A machine automatic splicing calibration system

Abstract

The application discloses a kind of machine automatic splicing calibration systems, including image acquisition module real-time acquisition calibration image on calibration plate;Conversion unit finds first pixel coordinate and is converted into first world coordinate, finds second pixel coordinate and is converted into second world coordinate;Angle calculation unit according to the column coordinate, line coordinate of each first world coordinate is handled to obtain first calibration straight line and second calibration straight line, the included angle between first calibration straight line and second calibration straight line is made difference with standard included angle and obtains deviation angle;Linearity calibration unit according to the column coordinate, line coordinate of each second world coordinate is handled to obtain first calibration line segment and second calibration line segment, and first deviation distance and second deviation distance are handled to obtain;Mobile module adjusts the included angle between first moving shaft and second moving shaft according to deviation angle, adjusts the linearity of first moving shaft and second moving shaft according to first deviation distance and second deviation distance.The application improves the calibration stability in the process of PCB board splicing calibration.

Description

TECHNICAL FIELD

[0001] The present application relates to the technical field of image processing, and particularly relates to a machine automatic splicing calibration system. BACKGROUND

[0002] The PCB board is generally calibrated by a gantry module and a camera. In the traditional mechanical splicing process of the PCB board, the precision calibration is performed by means of table punching, so that the XY axis perpendicularity of the gantry module and the perpendicularity of the camera and the X axis of the gantry module are kept at a high precision. However, due to the large human error and mechanical deviation of the manual table punching, the high-precision calibration requirement of the equipment cannot be met. In the prior art, image splicing algorithms are used to improve the calibration precision, such as a region-based correlation splicing algorithm and a feature-based registration method. The image splicing technology is a technology of splicing a plurality of images with overlapping parts (which may be obtained at different times, different angles or different sensors) into a seamless panoramic image or a high-resolution image. The image splicing algorithm can achieve relatively high precision calibration. However, in the PCB board splicing process, the PCB board is of various shapes, some of the overlapping areas have no feature points, and the correlation degree is low, so that the stability of the image splicing algorithm is insufficient, and the calibration stability is insufficient. SUMMARY

[0003] In view of the deficiencies in the prior art, the present application aims to provide a machine automatic splicing calibration system for improving the calibration precision and stability in the PCB board splicing process.

[0004] To achieve the above-mentioned purpose, the present application provides the following technical scheme: a machine automatic splicing calibration system, comprising:

[0005] A moving module is provided with a moving plane parallel to the horizontal plane, the moving plane is provided with a first moving shaft and a second moving shaft, and the first moving shaft is perpendicular to the second moving shaft;

[0006] A calibration board is provided with a plurality of calibration holes uniformly and spacedly arranged on the calibration board;

[0007] An image acquisition module is configured to acquire calibration images on the calibration board in real time;

[0008] The moving module moves according to a first moving instruction in the direction of the first moving shaft and the direction of the second moving shaft for a plurality of times according to a first moving distance, so that a first calibration hole located at the upper left corner of the calibration board forms a moving dot matrix, and the first moving distance is less than the spacing between the calibration holes;

[0009] The moving module moves according to a preset second moving instruction along the first moving axis direction and the second moving axis direction for a second moving distance several times, so that all the calibration circular holes are contained in a total calibration image formed by splicing the calibration images, and the second moving distance is equal to the interval between the calibration circular holes.

[0010] The processing module is connected to the image acquisition module and the moving module respectively, and includes:

[0011] The conversion unit finds first pixel coordinates of the first calibration circular holes in the calibration images according to a preset circular hole finding algorithm, and converts the first pixel coordinates into first world coordinates, and finds second pixel coordinates of the calibration circular holes in the total calibration image according to the circular hole finding algorithm, and converts the second pixel coordinates into second world coordinates.

[0012] The angle calculation unit is connected to the conversion unit, and is configured to fit and average process column coordinates of the first world coordinates to obtain a first calibration straight line, fit and average process row coordinates of the first world coordinates to obtain a second calibration straight line, and process a deviation angle between an included angle between the first calibration straight line and the second calibration straight line and a standard included angle.

[0013] The linearity calibration unit is connected to the conversion unit, and is configured to fit and average process the second world coordinates to obtain a first calibration line segment and a second calibration line segment, and to obtain a first deviation distance by subtracting a first standard line segment formed by transversely connecting the calibration circular holes in the same row on the calibration plate from the first calibration line segment, and to obtain a second deviation distance by subtracting a second standard line segment formed by longitudinally connecting the calibration circular holes in the same column on the calibration plate from the second calibration line segment.

