring the product's running speed on the conveyor belt in real time, the system calculates the product's coordinate offset on the conveyor belt. This allows the system to determine the product's position as it moves. Finally, through the position synchronization and following function, the system can continuously adjust the robot's gripping position to synchronize with the real-time trajectory position of the product on the conveyor belt, accurately gripping qualified or unqualified products into the corresponding material box.
(2) Machine vision
Adhesive circuit normal
The adhesive path has issues with glue breakage and uneven glue application.
Since visual positioning has been performed before dispensing, the visual inspection part mainly performs image preprocessing, extracts the outline of the dispensing area of the product, creates a dispensing inspection template, and then generates measurement sub-areas along the glue path based on the outline defect measuring device. Then, parameters such as ideal width, position offset range, width offset range, and detection polarity are set. After that, the corresponding point pairs are measured in each sub-area, and finally, the NG/OK signal is output to the unloading execution mechanism based on the distance between the point pairs.
02. Adhesive Circuit Inspection Process Flow
03. Solution Hardware Configuration
04. Core Application Advantages of the Solution
• Improve the accuracy and efficiency of adhesive circuit inspection and reduce operating costs.
• Provides user-friendly vision-based dispensing development and debugging software to simplify parameter setting and programming processes.
• The software interface (API) is open, facilitating rapid secondary software development, integration, and customization.
• Combining vision and motion control eliminates the need for an additional industrial PC, thus saving costs and reducing installation space.
02. VPLC7 Series Machine Vision and Motion Control Integrated Machine
Providing one-stop machine vision motion control solutions for high-speed, high-precision, special-purpose systems and medium-to-large production lines.
• An EtherCAT bus-based vision motion controller based on the x86 architecture, supporting offline operation, with rich built-in vision and motion control functions, greatly simplifying the configuration process.
• Fast data exchange within the kernel significantly reduces time and cost input, improving project implementation efficiency.
• Easy to install and remove, small footprint, and can be seamlessly integrated with other control unit components (such as servo drives, sensors, etc.).
• Provides integrated vision and motion control solutions with real-time soft controllers/soft PLCs in an all-in-one open IPC form factor.
