Market Application Background
Electronic detonators, also known as digital electronic detonators, are electric detonators that use electronic control modules and dedicated detonation equipment to control the detonation process. They are characterized by high safety, high reliability, high precision, detectability, high construction efficiency, and high controllability.
An electronic detonator ignition head, whose ignition powder raw materials are mixed in a certain mass ratio and combined with an adhesive, requires highly precise dosage in dispensing applications. Traditional manual or mechanical filling methods cannot meet the micro-level precision requirements. The vision-based dispensing machine, through upgrades in "precision, intelligence, and flexibility," solves the efficiency and quality problems in traditional production, achieving cost reduction and efficiency improvement in process manufacturing.
Traditional dispensing machine solution:
Traditional dispensing equipment mainly consists of several core components, including a dispensing control module, a motion execution module, a dispensing syringe, and sensors. Its working principle is based on motion path control programmed to preset points, driven by air pressure, thereby achieving precise extrusion of the adhesive and collaboratively completing the precision dispensing operation.
During operation, this equipment often faces process abnormalities such as glue valve dripping, unstable glue dispensing rate, poor glue quantity consistency, and glue interruption during operation, which directly affect product yield and production line efficiency.
Positive motion vision dispensing solution for pharmaceuticals:
In precision dispensing processes, equipment must meet three major technical challenges: high speed and high precision, adaptability to fluid medium characteristics, and complex dispensing paths. This places stringent requirements on the precision of the equipment's mechanical structure, the performance of the electrical control system, and the ease of use of the operating software.
Zheng Motion Technology's vision-based dispensing solution achieves deep integration of machine vision and motion control. This solution boasts multi-axis synchronous control capabilities and offers advantages such as rich interfaces, powerful functionality, and significant cost-effectiveness. Compared to traditional vision-based dispensing solutions, its highly integrated hardware and software configuration eliminates the need for external vision industrial control computers and other equipment, resulting in a smaller size and easier installation.
01. Application of Machine Vision Motion Control Integrated Machine in Vision Dispensing and Pill Dropping Machines
Design of a motion vision-based dispensing and pill-dropping machine solution
1. 24DI: Connects to origin, limit, and other sensors, as well as switch signals, and senses the magnetic positioning signal of the extrusion shaft.
2. 12DO: High-speed output port connected to the hard trigger input of an industrial camera, used for clamping cylinder control.
3-channel and 4-channel local pulse outputs: connected to pulse drivers to control the X, Y, Z axes and the extrusion axis.
4. RS232 communication interface: connected to the light source controller.
5. Ethernet interface: Gigabit Ethernet port, for connecting area scan cameras supporting the Gigabit protocol to achieve visual positioning applications.
Motion control technology implementation
Machine Vision
The main function used is template matching. It visually identifies the ignition head to be dispensed, which can be achieved through pre-set features such as shape, size, and Mark points. Finally, it obtains the position coordinates of the ignition head to be dispensed, so that the product can reach the processing area and the dispensing head can perform dispensing processing on each ignition head.
Motion control
(1) Precise control of adhesive application
By precisely adjusting the opening and closing timing of the dispensing valve and the movement trajectory of the needle, and optimizing parameters such as dispensing delay, dispensing delay, early dispensing, and gun retraction height, the system effectively solves process defects such as stringing and glue piling, ensuring accurate and controllable glue volume and adapting to diverse dispensing needs.
(2) Advanced functions are combined to achieve high-precision control
Dedicated look-ahead function for dispensing: It performs look-ahead processing on the dispensing motion path to achieve smooth optimization of irregular processing paths; in variable speed application scenarios, it performs look-ahead processing on the linear speed to avoid unnecessary acceleration and deceleration and ensure high-speed trajectory operation.
Supports S-shaped acceleration and deceleration: reduces equipment vibration and improves motion smoothness.
Supports PSO function: ensures precise synchronization between the glue dispensing from the spray valve and the movement trajectory of the glue valve.
Visual dispensing and pharmaceutical application process flow
Advantages of the solution
1. Precise dispensing with a motor: Using a motor as the pressure source ensures precise dispensing;
2. No dependence on compressed air source: The switching valve eliminates dependence on a compressed air source;
3. Precise glue dispensing control: Real-time adjustment of glue dispensing volume ensures accurate glue distribution with errors controlled within a minimal range, meeting high-precision dispensing requirements;
4. Reverse motor suction, anti-drip and anti-strain: The motor can reverse to suction back, easily solving the problems of glue dripping and stringing;
5. Visual positioning: The camera can locate the position of the propellant head in real time and automatically generate processing points without the need for additional array programming.
Solution Hardware Configuration
02. Highly Integrated Machine Vision and Motion Control All-in-One Machine VPLC712
The VPLC712 machine vision motion control all-in-one machine vision controller is an EtherCAT bus vision motion controller based on the x86 architecture. It adopts an integrated design, integrating real-time machine vision, motion control, I/O, and monitoring onto a single multi-core controller. This enables multi-task parallel real-time processing of automated equipment tasks. Through a shared memory mechanism, PC hardware resources are configured via MotionRT7 to achieve high-speed intra-core interaction, drive actuators to perform corresponding operations, and complete the overall control of the equipment.
The VPLC series machine vision motion control integrated machine is easy to install and remove, occupies little space, and can be seamlessly integrated with other control unit components (such as servo drives, sensors, encoders, control valves, etc.) to provide a complete end-to-end vision motion control solution.
The VPLC712 machine vision motion control all-in-one machine supports up to 64 axes and has a minimum EtherCAT communication cycle of 250µs. It features 20 digital inputs, 20 digital outputs, and 4 high-speed latch inputs; as well as 2 local differential pulse axes, 2 AD converters, and 2 DA converters.
03. Provides easy-to-use visual dispensing development and debugging software.
Positive Motion Technology continuously deepens and expands the application of the VPLC series vision motion control all-in-one machine in the dispensing industry, providing users with simple and easy-to-use vision dispensing development and debugging software.
The software combines rich vision and motion control functions, and can quickly build vision dispensing project programs with just simple parameter settings. This can significantly shorten the project development cycle, reduce development costs, and meet the different dispensing process requirements of different products.
Suitable for various dispensing applications such as bonding, spraying, sealing, potting, underfilling, dripping, and line/arc/circle dot dispensing.
▌Fully Functional
It supports dispensing trajectory dot, line, circle, arc, continuous line segment, array, pre-opening and closing of dispensing, manual teaching, camera teaching, and dispensing process functions.
▌Machine vision correction
The product can be placed at any position and angle, and the vision system can automatically recognize and complete operations such as dispensing and spraying glue.
User-friendly interface with comprehensive functions
The debugging and programming operations are simple and convenient, and support teaching and jogging motion on visual images.
