Market Application Background
The dispensing process in speaker manufacturing is mainly used for the precision bonding and sealing of key components such as the voice coil, diaphragm, magnet, and frame, which is crucial for ensuring speaker sound quality and long-term durability. This process is widely used in the production of LCD monitor speakers, Bluetooth speakers, car horns, and many other products.
▲ LCD monitor speakers and audio speakers▲
Key points of the horn dispensing process
1. Precise dispensing position:
● Diaphragm-Voice Coil: Achieving tight bonding ensures efficient transmission of voice coil vibration to the diaphragm, guaranteeing the clarity and accuracy of audio output.
● Magnet-basin stand: Securely fixes the magnet to prevent it from loosening due to vibration.
2. Strictly control the amount of glue evenly: The glue application must be made to ensure that the amount of glue is evenly distributed to avoid diaphragm vibration imbalance caused by uneven glue amount, which directly affects the sound quality.
Problems with traditional dispensing solutions in the loudspeaker industry
In loudspeaker production, traditional adhesive dispensing methods face significant challenges:
1. Limited space: The space in key areas such as the connection between the speaker base and the coil is extremely narrow, making it difficult for traditional straight needle dispensing heads to penetrate deeply for precise dispensing.
2. Special angle: The voice coil in the center of the speaker often needs to be tilted at a certain angle to apply adhesive, so as to ensure reliable bonding with the voice coil and other components.
3. Complex model changeover: Conventional dispensing equipment is usually designed for specific speaker models. Switching between different models may require frequent adjustments to the equipment and parameters, which is time-consuming and labor-intensive, and seriously affects production efficiency and flexibility.
Positive motion technology visual dispensing solution
To address the aforementioned industry pain points, ZhengMotion has launched a vision-based dispensing solution for speaker production lines, based on the VPLC series machine vision and motion control integrated machine, achieving deep integration of vision and motion control. The advantages of this solution are as follows:
1. High-efficiency operation without interruption: Through the linkage of XYZ+R axes and the precise control of belts, the speaker can be dispensed without interruption on the production line using rotary dispensing, which greatly improves production capacity.
2. Intelligent visual positioning: The built-in vision system automatically identifies the precise position and direction of the speaker on the conveyor belt and adjusts the dispensing head posture in real time to ensure that the glue evenly and accurately covers the target bonding/sealing area.
3. Advanced process assurance: Supports high-speed PSO, PWM, path planning, multi-axis synchronous following and other functions to ensure smooth dispensing trajectory and stable dispensing volume, meeting the needs of complex processes.
4. Flexible and efficient: Users can quickly adjust dispensing parameters according to actual production needs, simplify the process, significantly improve production speed and product yield, and effectively reduce overall costs.
01. Application of Machine Vision Motion Control Integrated Machine in Speaker Follow-up Dispensing
Design of synchronous following dispensing solution for positive motion technology
1. 20DI: Connects to origin, limit, and other sensors, as well as switch signals, single-ended encoders, etc.
2. 20DO: High-speed output port for connecting to hard-trigger output of industrial cameras, dispensing valves, tri-color LEDs, etc.
3. EtherCAT interface: Connects to the EtherCAT bus driver to control the movement of the X, Y, Z, and R axes;
4. Four-channel single-ended pulse output: can be connected to a pulse driver to directly control the conveyor belt;
5. RS232 communication interface: connected to the light source controller;
6. Ethernet interface: Gigabit Ethernet port, for connecting area scan cameras that support the Gigabit protocol to achieve visual positioning applications.
Application Demonstration Case of Positive Motion Speaker Following Dispensing Process
Machine Vision
The vision system accurately identifies and locates moving targets on the conveyor belt, ensuring that the dispensing head performs precise processing on each product.
During system initialization, camera calibration is first performed using a calibration board to determine the internal and external parameters of the industrial camera. Subsequently, machine position calibration establishes a precise mapping between image pixel coordinates and actual physical coordinates. A template of the target product, including its shape, size, and feature points, is pre-created. During runtime, the system performs fast and stable target recognition and positioning based on preset marker points.
▌Motion Control
Through synchronous motion commands, the system drives the synchronous motion axis to precisely follow the belt shaft according to preset parameters, thereby achieving precise dispensing of adhesive to moving objects in belt transmission and ensuring the accuracy and stability of motion in the processing process.
By calculating and analyzing encoder position data, the running speed of the product on the conveyor belt is monitored in real time. Based on this, coordinate offset calculations are performed, and the position of the dispensing head is dynamically adjusted to ensure that it is always accurately positioned at the target point on the processing path, thereby achieving continuous and stable dispensing while the product is in motion.
Speaker following the glue dispensing process
Core application advantages of the solution
1. High-precision visual positioning: The industrial camera identifies the position and angle of products on the production line, enabling automatic correction of the processing trajectory when products are placed and fed arbitrarily.
2. Needle angle adaptation: Based on a four-axis interpolation motion algorithm, the dispensing needle is driven to automatically tilt to the optimal angle, effectively avoiding interference areas of the horn structure.
3. Online intelligent glue discharge: The processing does not need to be interrupted. The system monitors the glue level at regular intervals. When the material is insufficient, the glue discharge action is automatically performed, and the processing can be seamlessly resumed after the glue is replenished.
4. Adaptive production line speed: The belt speed is dynamically adjusted according to the dispensing process requirements to achieve multi-position, high-degree-of-freedom dispensing operations.
5. Processing safety linkage control: The belt automatically stops before the dispensing head reaches the limit and starts precisely after processing is completed, achieving reliable collision protection.
6. Belt angle deviation compensation: Supports belt installation angle offset correction, automatically compensates for XYZ axis position deviation through calibration, and ensures precise synchronous following.
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 MotionRT750 to achieve high-speed intra-core interaction, driving actuators to perform corresponding operations and completing 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 build vision dispensing project programs with only simple parameter settings, which can significantly shorten the project development cycle, reduce development costs, and meet the different process requirements of different products.
It is suitable for various dispensing applications such as dot, line, potting, filling, underfill, encapsulation, sealing, and spraying.
▌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 visual system will automatically recognize and complete the dispensing and spraying of adhesive.
User-friendly interface with comprehensive functions
The debugging and programming operations are simple and convenient, and support teaching and jogging motion on visual images.
To help you better and faster develop and apply machine vision motion control integrated machines in speaker following dispensing solutions, we have prepared detailed documentation and source code for the motion control module. For further information on usage, parameter configuration, and practical application cases, please contact us at 400-089-8936.
