In the modern industrial automation production, involves a variety of inspection, measurement and parts identification applications, such as auto parts size inspection and automatic assembly integrity inspection, automatic assembly of electronic assembly line components, printing quality inspection of beverage bottle caps , product packaging on the bar code and character recognition. The common feature of this type of application is the continuous mass production and the very high demands on the appearance quality.
Normally this kind of highly repetitive and intelligent work can only be accomplished by manual inspection. We often see hundreds or even thousands of inspection workers behind the modernization lines of some factories to perform this process. While the factory has increased enormous labor costs and management costs, it still cannot guarantee a 100% inspection pass rate (ie, “zero defectsâ€), and today’s competition among enterprises has not allowed even 0.1% of defects to exist. In some cases, such as precise and rapid measurement of a small size, shape matching, color identification, etc., it is impossible for the human eye to perform continuously and stably, and other physical quantity sensors are also difficult to use. At this time, people began to consider the combination of the rapidity, reliability, and repeatability of results with the highly intelligent and abstract capabilities of human vision, resulting in the concept of machine vision. In general, machine vision is the use of machines instead of human eyes to do measurements and judgments. Firstly, the captured target is converted into an image signal by a CCD camera, transmitted to a dedicated image processing system, and converted into a digital signal according to pixel distribution, brightness, color, and other information; the image system performs various operations on these signals to extract the characteristics of the target. , Such as: area, length, quantity, location, etc.; Finally, according to the preset tolerance and other conditions, the output results, such as: size, angle, offset, number, pass/fail, yes/no, etc.
Machine vision is characterized by automation, objectivity, non-contact, and high precision. Compared with image processing systems in the general sense, machine vision emphasizes accuracy and speed, as well as reliability in industrial field environments. Machine vision is extremely suitable for measurement, inspection and identification in mass production processes, such as: part assembly integrity, assembly dimensional accuracy, part machining accuracy, position/angle measurement, part identification, and character/character recognition. Its largest application industries are: automotive, pharmaceutical, electronics and electrical, manufacturing, packaging/food/beverages, medicine. Such as the inspection of automobile dashboard precision, high-speed placement machine for the rapid positioning of electronic components, the inspection of the number of pins, the identification of the IC surface printing characters, capsule production in the capsule wall thickness and appearance defects inspection, bearing Inspection of the number and damage of balls in production, identification of production date on food packaging, and inspection of label placement.
At present, the application of the visual system in the world is in the ascendant. In 1998, the market size was 4.6 billion U.S. dollars. In China, the industrial vision system is still in the concept introduction period. Leading enterprises in various industries have begun to solve the problem of production automation. Look to the automation of vision measurement. Systematic composition and classification of machine vision A typical visual system generally includes the following parts: light source, lens, CCD camera, image processing unit (or image capture card), image processing software, monitor, communication/input/output unit, etc. The output of the vision system is not the image video signal, but the detection result after the operation processing, such as the size data. After the host computer such as PC and PLC obtains the test result in real time, the command motion system or I/O system performs corresponding control actions such as positioning and sorting. From the visual system operating environment classification, can be divided into PC-BASED system and PLC-BASED system. PC-based systems take advantage of its openness, high programming flexibility and a good Windows interface, while the overall system cost is lower. Take the United States DataTran- cine Inc. as an example. The system includes a high-performance image capture card. Generally, it can be connected to multiple lenses. The supporting software has several levels from low to high, such as the DLL for C/C++ programming in the Windows 95/98/NT environment. VisualX controls activeX provide graphical programming environment under VB and VC++, even object-oriented machine vision configuration software under Windows, users can use it to quickly develop complex advanced applications. In PLC-based systems, vision acts more like an intelligent sensor. The image processing unit is independent of the system and exchanges data with the PLC via the serial bus and I/O. System hardware generally uses high-speed dedicated ASIC or embedded computer for image processing. The system software is solidified in the image processor. The menu displayed on the monitor is configured through a simple device similar to the game keyboard, or the software is developed on the PC. download. The PLC-based system embodies the features of high reliability, integration, miniaturization, high speed, and low cost. Representative manufacturers are Panasonic of Japan and Siemens of Germany.
Examples are as follows:
1. Project: Check whether the printing pattern of the cigarette box matches the speed between the box body and the flip cover: 8-10/s. Benefit: Instead of manual, high speed.