[0014] The moving module adjusts an included angle between the first moving axis and the second moving axis according to the deviation angle, adjusts linearity of the first moving axis according to the first deviation distance, and adjusts linearity of the second moving axis according to the second deviation distance.

[0015] Further, the angle calculation unit includes:

[0016] The first fitting subunit is configured to fit and process the first world coordinates with a difference between column coordinates being lower than a preset first threshold value to obtain a plurality of first pre-calibration straight lines, and to fit and process the second world coordinates with a difference between row coordinates being lower than a preset second threshold value to obtain a plurality of second pre-calibration straight lines.

[0017] The first processing subunit is connected with the first fitting subunit and is configured to input each column coordinate contained in each of the first pre-calibration straight lines into a preset first calculation formula to obtain a corresponding number of calibration column coordinates, and fit the first calibration straight line according to each of the calibration column coordinates.

[0018] The second processing subunit is connected with the first fitting subunit and is configured to input each row coordinate contained in each of the second pre-calibration straight lines into a preset second calculation formula to obtain a corresponding number of calibration row coordinates, and fit the second calibration straight line according to each of the calibration row coordinates.

[0019] Further, the first calculation formula is configured as:

[0020]

[0021] wherein, is used to represent the calibration column coordinate;

[0022] m is used to represent the number of the first pre-calibration straight lines;

[0023] y m is used to represent the column coordinate in the mth first pre-calibration straight line.

[0024] Further, the second calculation formula is configured as:

[0025]

[0026] wherein, is used to represent the calibration row coordinate;

[0027] n is used to represent the number of the second pre-calibration straight lines;

[0028] x n is used to represent the row coordinate in the nth second pre-calibration straight line.

[0029] Further, when the standard included angle is 90°, the angle calculation unit further comprises:

[0030] The calculation subunit is connected with the first processing subunit and the second processing subunit respectively, and is configured to calculate an included angle between the first calibration straight line and the second calibration straight line in the world coordinate system;

[0031] The deviation subunit is connected with the calculation subunit, and is configured to input the included angle between the first calibration straight line and the second calibration straight line and the standard included angle into a preset deviation calculation formula to obtain the deviation angle.

[0032] Further, the deviation calculation formula is configured as:

[0033]

[0034]

[0035] wherein, δ is used to represent the deviation angle;

[0036] α is used to represent the included angle between the first calibration straight line and the second calibration straight line;

[0037] β is used to represent the standard included angle;

[0038] ε is used to represent the average value of the included angle between the first calibration straight line and the second calibration straight line and the standard included angle.

[0039] Further, the deviation calculation formula is configured as:

[0040]

[0041]

[0042] wherein, δ is used to represent the deviation angle;

[0043] α is used to represent the included angle between the first calibration straight line and the second calibration straight line;

[0044] β is used to represent the standard included angle;

[0045] ε is used to represent the average value of the included angle between the first calibration straight line and the second calibration straight line and the standard included angle.

[0046] Further, the linearity calibration unit comprises:

[0047] a second fitting sub-unit, configured to fit each of the second world coordinates with a difference between column coordinates being lower than the first threshold value to obtain a plurality of first pre-calibration line segments, and fit each of the second world coordinates with a difference between row coordinates being lower than the second threshold value to obtain a plurality of second pre-calibration line segments;

[0048] a third processing sub-unit, connected to the second fitting sub-unit, configured to average each of the first pre-calibration line segments to obtain the first calibration straight line, and average each of the second pre-calibration line segments to obtain the second calibration straight line.

[0049] Further, the processing module further comprises a comprehensive calculation unit connected to the angle calculation unit and the linearity calibration unit respectively, and the comprehensive calculation unit comprises:

[0050] a weight distribution sub-unit, configured to respectively distribute a first coefficient, a second coefficient and a third coefficient to the deviation angle, the first deviation distance and the second deviation distance.

[0051] The comprehensive calculation subunit is connected with the weight distribution subunit and is configured to input the first coefficient, the deviation angle, the second coefficient, the first deviation distance, the third coefficient and the second deviation distance into a preset comprehensive calculation formula to obtain a comprehensive deviation index for representing a comprehensive deviation degree of the mobile module.

[0052] The alarm subunit is connected with the comprehensive calculation subunit and is configured to generate an alarm instruction when the comprehensive deviation index is greater than a preset deviation threshold.

[0053] The mobile module is provided with an alarm device, and the alarm device performs alarm reminding according to the alarm instruction.

[0054] Further, the comprehensive calculation formula is configured as:

[0055]

[0056] Cd is used to represent the comprehensive deviation index.

[0057] k1, k2 and k3 are respectively used to represent the first coefficient, the second coefficient and the third coefficient.

[0058] is used to represent the deviation angle.

