A visual-based bent needle tip calibration device and method

Abstract

The present application relates to the technical field of equipment calibration, and discloses a visual-based curved needle tip calibration device and a calibration method. The visual-based curved needle tip calibration device comprises an automatic mechanism device, a glue bucket curved needle tip device and a processing device. The glue bucket curved needle tip device is mounted on the automatic mechanism device and comprises a curved needle tip. The processing device is used to send control instructions to the automatic mechanism device. The automatic mechanism device is used to move according to the control instructions, collect curved needle tip images of the curved needle tip, and transmit the curved needle tip images to the processing device. The processing device is also used to perform image processing on the curved needle tip images based on a preset image processing algorithm, identify the position of the curved needle tip in the curved needle tip images, and calibrate the curved needle tip based on the position of the curved needle tip in the curved needle tip images. Thus, the accurate identification and grasping of the position of the curved needle tip by using a mechanical structure in cooperation with industrial vision technology can effectively and accurately calibrate the equipment, improve the dispensing precision and accuracy of the dispensing equipment, and improve the product quality.

Description

Technical Field

[0001] This invention relates to the field of equipment calibration technology, and in particular to a vision-based needle tip calibration device and calibration method. Background Technology

[0002] In the needle valve component of dispensing equipment, the curved needle tip is a key component, and its dispensing plays a crucial role in the precise dispensing of adhesive to the sides or gaps of products. However, due to the special shape and angle of the curved needle tip, calibrating it using traditional straight-curved needle tip calibration methods results in slow calibration speed, low efficiency, excessive human intervention, and strong uncontrollability, failing to provide a more convenient and accurate calibration operation for precision dispensing. Summary of the Invention

[0003] The present invention aims to provide a vision-based calibration device and method for bent needle tips, which can solve the problems of slow calibration speed, low efficiency, and excessive human intervention caused by the existing traditional straight-bent needle tip calibration method, which cannot provide more convenient and accurate operation for precision dispensing.

[0004] To address the aforementioned technical problems, a first aspect of the present invention provides a vision-based bent needle tip calibration device, comprising an automated mechanism, a glue bucket bent needle tip device, and a processing device, wherein:

[0005] The glue bucket bending needle tip device is mounted on the automated mechanism device, including the bending needle tip;

[0006] The processing device is communicatively connected to the automated mechanism and is used to send control commands to the automated mechanism.

[0007] The automated mechanism is used to move according to the control command, acquire the image of the bent needle tip, and transmit it to the processing device.

[0008] The processing device is further configured to perform image processing on the bent needle tip image based on a preset image processing algorithm, identify the position of the bent needle tip in the bent needle tip image, and perform bent needle tip calibration based on the position of the bent needle tip in the bent needle tip image.

[0009] Optionally, the automated mechanism includes a moving platform and a photographic device, wherein:

[0010] The mobile platform is located on the upper part of the photographic device and is used to move the rotation center of the rotating axis to align with the center position of the camera of the photographic device according to the control command.

[0011] The photographic device is used to capture an image of the bent needle tip and transmit it to the processing device.

[0012] Optionally, the mobile platform includes an X-axis, a Y-axis, a Z-axis, and an R-axis, wherein the effective travel of the Z-axis is 0 to 360 degrees; the R-axis is a rotation axis with an effective travel of 0 to 360 degrees, and the clockwise direction of the rotation axis is set as positive, and rotating the tip of the bent needle to face due right is set as the 0 position of the rotation axis.

[0013] Optionally, the photographic device includes a camera and a coaxial light source, wherein:

[0014] The coaxial light source provides a white coaxial light source for the camera;

[0015] The camera is used to acquire an image of the bent needle tip under the illumination of a white coaxial light source provided by the coaxial light source, and transmit it to the processing device.

[0016] Optionally, the glue bucket bending needle tip device further includes a metal pad and a needle tube, wherein:

[0017] The needle is mounted on the Z-axis of the moving platform;

[0018] The curved needle tip is located below the needle tube, and the curved needle tip is locked onto the needle tube by the metal pad;

[0019] The metal pad is screwed under the needle tube, and the metal pad has an opening in the middle so that the bent needle tip can pass through it and be snapped into the opening in the middle of the metal pad.

[0020] Optionally, the back of the metal pad is a silver reflective material to ensure that the background appears white when the camera captures the image of the bent needle tip under the illumination of the white coaxial light source provided by the coaxial light source, thereby reducing noise.

[0021] Accordingly, a second aspect of the present invention provides a vision-based method for calibrating bent needle tips, applied to the vision-based bent needle tip calibration device described in the first aspect of the present invention. The vision-based bent needle tip calibration device includes an automated mechanism, a glue bucket bent needle tip device, and a processing device. The vision-based bent needle tip calibration method includes:

[0022] The glue bucket bending needle tip device is mounted on the automated mechanism device, and the glue bucket bending needle tip device includes a bending needle tip;

[0023] The processing device sends control commands to the automated mechanism.

[0024] The automated mechanism moves according to the control command, acquires an image of the bent needle tip, and transmits it to the processing device.