2. Project: Check the shape of the biscuits placed on the chassis (fragrance) and completeness (absence of deletion) Speed: 16 b/s Benefit: Ensure that each biscuit is intact before packing.
3. Item: Final inspection of cosmetic bottle appearance quality i. Type of label ii. Label position and offset iii. Type of bottle iv. Cap is tightly capped Speed: 20 pcs/s Benefit: Only products with the most perfect appearance can leave The filling line, label and bottle contents correspond exactly.
4. Project: Beer bottle detection on filling line i. Bottle classification ii. Label inspection iii. Bottle mouth breakage detection iv. Filling level measurement speed: 25pcs/sec, support static and dynamic measurement Benefits: Reduce system downtime Time, improve efficiency.
5. Project: whether the label printing is in line with the physical object i. Printed-code identification (OCR) ii. Print quality inspection iii. Surface inspection iv. Profile inspection Speed: 10 pcs/s, support static and dynamic measurements 6. Project: Unscrew Cap inner liner measurement i. Internal liner integrity (multiple/less material) ii. Oil detection speed: 16 pcs/s 7. Project: Crown cap printing quality measurement i. Pattern is offset ii Whether the pattern is blurred Speed: 10 / sec 8. Item: Oral liquid bottle size and appearance check i. Bottle height, bottle diameter, verticality ii. Bottle crack speed: 10 / sec.
Conclusion: In summary, applying machine vision systems can significantly reduce inspection costs, improve product quality, and accelerate production speed and efficiency. As a high-precision, non-contact measurement scheme, the vision system involves optical and image processing algorithms, and is itself a highly specialized product. In the entire measurement control system, it is often necessary to cooperate with the motion control system to complete the position correction and feed control; In addition, the visual system must have a distributed networking capability when the production line performs synchronous continuous inspection of multiple processes. The combination of advanced technologies such as machine vision and motion control, network communications is changing the face of industrial automation production. At present, there have been system integrators such as Beijing Stone Electrical Machinery Co., Ltd. with technical backgrounds in motion control, machine vision, and network communication. Their specialized technical support and service capabilities have made it an original supplier and end-user. The bridge between. For packaging companies, being aware of the trends in technology development and putting them into practice first will undoubtedly lead the competition.
Normally this kind of highly repetitive and intelligent work can only be accomplished by manual inspection. We often see hundreds or even thousands of inspection workers behind the modernization lines of some factories to perform this process. While the factory has increased enormous labor costs and management costs, it still cannot guarantee a 100% inspection pass rate (ie, “zero defectsâ€), and today’s competition among enterprises has not allowed even 0.1% of defects to exist. In some cases, such as precise and rapid measurement of a small size, shape matching, color identification, etc., it is impossible for the human eye to perform continuously and stably, and other physical quantity sensors are also difficult to use. At this time, people began to consider the combination of the rapidity, reliability, and repeatability of results with the highly intelligent and abstract capabilities of human vision, resulting in the concept of machine vision. In general, machine vision is the use of machines instead of human eyes to do measurements and judgments. Firstly, the captured target is converted into an image signal by a CCD camera, transmitted to a dedicated image processing system, and converted into a digital signal according to pixel distribution, brightness, color, and other information; the image system performs various operations on these signals to extract the characteristics of the target. , Such as: area, length, quantity, location, etc.; Finally, according to the preset tolerance and other conditions, the output results, such as: size, angle, offset, number, pass/fail, yes/no, etc.
Machine vision is characterized by automation, objectivity, non-contact, and high precision. Compared with image processing systems in the general sense, machine vision emphasizes accuracy and speed, as well as reliability in industrial field environments. Machine vision is extremely suitable for measurement, inspection and identification in mass production processes, such as: part assembly integrity, assembly dimensional accuracy, part machining accuracy, position/angle measurement, part identification, and character/character recognition. Its largest application industries are: automotive, pharmaceutical, electronics and electrical, manufacturing, packaging/food/beverages, medicine. Such as the inspection of automobile dashboard precision, high-speed placement machine for the rapid positioning of electronic components, the inspection of the number of pins, the identification of the IC surface printing characters, capsule production in the capsule wall thickness and appearance defects inspection, bearing Inspection of the number and damage of balls in production, identification of production date on food packaging, and inspection of label placement.