[0059] D d1 is used to represent the first deviation distance.

[0060] D d2 is used to represent the second deviation distance.

[0061] Further, the mobile module comprises:

[0062] The priority calculation unit is configured to calculate a first deviation index of the deviation angle with respect to a preset standard deviation angle, a second deviation index of the first deviation distance with respect to a preset first standard deviation distance and a third deviation index of the second deviation distance with respect to a preset second standard deviation distance.

[0063] The priority arrangement unit is connected with the priority calculation unit and is configured to arrange the first deviation index, the second deviation index and the third deviation index in descending order of numerical value.

[0064] The priority arrangement unit is connected with the priority calculation unit and is configured to arrange the first deviation index, the second deviation index and the third deviation index in descending order of numerical value.

[0065] An adjusting unit is connected to the priority arrangement unit and is configured to adjust the included angle between the first moving axis and the second moving axis, the linearity of the first moving axis, and the linearity of the second moving axis according to the first driving priority, the second driving priority, and the third driving priority.

[0066] The present application has the following advantages:

[0067] The present application uses the image acquisition module to acquire the calibration images on the calibration plate, and drives the moving module to move several times along the first moving axis direction and the second moving axis direction so that the first calibration circular holes form a moving point array, and each calibration image is spliced to form an overall calibration image. The first pixel coordinates and the second pixel coordinates in each calibration image are found by using a circle finding algorithm, and are converted into first world coordinates and second world coordinates. Finally, the deviation angle, the first deviation distance, and the second deviation distance are respectively processed according to the first world coordinates and the second world coordinates, so as to respectively adjust the included angle between the first moving axis and the second moving axis of the moving module, the linearity of the first moving axis, and the linearity of the second moving axis. The high-precision calibration of the moving module is completed. The calibration process is not affected by the PCB board, and the precision of the first moving axis and the second moving axis of the moving module can be automatically adjusted and optimized, thereby effectively improving the calibration precision and stability in the PCB board splicing calibration process. BRIEF DESCRIPTION OF DRAWINGS

[0068] Figure 1 is a structural schematic diagram of the machine automatic splicing calibration system in the present application.

[0069] Reference signs: 1, moving module; 11, priority calculation unit; 12, priority arrangement unit; 13, priority sorting unit; 14, adjusting unit; 2, image acquisition module; 3, processing module; 31, conversion unit; 32, angle calculation unit; 321, first fitting subunit; 322, first processing subunit; 323, second processing subunit; 324, calculation subunit; 325, deviation subunit; 33, linearity calibration unit; 331, second fitting subunit; 332, third processing subunit; 34, comprehensive calculation unit; 341, weight distribution subunit; 342, comprehensive calculation subunit; 343, alarm subunit. DETAILED DESCRIPTION

[0070] The present application will be further described in detail below in combination with the drawings and examples. Identical parts are denoted by identical reference signs. It should be noted that the words "front", "back", "left", "right", "up", and "down" used in the following description refer to the directions in the drawings, and the words "bottom surface" and "top surface", "inner" and "outer" refer to the directions towards or away from the geometric center of a particular part.

[0071] As shown in Figure 1 The machine automatic splicing calibration system of the embodiment comprises:

[0072] The moving module 1 is provided with a moving plane parallel to the horizontal plane, and the moving plane is provided with a first moving shaft and a second moving shaft, and the first moving shaft is perpendicular to the second moving shaft;

[0073] The calibration plate is uniformly and spacedly provided with a plurality of calibration holes;

[0074] The image acquisition module 2 is used for acquiring the calibration images on the calibration plate in real time;

[0075] The moving module 1 moves according to the first moving distance in the first moving shaft direction and the second moving shaft direction according to the preset first moving instruction for several times, so that the first calibration hole located at the upper left corner of the calibration plate forms a moving dot matrix, and the first moving distance is smaller than the interval between the calibration holes;

[0076] The moving module 1 moves according to the second moving distance in the first moving shaft direction and the second moving shaft direction according to the preset second moving instruction for several times, so that the overall calibration image formed by splicing the calibration images contains all the calibration holes, and the second moving distance is equal to the interval between the calibration holes;

[0077] The processing module 3 is connected with the image acquisition module 2 and the moving module 1 respectively, and comprises:

[0078] The conversion unit 31 finds the first pixel coordinates of each first calibration hole in each calibration image in the moving dot matrix according to the preset circle finding algorithm, and converts each first pixel coordinate into a first world coordinate, and finds the second pixel coordinates of each calibration hole in the overall calibration image according to the circle finding algorithm, and converts each second pixel coordinate into a second world coordinate;