[0025] The processing device performs image processing on the bent needle tip image based on a preset image processing algorithm, identifies the position of the bent needle tip in the bent needle tip image, and performs bent needle tip calibration based on the position of the bent needle tip in the bent needle tip image.

[0026] Optionally, the automated mechanism moves according to the control command, acquires an image of the bent needle tip, and transmits it to the processing device, including:

[0027] Based on the angle of one revolution of the mobile platform's rotation axis, the plane on which the rotation axis rotates one revolution is divided into several rotation positions by a preset rotation angle. The preset rotation angle is the angle of one revolution of the mobile platform's rotation axis, which is divided equally by the number of rotation positions.

[0028] Adjust the camera parameters, use the camera to acquire images of the bent needle tip at each rotation position, and transmit them to the processing device.

[0029] Optionally, the vision-based bent needle tip calibration method further includes the processing device determining the calibration relationship between the camera center and the moving platform.

[0030] Optionally, the processing device performs image processing on the bent needle tip image based on a preset image processing algorithm, identifies the position of the bent needle tip in the bent needle tip image, and performs bent needle tip calibration based on the position of the bent needle tip in the bent needle tip image, including:

[0031] Based on the preset image processing algorithm and the calibration relationship between the camera center and the moving platform, the bent needle tip is searched from the bent needle tip image at each rotation position to obtain the result of finding the bent needle tip.

[0032] Based on the results of finding the bent needle tip, the successfully found bent needle tip is calibrated.

[0033] Compared to existing technologies, this invention provides a vision-based needle tip calibration device and method. The vision-based needle tip calibration device includes an automated mechanism, a glue bucket needle tip device, and a processing device. The glue bucket needle tip device is mounted on the automated mechanism. The automated mechanism moves according to control commands from the processing device, acquiring images of the needle tips within the glue bucket needle tip device. The processing device performs image processing on the needle tip images based on a preset image processing algorithm, identifies the positions of the needle tips in the images, and performs needle tip calibration based on these positions. This system utilizes a mechanical structure combined with industrial vision technology to accurately identify and capture the position of the bent needle tip for effective and precise equipment calibration. This further enables stable, reliable, convenient, and accurate dispensing of adhesive to product sides or gaps, improving dispensing precision and enhancing the process accuracy and product quality of the dispensing equipment. The automated mechanism moves according to the control commands of the processing unit, automatically acquiring images of the bent needle tip in the glue container. The processing unit automatically captures these images based on a preset image processing algorithm. This automated image processing and capture process reduces manual intervention and improves the efficiency of the dispensing equipment. The processing unit calibrates the bent needle tip based on its position in the image, improving system reliability. This solves the problems of slow calibration speed, low efficiency, and excessive manual intervention associated with traditional straight-bent needle tip calibration methods, which fail to provide convenient and accurate calibration for precision dispensing. Attached Figure Description

[0034] One or more embodiments are illustrated by way of example with reference numerals in the accompanying drawings. These illustrations do not constitute a limitation on the embodiments. Elements with the same reference numerals in the drawings are denoted as similar elements. Unless otherwise stated, the figures in the drawings are not to be limited by scale.

[0035] Figure 1 This is a schematic diagram of the structure of a vision-based bent needle tip calibration device provided by the present invention;

[0036] Figure 2 This is a schematic flowchart of a vision-based needle tip calibration method provided by the present invention;

[0037] Figure 3 This is a 75° bent needle tip image captured by a camera in a vision-based bent needle tip calibration method provided by the present invention;

[0038] Figure 4 This is a 90° bent needle tip image captured by a camera in a vision-based bent needle tip calibration method provided by this invention.

[0039] The reference numerals in the attached figures are shown in the table below:

[0040]

[0041] Detailed Implementation

[0042] To facilitate understanding of the present invention, a more detailed description is provided below with reference to the accompanying drawings and specific embodiments. It should be noted that when an element is described as being "fixed to" another element, it can be directly on the other element, or one or more intermediate elements may exist between them. When an element is described as being "connected" to another element, it can be directly connected to the other element, or one or more intermediate elements may exist between them. The terms "upper," "lower," "inner," "outer," "bottom," etc., used in this specification indicate the orientation or positional relationship based on the orientation or positional relationship shown in the accompanying drawings, and are only for the convenience of describing the present invention and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation, and therefore should not be construed as a limitation of the present invention. Furthermore, the terms "first," "second," "third," etc., are used for descriptive purposes only and should not be construed as indicating or implying relative importance.

[0043] Unless otherwise defined, all technical and scientific terms used in this specification have the same meaning as commonly understood by one of ordinary skill in the art to which this invention pertains. The terminology used in this specification is for the purpose of describing particular embodiments only and is not intended to limit the invention. The term "and / or" as used in this specification includes any and all combinations of one or more of the associated listed items.

[0044] Furthermore, the technical features involved in the different embodiments of the present invention described below can be combined with each other as long as they do not conflict with each other.

[0045] In one embodiment, such as Figure 1 As shown, the present invention provides a vision-based needle tip calibration device 100, comprising: an automated mechanism 10, a glue bucket needle tip calibration device 20, and a processing device 30, wherein:

[0046] The glue bucket bending needle tip device 20 is mounted on the automated mechanism device 10, including the bending needle tip 21;

[0047] The processing device 30 is communicatively connected to the automated mechanism device 10 and is used to send control commands to the automated mechanism device 10.