At present, the application of the visual system in the world is in the ascendant. In 1998, the market size was 4.6 billion U.S. dollars. In China, the industrial vision system is still in the concept introduction period. Leading enterprises in various industries have begun to solve the problem of production automation. Look to the automation of vision measurement. Systematic composition and classification of machine vision A typical visual system generally includes the following parts: light source, lens, CCD camera, image processing unit (or image capture card), image processing software, monitor, communication/input/output unit, etc. The output of the vision system is not the image video signal, but the detection result after the operation processing, such as the size data. After the host computer such as PC and PLC obtains the test result in real time, the command motion system or I/O system performs corresponding control actions such as positioning and sorting. From the visual system operating environment classification, can be divided into PC-BASED system and PLC-BASED system. PC-based systems take advantage of its openness, high programming flexibility and a good Windows interface, while the overall system cost is lower. Take the United States DataTran- cine Inc. as an example. The system includes a high-performance image capture card. Generally, it can be connected to multiple lenses. The supporting software has several levels from low to high, such as the DLL for C/C++ programming in the Windows 95/98/NT environment. VisualX controls activeX provide graphical programming environment under VB and VC++, even object-oriented machine vision configuration software under Windows, users can use it to quickly develop complex advanced applications. In PLC-based systems, vision acts more like an intelligent sensor. The image processing unit is independent of the system and exchanges data with the PLC via the serial bus and I/O. System hardware generally uses high-speed dedicated ASIC or embedded computer for image processing. The system software is solidified in the image processor. The menu displayed on the monitor is configured through a simple device similar to the game keyboard, or the software is developed on the PC. download. The PLC-based system embodies the features of high reliability, integration, miniaturization, high speed, and low cost. Representative manufacturers are Panasonic of Japan and Siemens of Germany.
Examples are as follows:
1. Project: Check whether the printing pattern of the cigarette box matches the speed between the box body and the flip cover: 8-10/s. Benefit: Instead of manual, high speed.
2. Project: Check the shape of the biscuits placed on the chassis (fragrance) and completeness (absence of deletion) Speed: 16 b/s Benefit: Ensure that each biscuit is intact before packing.
3. Item: Final inspection of cosmetic bottle appearance quality i. Type of label ii. Label position and offset iii. Type of bottle iv. Cap is tightly capped Speed: 20 pcs/s Benefit: Only products with the most perfect appearance can leave The filling line, label and bottle contents correspond exactly.
4. Project: Beer bottle detection on filling line i. Bottle classification ii. Label inspection iii. Bottle mouth breakage detection iv. Filling level measurement speed: 25pcs/sec, support static and dynamic measurement Benefits: Reduce system downtime Time, improve efficiency.
5. Project: whether the label printing is in line with the physical object i. Printed-code identification (OCR) ii. Print quality inspection iii. Surface inspection iv. Profile inspection Speed: 10 pcs/s, support static and dynamic measurements 6. Project: Unscrew Cap inner liner measurement i. Internal liner integrity (multiple/less material) ii. Oil detection speed: 16 pcs/s 7. Project: Crown cap printing quality measurement i. Pattern is offset ii Whether the pattern is blurred Speed: 10 / sec 8. Item: Oral liquid bottle size and appearance check i. Bottle height, bottle diameter, verticality ii. Bottle crack speed: 10 / sec.
Conclusion: In summary, applying machine vision systems can significantly reduce inspection costs, improve product quality, and accelerate production speed and efficiency. As a high-precision, non-contact measurement scheme, the vision system involves optical and image processing algorithms, and is itself a highly specialized product. In the entire measurement control system, it is often necessary to cooperate with the motion control system to complete the position correction and feed control; In addition, the visual system must have a distributed networking capability when the production line performs synchronous continuous inspection of multiple processes. The combination of advanced technologies such as machine vision and motion control, network communications is changing the face of industrial automation production. At present, there have been system integrators such as Beijing Stone Electrical Machinery Co., Ltd. with technical backgrounds in motion control, machine vision, and network communication. Their specialized technical support and service capabilities have made it an original supplier and end-user. The bridge between. For packaging companies, being aware of the trends in technology development and putting them into practice first will undoubtedly lead the competition.
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