[0079] The angle calculation unit 32 is connected with the conversion unit 31, and is used for fitting and mean processing the column coordinates of each first world coordinate to obtain a first calibration straight line, fitting and mean processing the row coordinates of each first world coordinate to obtain a second calibration straight line, and processing the included angle between the first calibration straight line and the second calibration straight line to obtain a deviation angle according to a standard included angle;

[0080] The linearity calibration unit 33 is connected with the conversion unit 31, and is used for fitting and mean processing each second world coordinate to obtain a first calibration line segment and a second calibration line segment, and obtaining a first deviation distance by subtracting a first standard line segment formed by transversely connecting each calibration hole in the same row on the calibration plate from the first calibration line segment, and obtaining a second deviation distance by subtracting a second standard line segment formed by longitudinally connecting each calibration hole in the same column on the calibration plate from the second calibration line segment;

[0081] The mobile module 1 adjusts the included angle between the first moving shaft and the second moving shaft according to the deviation angle, adjusts the linearity of the first moving shaft according to the first deviation distance, and adjusts the linearity of the second moving shaft according to the second deviation distance.

[0082] Specifically, in the embodiment, the mobile module 1 can be a gantry module, the first moving shaft can be an X-axis of the gantry module, the second moving shaft can be a Y-axis of the gantry module, and the image acquisition module 2 can be a camera. The camera is arranged on the gantry module and faces the calibration plate. During the movement of the X-axis and the Y-axis of the gantry module, the camera acquires calibration images on the calibration plate in real time. The length and the width of the calibration plate are 500 mm and 450 mm respectively, the diameter of the calibration circle holes on the calibration plate can be 5 mm, and the calibration circle holes on the calibration plate are uniformly distributed according to 7 rows and 8 columns with a spacing of 50 mm. Before the gantry module starts to move, the center of the camera is aligned with the first calibration circle hole at the upper left corner of the calibration plate, and a pixel coordinate system and a world coordinate system with the camera as the center are established. The gantry module moves according to a first moving instruction along the X-axis direction and the Y-axis direction for 3 times respectively according to a first moving distance, so that the first calibration circle hole at the upper left corner of the calibration plate forms a 3*3 moving point array. The first moving distance is 10 mm, and the side length of the moving point array is 30 mm, which is smaller than the spacing between the calibration circle holes, so that only the first calibration circle hole is contained in the moving point array, and accurate identification of the first calibration circle hole in a small range is realized. The conversion unit 31 finds the first pixel coordinates of each first calibration circle hole in each calibration image by using a circle finding algorithm in the prior art. The circle finding algorithm first finds the contour of the circle, and then finds the first pixel coordinates of the first calibration circle hole in the pixel coordinate system of the first calibration circle hole by finding the centroid of the circle hole, and converts each first pixel coordinate into a first world coordinate in the world coordinate system. The angle calculation unit 32 fits and processes by averaging the column coordinates of each first world coordinate to obtain a first calibration straight line, fits and processes by averaging the row coordinates of each first world coordinate to obtain a second calibration straight line, and processes the included angle between the first calibration straight line and the second calibration straight line to obtain a deviation angle. The gantry module adjusts the included angle between the X-axis and the Y-axis according to the deviation angle, realizes accurate calibration of the included angle between the X-axis and the Y-axis of the gantry module, and the calibration process is not affected by the PCB, thereby effectively improving the calibration accuracy and stability in the PCB splicing calibration process.

[0083] The gantry module moves 8 times along the X-axis direction and 7 times along the Y-axis direction according to the second movement instruction and the second movement distance, wherein the second movement distance is 50 mm, which is consistent with the interval between each calibration hole, and the center of the camera is aligned with the first calibration hole in the upper left corner of the calibration plate before the gantry module starts to move, so as to establish the pixel coordinate system and the world coordinate system with the camera as the center. Therefore, theoretically, the movement of the gantry module corresponds to the calibration hole on the calibration plate each time, and the adjustment range of the movement of the gantry module is consistent with the coverage range of the calibration hole on the calibration plate. However, due to the slight deviation of the X-axis and Y-axis lead screws of the gantry module in the actual linear movement process, the linearity of the X-axis and Y-axis of the gantry module needs to be adjusted. The conversion unit 31 first finds the second pixel coordinates of each calibration hole in the overall calibration image captured by the camera in the pixel coordinate system by using the circle finding algorithm, and converts each second pixel coordinate into a second world coordinate in the world coordinate system. The linearity calibration unit 33 fits and processes the mean value of the column coordinates of each second world coordinate to obtain a first calibration line segment, and fits and processes the mean value of the row coordinates of each second world coordinate to obtain a second calibration line segment. The first deviation distance is obtained by subtracting the first standard line segment formed by connecting the calibration holes in the same row on the calibration plate horizontally from the first calibration line segment, and the second deviation distance is obtained by subtracting the second standard line segment formed by connecting the calibration holes in the same column on the calibration plate vertically from the second calibration line segment. The gantry module adjusts the linearity of the X-axis and Y-axis according to the first deviation distance and the second deviation distance respectively, realizes the correction and calibration of the X-axis and Y-axis, and improves the mechanical precision of the X-axis and Y-axis of the gantry module, thereby effectively improving the calibration precision and stability in the PCB splicing calibration process.