[0048] The automated mechanism 10 is used to move according to the control command of the processing device 30, acquire the bending tip image of the bending tip 21 in the glue bucket bending tip device 20, and transmit it to the processing device 30.

[0049] The processing device 30 is also used to perform image processing on the bent needle tip image based on a preset image processing algorithm, identify the position of the bent needle tip in the bent needle tip image, and perform bent needle tip calibration based on the position of the bent needle tip in the bent needle tip image.

[0050] In this embodiment, a vision-based needle tip calibration device is provided, including an automated mechanism, a glue bucket needle tip device, and a processing device. The glue bucket needle tip device is mounted on the automated mechanism. The automated mechanism moves according to the control instructions of the processing device and acquires images of the needle tips in the glue bucket needle tip device. The processing device performs image processing on the needle tip images based on a preset image processing algorithm, identifies the position of the needle tips in the needle tip images, and performs needle tip calibration based on the position of the needle tips in the needle tip images. This system utilizes a mechanical structure combined with industrial vision technology to accurately identify and capture the position of the bent needle tip for effective and precise equipment calibration. This further enables stable, reliable, convenient, and accurate dispensing of adhesive to product sides or gaps, improving dispensing precision and enhancing the process accuracy and product quality of the dispensing equipment. The automated mechanism moves according to the control commands of the processing unit, automatically acquiring images of the bent needle tip in the glue container. The processing unit automatically captures these images based on a preset image processing algorithm. This automated image processing and capture process reduces manual intervention and improves the efficiency of the dispensing equipment. The processing unit calibrates the bent needle tip based on its position in the image, improving system reliability. This solves the problems of slow calibration speed, low efficiency, and excessive manual intervention associated with traditional straight-bent needle tip calibration methods, which fail to provide convenient and accurate calibration for precision dispensing.

[0051] In one embodiment, the automated mechanism 10 is used to move according to the control command of the processing device 30, acquire the bending tip image of the bending tip 21 in the glue bucket bending tip device 20, and transmit it to the processing device 30.

[0052] Specifically, such as Figure 1 As shown, the automated mechanism 10 includes a moving platform 11 in the upper part and a photographic device 12 in the lower part, wherein:

[0053] The moving platform 11 is located on the upper part of the photographic device 12 and is used to move the rotation center of the rotating axis to align with the center position of the camera of the photographic device 12 according to the control command of the processing device 30.

[0054] Specifically, such as Figure 1As shown, the mobile platform 11 includes an X-axis, a Y-axis, a Z-axis, and an R-axis. The effective travel of the Z-axis is 0 to 360 degrees. The R-axis is a rotation axis with an effective travel of 0 to 360 degrees. The clockwise direction of the rotation axis is set as positive. Rotating the bent needle tip 21 to the right is set as the 0 position of the rotation axis.

[0055] The photographic device 12 is used to capture the image of the bent needle tip 21 in the bent needle tip device 20 of the glue bucket and transmit it to the processing device 30.

[0056] Specifically, such as Figure 1 As shown, the photographic device 12 includes a camera 121 and a coaxial light source 122.

[0057] The coaxial light source 122 is paired with the camera 121 to provide a white coaxial light source for the camera 121.

[0058] Camera 121 is used to acquire images of the bent needle tip 21 in the glue bucket bent needle tip device 20 under the illumination of a white coaxial light source provided by coaxial light source 122, and transmit the images to the processing device 30.

[0059] For example, camera 121 is a vertically fixed 1.3-megapixel 2D black and white camera. With the help of coaxial light source 122, camera 121 acquires the image of the bent needle tip 21 under the illumination of white coaxial light source provided by coaxial light source 122 based on a suitable field of view and focal length, and transmits the bent needle tip image to processing device 30.

[0060] In this embodiment, an automated mechanism is used, comprising a moving platform at the top and a camera at the bottom. The moving platform carries a glue bucket bending needle tip device. The camera, illuminated by a white coaxial light source, captures images of the bending needle tip in the glue bucket bending needle tip device, thereby achieving automated image capture, reducing manual intervention, and improving the working efficiency of the dispensing equipment.

[0061] In one embodiment, the glue bucket bending needle tip device 20 is mounted on the automated mechanism device 10.

[0062] Specifically, the glue bucket bent needle tip device 20 is mounted on the Z-axis of the moving platform, and under the action of air pressure, the glue can be dispensed from the bent needle tip 21 along the needle tube.

[0063] like Figure 1 As shown, the glue bucket bent needle tip device 20 includes a bent needle tip 21, a metal pad 22, and a needle tube 23.

[0064] in:

[0065] The syringe 23 is mounted on the Z-axis of the mobile platform.

[0066] The bent needle tip 21 is located below the needle tube 23. The bent needle tip 21 is locked to the needle tube 23 by the metal pad 22. The bending angle of the bent needle tip 21 can be 75 degrees or 90 degrees. The diameter of the needle hole of the bent needle tip 21 is very small. Under the action of air pressure, the glue can be dispensed from the bent needle tip 21 along the needle tube 23.