[0084] Preferably, the angle calculation unit 32 comprises:

[0085] The first fitting sub-unit 321 is configured to fit and process each first world coordinate with a column coordinate difference lower than a preset first threshold value to obtain a plurality of first pre-calibration straight lines, and fit and process each second world coordinate with a row coordinate difference lower than a preset second threshold value to obtain a plurality of second pre-calibration straight lines.

[0086] The first processing sub-unit 322 is connected to the first fitting sub-unit 321 and configured to input each column coordinate contained in each first pre-calibration straight line into a preset first calculation formula to obtain a plurality of calibration column coordinates, and fit a first calibration straight line according to the calibration column coordinates.

[0087] The second processing sub-unit 323 is connected to the first fitting sub-unit 321 and configured to input each row coordinate contained in each second pre-calibration straight line into a preset second calculation formula to obtain a plurality of calibration row coordinates, and fit a second calibration straight line according to the calibration row coordinates.

[0088] Specifically, in the embodiment, since the lead screws of the X-axis and the Y-axis of the gantry module are not completely perpendicular, the column coordinates of the first world coordinates in the same row may also have slight differences. In the fitting process, the first world coordinates with a difference between column coordinates lower than the first threshold are identified as the same row, and the first world coordinates in the same row are fitted into one first pre-calibration straight line. Since the arrangement of the moving dot matrix is 3*3, there are three groups of first world coordinates in the same row, and thus there are three first pre-calibration straight lines. Similarly, there are also three second pre-calibration straight lines. The first processing subunit 322 obtains the calibration column coordinates by performing mean value operation processing on the column coordinates of the first world coordinates in each first pre-calibration straight line, and then obtains the first calibration straight line according to the calibration column coordinates. The first calibration straight line can reflect the average level of the three first pre-calibration straight lines, so that the first calibration straight line is more stable and extreme abnormal situations are avoided. The second processing subunit 323 obtains the calibration row coordinates by performing mean value operation processing on the row coordinates of the first world coordinates in each second pre-calibration straight line, and then obtains the second calibration straight line according to the calibration row coordinates. The second calibration straight line can reflect the average level of the three second pre-calibration straight lines, so that the second calibration straight line is more stable and the stability of the gantry module calibration is improved.

[0089] Preferably, the first calculation formula is configured as:

[0090]

[0091] wherein, is used to represent the calibration column coordinates;

[0092] m is used to represent the number of the first pre-calibration straight lines;

[0093] y m is used to represent the column coordinates in the mth first pre-calibration straight line.

[0094] Preferably, the second calculation formula is configured as:

[0095]

[0096] wherein, is used to represent the calibration row coordinates;

[0097] n is used to represent the number of the second pre-calibration straight lines;

[0098] x n is used to represent the row coordinates in the nth second pre-calibration straight line.

[0099] Preferably, the standard included angle is 90°, and the angle calculation unit 32 further comprises:

[0100] The calculating sub-unit 324 is connected with the first processing sub-unit 322 and the second processing sub-unit 323 respectively, and is configured to calculate an included angle between the first calibration straight line and the second calibration straight line in the world coordinate system.

[0101] The deviation sub-unit 325 is connected with the calculating sub-unit 324, and is configured to input the included angle between the first calibration straight line and the second calibration straight line and a standard included angle into a preset deviation calculation formula to obtain a deviation angle.

[0102] Preferably, the deviation calculation formula is configured as:

[0103]

[0104]

[0105] Wherein, δ is used to represent the deviation angle;

[0106] α is used to represent the included angle between the first calibration straight line and the second calibration straight line;

[0107] β is used to represent the standard included angle;

[0108] ε is used to represent an average value of the included angle between the first calibration straight line and the second calibration straight line and the standard included angle.

[0109] Specifically, in the embodiment, by setting the above deviation calculation formula, the accuracy of the deviation angle calculation is effectively improved.

[0110] Preferably, the linearity calibration unit 33 comprises:

[0111] The second fitting sub-unit 331 is configured to fit each second world coordinate whose difference between column coordinates is lower than the first threshold value to obtain a plurality of first pre-calibration line segments, and fit each second world coordinate whose difference between row coordinates is lower than the second threshold value to obtain a plurality of second pre-calibration line segments.

[0112] The third processing sub-unit 332 is connected with the second fitting sub-unit 331, and is configured to average each first pre-calibration line segment to obtain a first calibration line segment, and average each second pre-calibration line segment to obtain a second calibration line segment.

[0113] Specifically, in the embodiment, since the micromovement exists in the actual straight movement of the lead screws of the X-axis and the Y-axis of the gantry module, the lengths between the mutually parallel first pre-calibration line segments obtained by fitting have slight differences, and the lengths between the mutually parallel second pre-calibration line segments obtained by fitting have slight differences. In the fitting process, the second world coordinates with a difference between column coordinates lower than the first threshold value are identified as the same row, and the second world coordinates of the same row are fitted into one first pre-calibration line segment. Since the gantry module moves 8 times along the X-axis direction and 7 times along the Y-axis direction according to the second movement distance, there are 7 groups of second world coordinates of the same row, and thus there are 7 first pre-calibration line segments. Similarly, there are 8 groups of second world coordinates of the same column, and thus there are 8 second pre-calibration line segments. The first calibration line segment is obtained by averaging the first pre-calibration line segments, and the second calibration line segment is obtained by averaging the second pre-calibration line segments. The first calibration line segment reflects the average level of the 7 first pre-calibration line segments, so that the first calibration line segment is more stable and extreme abnormal situations are avoided. Similarly, the second calibration line segment reflects the average level of the 8 second pre-calibration line segments, so that the second calibration line segment is more stable.

[0114] Preferably, the processing module 3 further comprises a comprehensive calculation unit 34 connected with the angle calculation unit 32 and the linearity calibration unit 33, and the comprehensive calculation unit 34 comprises:

[0115] a weight distribution sub-unit 341 configured to respectively distribute preset first, second and third coefficients to the deviation angle, the first deviation distance and the second deviation distance;

[0116] a comprehensive calculation sub-unit 342 connected with the weight distribution sub-unit 341 and configured to input the first coefficient, the deviation angle, the second coefficient, the first deviation distance, the third coefficient and the second deviation distance into a preset comprehensive calculation formula to obtain a comprehensive deviation index for representing the comprehensive deviation degree of the movement module 1;

[0117] an alarm sub-unit 343 connected with the comprehensive calculation sub-unit 342 and configured to generate an alarm instruction when the comprehensive deviation index is greater than a preset deviation threshold value;

[0118] The movement module 1 is provided with an alarm device, and the alarm device alarms according to the alarm instruction.

[0119] Specifically, in the embodiment, the comprehensive deviation index is calculated and the alarm instruction is generated, so that the alarm device automatically alarms, the alarm reminding of the relevant personnel is realized, the mechanical deviation of the gantry module is avoided from being too much without correction, the relevant personnel is reminded to manually correct and calibrate the gantry module in time through the alarm, and the calibration stability is improved.

[0120] Preferably, the comprehensive calculation formula is configured as:

[0121]

[0122] wherein Cd is used to represent a comprehensive deviation index;

[0123] k1, k2, k3 are respectively used to represent a first coefficient, a second coefficient and a third coefficient;

[0124] δ is used to represent a deviation angle;

[0125] D d1 is used to represent a first deviation distance;

[0126] D d2 is used to represent a second deviation distance.

[0127] Preferably, the mobile module 1 comprises:

[0128] a priority calculation unit 11, configured to calculate a first deviation index of the deviation angle with respect to a preset standard deviation angle, a second deviation index of the first deviation distance with respect to a preset first standard deviation distance, and a third deviation index of the second deviation distance with respect to a preset second standard deviation distance, respectively;

[0129] a priority arrangement unit 12, connected to the priority calculation unit 11, configured to arrange the first deviation index, the second deviation index and the third deviation index in descending order according to the numerical value;

[0130] a priority sorting unit 13, connected to the priority arrangement unit 12, configured to generate a first driving priority, a second driving priority and a third driving priority according to the arrangement order of the first deviation index, the second deviation index and the third deviation index, wherein the first driving priority is higher than the second driving priority, and the second driving priority is higher than the third driving priority;

[0131] an adjustment unit 14, connected to the priority sorting unit 13, configured to adjust the included angle between the first moving shaft and the second moving shaft, the linearity of the first moving shaft and the linearity of the second moving shaft according to the first driving priority, the second driving priority and the third driving priority.