[0067] The metal pad 22 is screwed under the needle tube 23. An opening is provided in the center of the metal pad 22 to allow the bent needle tip 21 to pass through, facilitating quick and easy replacement of the bent needle tip 21. The metal pad 22 is made of frosted material, primarily to absorb light and facilitate manual adjustment. The back 221 of the metal pad 22 is a silver reflective material, effectively ensuring that when the camera 121 captures the image of the bent needle tip 21, the background appears white under the illumination of the white coaxial light source provided by the coaxial light source 122, minimizing noise and facilitating binarization analysis during image processing.

[0068] After the curved needle tip 21 passes through the opening in the middle of the metal pad 22, it can be locked in the opening in the middle of the metal pad 22 and will not fall off. The metal pad 22 is screwed under the needle tube 23. By manually turning it to loosen or tighten it, the curved needle tip 21 can be fixedly installed under the needle tube 23 and connected to the needle tube 23, so that under the action of air pressure, the glue can be sprayed out from the curved needle tip 21 along the needle tube 23.

[0069] In one embodiment, the processing device 30 is communicatively connected to the automated mechanism device 10, and is used to send control commands to the automated mechanism device 10, and receive the bent needle tip image transmitted from the automated mechanism device 10, perform image processing on the bent needle tip image based on a preset image processing algorithm, identify the bent needle tip position in the bent needle tip image, and perform bent needle tip calibration based on the bent needle tip position in the bent needle tip image.

[0070] For the specific processing procedure, please refer to step S5 in the vision-based bent needle tip calibration method, which will not be repeated here.

[0071] For example, the processing device 30 is an electronic device with data processing and communication functions, which may be a personal computer, server or workstation.

[0072] Based on the same concept, in one embodiment, such as Figure 2 As shown, the present invention provides a vision-based needle tip calibration method, applied to the vision-based needle tip calibration device 100 described in any of the above embodiments. The vision-based needle tip calibration device 100 includes an automated mechanism, a glue bucket needle tip device, and a processing device; the vision-based needle tip calibration method includes:

[0073] S1. The glue bucket bending needle tip device is mounted on the automated mechanism device. The glue bucket bending needle tip device includes a bending needle tip.

[0074] S2. The processing device sends control commands to the automated mechanism.

[0075] S3. The automated mechanism moves according to the control command of the processing device, collects the image of the bent needle tip in the glue bucket bent needle tip device, and transmits it to the processing device.

[0076] S5. The processing device performs image processing on the bent needle tip image based on a preset image processing algorithm, identifies the position of the bent needle tip in the bent needle tip image, and performs bent needle tip calibration based on the position of the bent needle tip in the bent needle tip image.

[0077] In this embodiment, a vision-based needle tip calibration method is provided. The glue bucket needle tip device is mounted on an automated mechanism device, and the glue bucket needle tip device includes a needle tip. The automated mechanism device moves according to the control command of the processing device, and acquires the needle tip image of the glue bucket needle tip device. The processing device performs image processing on the needle tip image based on a preset image processing algorithm, identifies the position of the needle tip in the needle tip image, and performs needle tip calibration based on the position of the needle tip in the needle tip image. This system utilizes a mechanical structure combined with industrial vision technology to accurately identify and capture the position of the bent needle tip for effective and precise equipment calibration. This further enables stable, reliable, convenient, and accurate dispensing of adhesive to product sides or gaps, improving dispensing precision and enhancing the process accuracy and product quality of the dispensing equipment. The automated mechanism moves according to the control commands of the processing unit, automatically acquiring images of the bent needle tip in the glue container. The processing unit automatically captures these images based on a preset image processing algorithm. This automated image processing and capture process reduces manual intervention and improves the efficiency of the dispensing equipment. The processing unit calibrates the bent needle tip based on its position in the image, improving system reliability. This solves the problems of slow calibration speed, low efficiency, and excessive manual intervention associated with traditional straight-bent needle tip calibration methods, which fail to provide convenient and accurate calibration for precision dispensing.

[0078] In one embodiment, in step S3, the automated mechanism moves according to the control command of the processing device, acquires an image of the bent needle tip in the glue bucket bent needle tip device, and transmits it to the processing device, including:

[0079] S31. Based on the angle of one revolution of the mobile platform's rotation axis, the plane containing one revolution of the rotation axis is divided into several rotation positions by a preset rotation angle. The preset rotation angle is the angle of one revolution of the mobile platform's rotation axis, evenly distributed among the several rotation positions. Specifically, this includes:

[0080] S311. Determine the rightward rotation direction of the mobile platform's rotation axis as the 0 position of the rotation axis, and the clockwise direction as the positive direction.

[0081] S312. Under the premise that the XYZ axis of the calibration origin remains unchanged, based on the angle of the rotating axis of the mobile platform rotating 360°, divide the plane on which the rotating axis rotates 360° in a clockwise direction by a preset rotation angle into several rotation positions. The preset rotation angle is the angle of the rotating axis of the mobile platform rotating 360° in a clockwise direction, which is divided equally by the number of rotation positions.