[0132] Specifically, in the embodiment, the priority calculation unit 11 compares the deviation angle, the first deviation distance and the second deviation distance by calculating the first deviation index, the second deviation index and the third deviation index, the priority arrangement unit 12 arranges the first deviation index, the second deviation index and the third deviation index in descending order by comparing the numerical values of the first deviation index, the second deviation index and the third deviation index. The priority arrangement unit 13 generates the first driving priority, the second driving priority and the third driving priority according to the arrangement order of the first deviation index, the second deviation index and the third deviation index, and then the adjustment unit 14 adjusts the angle between the first moving shaft and the second moving shaft, the linearity of the first moving shaft and the linearity of the second moving shaft according to the first driving priority, the second driving priority and the third driving priority. In a specific embodiment, the first deviation index is greater than the second deviation index, and the second deviation index is greater than the third deviation index, so the first deviation index is assigned the first priority, the second deviation index is assigned the second priority, and the third deviation index is assigned the third priority. The angle between the X-axis and the Y-axis of the gantry module corresponding to the first deviation index is adjusted first, the linearity of the X-axis of the gantry module corresponding to the second deviation index is adjusted second, and the linearity of the Y-axis of the gantry module corresponding to the third deviation index is adjusted last. By such arrangement, the adjustment order of different positions of the gantry module is realized according to the deviation degree of different positions, the position with high deviation degree is corrected first, and the position with low deviation degree is corrected later, so the correction of the gantry module is more reasonable.

[0133] The above is only the preferred embodiment of the present application, and the protection scope of the present application is not limited to the above embodiment. Any technical solution falling within the concept of the present application shall fall within the protection scope of the present application. It should be noted that, for ordinary skilled in the art, some improvements and refinements without departing from the principles of the present application shall also be considered as the protection scope of the present application.

Claims

1. A machine-automated splicing and calibration system, characterized in that, include: The moving module (1) is provided with a moving plane parallel to the horizontal plane, and a first moving axis and a second moving axis are provided on the moving plane, wherein the first moving axis is perpendicular to the second moving axis; A calibration plate, wherein a plurality of calibration holes are evenly spaced on the calibration plate; Image acquisition module (2) is used to acquire calibration images on the calibration board in real time; The moving module (1) moves several times along the first moving axis and the second moving axis according to the preset first moving instruction, according to the first moving instruction, so that the first calibration circular hole located at the upper left corner of the calibration plate forms a moving dot matrix, and the first moving distance is less than the spacing between each calibration circular hole. The moving module (1) moves several times along the first moving axis direction and the second moving axis direction according to the preset second moving instruction and according to the second moving distance, so that the overall calibration image formed by splicing the calibration images contains all the calibration holes, and the second moving distance is equal to the distance between the calibration holes. The processing module (3), connected to the image acquisition module (2) and the moving module (1) respectively, includes: The conversion unit (31) finds the first pixel coordinates of each first calibration hole in the moving dot matrix in each calibration image according to the preset circle finding algorithm, and converts each first pixel coordinate into first world coordinates; and finds the second pixel coordinates of each calibration hole in the overall calibration image according to the circle finding algorithm, and converts each second pixel coordinate into second world coordinates. An angle calculation unit (32) is connected to the conversion unit (31) and is used to fit and average the column coordinates of each first world coordinate to obtain a first calibration line, and to fit and average the row coordinates of each first world coordinate to obtain a second calibration line, and to obtain a deviation angle based on the angle between the first calibration line and the second calibration line and the standard angle. Linearity calibration unit (33), connected to the conversion unit (31), is used to fit and average each of the second world coordinates to obtain a first calibration line segment and a second calibration line segment, and to obtain a first deviation distance by subtracting the first calibration line segment from the first standard line segment formed by horizontally connecting each of the calibration holes in the same row on the calibration plate, and to obtain a second deviation distance by subtracting the second calibration line segment from the second standard line segment formed by vertically connecting each of the calibration holes in the same column on the calibration plate; The moving module (1) adjusts the angle between the first moving axis and the second moving axis according to the deviation angle, adjusts the linearity of the first moving axis according to the first deviation distance, and adjusts the linearity of the second moving axis according to the second deviation distance; If the standard included angle is 90°, then the angle calculation unit (32) further includes: The calculation subunit (324) is connected to the first processing subunit (322) and the second processing subunit (323) respectively, and is used to calculate the angle between the first calibration line and the second calibration line in the world coordinate system; The deviation subunit (325) is connected to the calculation subunit (324) and is used to input the included angle between the first calibration line and the second calibration line and the standard angle into a preset deviation calculation formula to obtain the deviation angle; The deviation calculation formula is configured as follows: Wherein, δ is used to represent the deviation angle; α is used to represent the angle between the first calibration line and the second calibration line; β is used to represent the standard included angle; ε is used to represent the average value of the angle between the first calibration line and the second calibration line and the standard angle.