[0082] For example, the rotation angle of the mobile platform's rotating axis is 360°. The plane on which the rotating axis rotates once is divided into 8 rotation positions in a clockwise direction based on a preset rotation angle. The preset rotation angle is the angle of the mobile platform's rotating axis rotated once, which is divided into 8 positions corresponding to the number 8. That is, the preset rotation angle is 45° (360° / 8=45°). The plane on which the rotating axis rotates once is divided into 8 rotation positions in a clockwise direction based on the preset rotation angle of 45°, namely the positions of 0°, 45°, 90°, 135°, 180°, 225°, 270°, and 315°, for a total of 8 rotation positions.

[0083] In the later embodiments of the present invention, the example is given by dividing the plane into eight rotation positions in a clockwise direction with a preset rotation angle of 45°. However, it is understood that the number of rotation positions in the present invention, which is to divide the plane into several rotation positions in a clockwise direction with a preset rotation angle, is not limited to eight, and the number can be even.

[0084] S32. Adjust camera parameters, use the camera to acquire images of the bent needle tip at each rotation position, and transmit them to the processing device; specifically including:

[0085] S321. Rotate the rotating axis of the mobile platform to one of the rotation positions.

[0086] S322. Adjust the moving platform to the center position of the camera, and adjust the camera light source and camera focal length parameters to make the bent needle tip clear in the camera's field of view.

[0087] S323. Acquire images of the curved needle tip within the camera's field of view, such as... Figure 1 or Figure 2 As shown.

[0088] Figure 3 Image of a 75° bent needle tip. Figure 4 The image is of a 90° bent needle tip, the difference being... Figure 3The tip of the bent needle is relatively short. Figure 4 The tip of the curved needle is relatively long. Figure 3 The inner width of the white part at the tip of the curved needle is close to 0. Figure 4 The white part at the tip of the curved needle is the obvious inner width.

[0089] S324. Repeat steps S321 to S323 until the bent needle tip image at each rotation position is obtained, and transmit the bent needle tip image at each rotation position to the processing device.

[0090] For example, let's take a preset rotation angle of 45° and divide the plane of the rotation axis in a clockwise direction into 8 equal rotation positions. Rotate the moving platform's rotation axis to the first rotation position (0°), and obtain the image of the bent needle tip at this position. Then rotate the moving platform's rotation axis to the second rotation position (45°), and obtain the image of the bent needle tip at this position. Next, rotate the moving platform's rotation axis to the third rotation position (90°), and obtain the image of the bent needle tip at this position. This process continues until the image of the bent needle tip at the ninth rotation position (315°) is obtained.

[0091] In this embodiment, by dividing the plane of the rotating axis of the mobile platform into several rotation positions at a preset rotation angle, the angle of rotation of the axis is used to capture the bent needle tip image at each rotation position and transmit it to the processing device. This enables automated image capture, reduces manual intervention, and improves the working efficiency of the dispensing equipment.

[0092] In one embodiment, such as Figure 2 As shown, the vision-based bent needle tip calibration method also includes: S4, a processing device determining the calibration relationship between the camera center and the moving platform. Specifically, it includes:

[0093] S41. Move the mobile platform to the center of rotation of the rotating axis, aligning it with the center of the camera. The tip of the rotating axis needle should be pointing to the right. Record the current position as the origin.

[0094] S42. Adjust the camera image field of view to achieve optimal clarity, specifically including:

[0095] In continuous camera acquisition mode, adjust the light source brightness, camera exposure, gain, and contrast to their optimal values.

[0096] S43. Use a camera to acquire images of the bent needle tip, and perform 4*4 matrix camera calibration based on the bent needle tip images to determine the calibration relationship between the camera center and the moving platform, including:

[0097] S431. Create a template diagram and match parameters to the template diagram, specifically including:

[0098] Acquire a single frame of the bent needle tip image, draw a green rectangular frame on the bent needle tip image, and select the center region of the bent needle tip in the image as the template image; draw a red rectangular frame on the bent needle tip image, and use the entire bent needle tip image as the search area image; match parameters for the template image, including search score, angle, scaling ratio, noise, and contrast, to ensure that the match is successful and accurate every time, and mark the center position of the template with a red crosshair.

[0099] S432. Within the preset camera image field of view, generate several physical coordinates of rotational positions at the current coordinate position of the mobile platform, forming a trajectory list, specifically including:

[0100] Set the camera's field of view size to 10mm*10mm (close to but smaller than the actual field of view size); generate 16 physical coordinates in 4 rows*4 columns up, down, left, and right at the current coordinate position of the moving platform to form a trajectory table. The maximum horizontal travel distance is no more than 10mm, and the maximum column travel distance is no more than 10mm. That is, all 16 physical coordinates are within the camera's field of view. Here, only the X and Y axes are changed, while the Z axis remains unchanged.

[0101] S433. Based on the physical coordinates of several rotation positions in the trajectory list, obtain the corresponding template center coordinates on the template image, and initially generate the calibration relationship between the camera center and the moving platform, specifically including:

[0102] Traverse the physical coordinates of the 16 positions in the trajectory list, obtain the 16 positions from left to right and top to bottom on the template diagram, and obtain the template center position coordinates of each position on the template diagram. Record the template center position coordinates corresponding to the physical coordinates of the 16 positions in the template diagram in sequence.

[0103] S434. Based on the coordinates of the template center position corresponding to several rotational physical coordinates on the template image, the camera calibration is calculated using the homography matrix method, specifically including:

[0104] Using the least squares method, and through linear transformation and perspective matrix transformation, the physical coordinates of the 16 locations are mapped to the corresponding center coordinates of the template in the template image to construct a system of equations to solve for the homography matrix, thus enabling camera calibration. This is essentially a projection matrix from one image coordinate plane to another physical coordinate plane, mapping points on one plane to corresponding points on another. Specifically, given the coordinates of 16 corresponding points in two images, these are substituted into the corresponding equations to construct a system of equations to solve for the homography matrix.

[0105] S435. Based on the pixel size of the entire bent needle tip image, determine the true field of view of the camera image. Repeat steps S432 and S434 above to accurately generate the calibration relationship between the camera center and the moving platform.

[0106] S436. Verify the calibration relationship between the camera center and the moving platform: Select any feature point on the curved needle tip image, and use the calibration relationship between the camera center and the moving platform to determine the corresponding physical coordinate position.

[0107] In one embodiment, in step S5, the processing device performs image processing on the bent needle tip image based on a preset image processing algorithm, identifies the position of the bent needle tip in the bent needle tip image, and performs bent needle tip calibration based on the position of the bent needle tip in the bent needle tip image. Specifically, this includes:

[0108] S51. Based on a preset image processing algorithm, find the bent needle tip from the bent needle tip image at each rotation position to obtain the bent needle tip finding result. Specifically, this includes:

[0109] S511. Perform image processing on the bent needle tip image at a preset rotation angle position to obtain a processed bent needle tip image; including:

[0110] S5111. Use an image processing library (such as OpenCV) to extract the edges of the bent needle tip image at a preset rotation angle position, and perform grayscale processing to convert it into grayscale space to obtain a binarized image.

[0111] S5112. Use the Canny edge detection operator to perform image edge detection on the binarized image to obtain the image edge group E.

[0112] Furthermore, in order to remove noise and refine edges, morphological operations (e.g., dilation, erosion, opening, and closing operations) are used to obtain an optimized set of image edges E.

[0113] S512. Determine the position of the bent needle tip based on the image edge group E.

[0114] S5121. Determine the center point of the image. The center point of the image is the point with a pixel size of (width / 2, height / 2) of the entire bent needle tip image.

[0115] S5122. Using the center point of the image as the center, draw a set of concentric circles. Each concentric circle intersects with the image edge group E to obtain a set of points. Select point pairs in the point set whose distance is between the parameters [minimum distance, maximum distance], and use the center of the point pair as the candidate point. In this way, obtain the candidate points of all concentric circles and form a candidate point set.

[0116] S5123. Fit a straight line using the candidate points in the candidate point set, discarding lines shorter than the image center point and retaining lines longer than the image center point. In some embodiments, inner width and outer width are also provided to define the lines to be retained.

[0117] S5124. Among the retained straight lines, the segment from which the two ends of the line are furthest from the center point of the image is the approximate location of the needle tip.

[0118] S5125. Find the intersection of the straight line and the image edge group E at the approximate location of the bent needle tip. This is the location of the bent needle tip. At this point, draw the green cross line of the bent needle tip.

[0119] S513. Measure the parameters of the bent needle tip based on the bent needle tip image and bent needle tip position.

[0120] S5131. Measure the inner and outer widths of the curved needle tip, including: determining the inner and outer edges of the curved needle tip through edge analysis of the curved needle tip image, and then measuring the inner and outer widths. In step S5123 above, the required edge line can be found more accurately.

[0121] S5132. Measure the length of the bent needle tip, including: using the straight line characteristics of the bent needle tip, extract the distance from the endpoint of the bent needle tip to the center point of the image to obtain the length, and extend the green line of the bent needle tip based on the above step j.

[0122] S5133. Adjust the contrast and threshold of the bent needle tip image. Ironblood: Dynamically adjust the contrast and threshold of the bent needle tip image according to different lighting conditions and bent needle tip material to enhance the distinction between the bent needle tip and the background.

[0123] S514. Based on the position of the bent needle tip, locate the bent needle tip from the bent needle tip image and obtain the result of the bent needle tip location; specifically including:

[0124] S5141. Determine the selection area in the bent needle tip image, including: drawing a green rectangle with arrows based on the size and shape of the bent needle tip. The direction of the arrows is the template angle direction, with 0 degrees to the right. This determines the selection area and prevents other interfering factors from entering the detection range. The selection criteria are: at the origin position, in continuous image acquisition mode, with the rotation axis rotated 360 degrees, the position of the bent needle tip does not exceed the green rectangle. The selection area stores the pixel parameter data of the green rectangle, such as center coordinates, length, width, and angle.

[0125] S5142. Determine the direction of the bent needle tip in the bent needle tip image, including: determining the direction of the bent needle tip in the bent needle tip image by analyzing the shape features and edge direction of the bent needle tip. The specific process can be referred to steps S5121 to S5125 above, and will not be repeated here.

[0126] Center positioning: Calculate the center position of the image and adjust the upper moving mechanism to ensure that one end of the bent needle tip is always located in the exact center area of ​​the image. The specific process can be found in step S5121 above, and will not be repeated here.