2. The automatic machine splicing and calibration system according to claim 1, characterized in that: The angle calculation unit (32) includes: The first fitting subunit (321) is used to fit and process each of the first world coordinates whose difference between column coordinates is lower than a preset first threshold to obtain a plurality of first pre-calibrated lines, and to fit and process each of the second world coordinates whose difference between row coordinates is lower than a preset second threshold to obtain a plurality of second pre-calibrated lines. The first processing subunit (322) is connected to the first fitting subunit (321) and is used to substitute the column coordinates contained in each of the first precalibrated lines into a preset first calculation formula to obtain a number of corresponding calibration column coordinates, and to fit the first calibration line according to each of the calibration column coordinates. The second processing subunit (323) is connected to the first fitting subunit (321) and is used to substitute the row coordinates contained in each of the second precalibrated lines into a preset second calculation formula to obtain a number of corresponding calibration row coordinates, and to fit the second calibration line according to each of the calibration row coordinates.

3. The automatic machine splicing and calibration system according to claim 2, characterized in that: The first calculation formula is configured as follows: in, Used to represent the coordinates of the calibration column; m is used to represent the number of the first pre-calibrated straight lines; y m Used to represent the column coordinates in the m-th first pre-calibrated straight line.

4. The automatic machine splicing and calibration system according to claim 2, characterized in that: The second calculation formula is configured as follows: in, Used to represent the coordinates of the calibration row; n is used to represent the number of the second pre-calibrated lines; x n Used to represent the row coordinates in the nth second pre-calibrated straight line.

5. The automatic machine splicing and calibration system according to claim 2, characterized in that: The linearity calibration unit (33) includes: The second fitting subunit (331) is used to fit and process each second world coordinate with a difference between column coordinates that is lower than the first threshold to obtain a number of first pre-calibration line segments, and to fit and process each second world coordinate with a difference between row coordinates that is lower than the second threshold to obtain a number of second pre-calibration line segments. The third processing subunit (332) is connected to the second fitting subunit (331) and is used to average each of the first pre-calibration line segments to obtain the first calibration line segment, and to average each of the second pre-calibration line segments to obtain the second calibration line segment.

6. The automatic machine splicing and calibration system according to claim 1, characterized in that: The processing module (3) further includes a comprehensive calculation unit (34), which is connected to the angle calculation unit (32) and the linearity calibration unit (33) respectively. The comprehensive calculation unit (34) includes: The weight allocation subunit (341) is used to allocate a preset first coefficient, a second coefficient, and a third coefficient to the deviation angle, the first deviation distance, and the second deviation distance, respectively; The comprehensive calculation subunit (342) (324) is connected to the weight allocation subunit (341) and is used to substitute the first coefficient, the deviation angle, the second coefficient, the first deviation distance, the third coefficient and the second deviation distance into the preset comprehensive calculation formula to obtain a comprehensive deviation index used to characterize the comprehensive deviation degree of the moving module (1); The alarm subunit (343), connected to the comprehensive calculation subunit (342)(324), is used to generate an alarm command when the comprehensive deviation index is greater than a preset deviation threshold. The mobile module (1) is equipped with an alarm device, which provides an alarm reminder according to the alarm command.

7. The automatic machine splicing and calibration system according to claim 6, characterized in that: The comprehensive calculation formula is configured as follows: Wherein, Cd represents the comprehensive deviation index; k1, k2, and k3 are used to represent the first coefficient, the second coefficient, and the third coefficient, respectively; δ is used to represent the deviation angle; D d1 Used to represent the first deviation distance; D d2 Used to represent the second deviation distance.

8. The automatic machine splicing and calibration system according to claim 1, characterized in that: The mobile module (1) includes: The priority calculation unit (11) is used to calculate the first deviation index of the deviation angle with respect to the preset standard deviation angle, the second deviation index of the first deviation distance with respect to the preset first standard deviation distance, and the third deviation index of the second deviation distance with respect to the preset second standard deviation distance. The priority arrangement unit (12) is connected to the priority calculation unit (11) and is used to arrange the first deviation index, the second deviation index and the third deviation index in descending order of their numerical values. Priority sorting unit (13), connected to priority arrangement unit (12), is used to generate a first driving priority, a second driving priority and a third driving priority according to the arrangement order of the first deviation index, the second deviation index and the third deviation index, wherein the first driving priority is higher than the second driving priority and the second driving priority is higher than the third driving priority; The adjustment unit (14) is connected to the priority sorting unit (13) and is used to adjust the angle between the first moving axis and the second moving axis, the linearity of the first moving axis and the linearity of the second moving axis according to the first driving priority, the second driving priority and the third driving priority.

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