[0127] S5143. Based on the direction of the bent needle tip, find the bent needle tip in the bent needle tip image, including: using edge detection algorithms and shape analysis to identify the position of the bent needle tip in the bent needle tip image.

[0128] Specifically, after determining the direction of the beveled tip, the beveled tip image is binarized. Edge detection algorithms and shape analysis are used to extract the edge regions, separating the beveled tip from the background. The beveled tip appears as a distinct black stripe. The inner and outer edges of this black stripe are captured to obtain the position of the beveled tip in the image. During the process of separating the beveled tip from the background, it is crucial to avoid significant noise in the background image. Excessive noise may cause misalignment of the beveled tip's position; therefore, the beveled tip image must be clear.

[0129] S5144. Based on the identified position of the bent needle tip in the bent needle tip image, mark the results of finding the bent needle tip, including:

[0130] If the bend tip is successfully located in the bend tip image, mark its position in the image using a marker symbol or color, and record the corresponding pixel coordinates so that the operator can intuitively understand the location of the bend tip. For example, a successful location is indicated by a green crosshair.

[0131] If the bent needle tip is not found in the bent needle tip image, a message indicating a failure to find the bent needle tip is displayed so that timely action can be taken. For example, a failure to find the bent needle tip is displayed in red as "NG".

[0132] S52. Based on the results of finding the bent needle tip, calibrate the bent needle tip that was successfully found.

[0133] Specifically, after finding the bend tip at several rotational positions (e.g., 8 rotational positions) and recording the corresponding pixel coordinate values ​​of the successfully found bend tips, the successfully found bend tips can be calibrated.

[0134] In this invention, eight rotation positions are used as an example for explanation. After completing the rotation of the bend tip at the eight rotation positions, eight bend tip finding results are obtained, resulting in eight bend tip points. These eight bend tip points are used to fit an ellipse, and the position of the bend tip is inferred using the ellipse equation and rotation angle, thus performing bend tip calibration.

[0135] The specific process is as follows:

[0136] Assuming the center of the ellipse is the center of rotation, the position of the needle tip at any rotation angle can be calculated using the following formula.

[0137] 1) General form of the equation of an ellipse: The general equation of an ellipse in a Cartesian coordinate system is:

[0138] Ax 2 +Bxy+Cy 2 +Dx+Ey+F=0

[0139] 2) Rotation Angle and Coordinate Transformation: Let the original point coordinates be (x, y), the rotation angle be θ, and the rotated coordinates be (x', y'). Then the coordinate transformation formula is:

[0140] x′=xcosθ-ysinθ

[0141] y′=xsinθ+ycosθ

[0142] 3) Coordinates of the bend tip and the equation of the ellipse: Given 8 bend tips, let the original coordinates of the bend tips be (xi, yi), and the rotation angles be θ1, θ2…θ8. Then the coordinates of the rotated bend tips are (xi′, yi′), which satisfy the equation of the ellipse:

[0143]

[0144] Substituting the coordinate transformation formula into the ellipse equation, we obtain the equations for the original coordinates of the needle tip and the rotation angle:

[0145] A(x i cosθ i -y i sinθ j ) 2 +B(x i cosθ j-y i sinθ j (x) i sinθ j +y i cosθ j )

[0146] +C(x i sinθ j +y i cosθ j ) 2 +D(x i cosθ j -y i sinθ j )+E(x i sinθ j +y i cosθ j )+F=0

[0147] Further organized as follows:

[0148]

[0149] 4) Fitting an ellipse using the tips of the bent needles: There are 8 tips of the bent needles, which means there are 8 systems of equations:

[0150]

[0151] Transform it into matrix form:

[0152]

[0153] 5) Estimate the coefficients A, B, C, D, E, and F in the equation of the ellipse using methods such as the least squares method.

[0154]

[0155] Once the coefficients of the ellipse equation are determined, the position of the bent needle tip can be deduced using coordinate transformation formulas based on a given rotation angle. The specific process is as follows:

[0156] ① Let the equation of the ellipse be:

[0157] (x 2 / a 2 )+(y 2 / b 2 ) = 1, where a and b are known coefficients.

[0158] ② Let the rotation angle be θ.

[0159] ③ The coordinate transformation formula is as follows:

[0160] For the original coordinates (x, y), the rotated coordinates are (x', y'):

[0161] x'=x*cosθ-y*sinθ

[0162] y'=x*sinθ+y*cosθ

[0163] ④ It is now known that the position of the rotated needle tip lies on an ellipse, satisfying the following equation of the ellipse:

[0164] (x' 2 / a 2 )+(y' 2 / b 2 ) = 1

[0165] Substituting the coordinate transformation formula into the above ellipse equation, we obtain the following equation:

[0166]

[0167] Using the equation above, given the coefficients a and b of the ellipse equation and the rotation angle θ, the original coordinates (x, y) of the bent needle tip can be deduced. An example is shown below:

[0168] ⑤ Assuming coefficients A = 9, B = 0, C = 4, D = 0, E = 0, and F = -36, the fitted ellipse equation is:

[0169] 9x 2 +4y 2 -36 = 0, after transformation we get: x 2 / 4+y 2 / 9 = 1.

[0170] Therefore, we know that the center of the ellipse is at (0,0), the major semi-axis is a = 2, the minor semi-axis is b = 3, and the ellipse has rotated 45° counterclockwise around the origin. First, convert the angle 45° to radians θ = π / 4. After rotation, the coordinates of the bent needle tip are (x', y') = (1, 2). Then, according to the coordinate transformation formula, we first calculate:

[0171]

[0172] Then calculate the value of x:

[0173]

[0174] Calculate the value of y again:

[0175]

[0176] Therefore, the original position of the bent needle tip can be determined as follows:

[0177] In summary, the above formulas and methods can be used to deduce the position of the bent needle tip using the equation of an ellipse and the rotation angle, thus enabling the calibration of the bent needle tip.

[0178] In this embodiment, based on the established calibration relationship between the camera center and the moving platform, a preset image processing algorithm is used to search for the bent needle tip from the images of the bent needle tip at each rotation position, yielding the found bent needle tip results. From these results, the successfully found bent needle tips are calibrated using the ellipse equation and rotation angle. This allows for precise control of the bent needle tip's position and parameters, improving dispensing accuracy, ensuring dispensing precision and stability, and enhancing product quality. Automated image capture and processing reduces manual intervention, increasing the efficiency of the dispensing equipment. During calibration, timely anomaly alerts prevent dispensing errors caused by inaccurate or missing bent needle tips, improving system reliability. By utilizing mechanical structures in conjunction with industrial vision technology to accurately identify and capture the bent needle tip position for effective and accurate equipment calibration, this system provides stable, reliable, convenient, and precise dispensing for product sides or gaps, improving the process precision, accuracy, and reliability of the dispensing equipment. This solves the problems of slow calibration speed, low efficiency, and excessive human intervention caused by the existing traditional straight-bend needle tip calibration method for calibrating bent needle tips, which cannot provide more convenient and accurate operation for precision dispensing.

[0179] In one embodiment, the vision-based bent needle tip calibration method further includes: S6, after the bent needle tip calibration is completed, verifying the correctness of the bent needle tip calibration.

[0180] Specifically, after the bend tip calibration is completed, a bend tip calibration can be used to verify the correctness of the bend tip calibration. If the rotating axis does not have a zero-return or limit signal, the zero-return of the rotating axis depends on the direction of the template made by the bend tip. This gives the initial bend tip position more directional flexibility. Depending on the product material placement characteristics, users can configure different rotation values ​​for the rotating axis. The dispensing path generated by the trajectory clearly shows the dispensing quality, thereby verifying the correctness of the bend tip calibration.

[0181] It should be noted that the above-described vision-based needle tip calibration method embodiment and the above-described vision-based needle tip calibration device embodiment belong to the same concept. For details of its specific implementation process, please refer to the vision-based needle tip calibration device embodiment. Furthermore, the technical features of the vision-based needle tip calibration device embodiment are all applicable to the above-described vision-based needle tip calibration method embodiment, and will not be repeated here.

[0182] It should be noted that, in this document, the terms "comprising," "including," or any other variations thereof are intended to cover non-exclusive inclusion, such that a process, method, article, or apparatus that comprises a list of elements includes not only those elements but also other elements not expressly listed, or elements inherent to such a process, method, article, or apparatus. Without further limitation, an element defined by the phrase "comprising one..." does not exclude the presence of other identical elements in the process, method, article, or apparatus that includes said element.

[0183] The above embodiments are only used to illustrate the technical solutions of the present invention, and are not intended to limit it. Under the concept of the present invention, the technical features of the above embodiments or different embodiments can also be combined, the steps can be implemented in any order, and there are many other variations of different aspects of the present invention as described above. For the sake of brevity, they are not provided in detail. Although the present invention has been described in detail with reference to the foregoing embodiments, those skilled in the art should understand that modifications can still be made to the technical solutions described in the foregoing embodiments, or equivalent substitutions can be made to some of the technical features. These modifications or substitutions do not cause the essence of the corresponding technical solutions to deviate from the scope of the technical solutions of the embodiments of the present invention.

Claims

1. A vision-based needle tip calibration device, characterized in that, It includes an automated mechanism, a glue bucket bending needle tip device, and a processing device, wherein: The glue bucket bending needle tip device is mounted on the automated mechanism device, including the bending needle tip; The processing device is communicatively connected to the automated mechanism and is used to send control commands to the automated mechanism. The automated mechanism includes a moving platform and a photographic device. The moving platform is located above the photographic device and includes an X-axis, Y-axis, Z-axis, and R-axis. The R-axis is a rotation axis used to move according to the control command, and the rotation center of the rotation axis is aligned with the center position of the camera of the photographic device. The photographic device includes a camera and a coaxial light source, and the coaxial light source provides a white coaxial light source for the camera. The camera is used to capture an image of the bent needle tip under the illumination of the white coaxial light source provided by the coaxial light source and transmit it to the processing device. The processing device is further configured to perform image processing on the bent needle tip image based on a preset image processing algorithm, identify the position of the bent needle tip in the bent needle tip image, and perform bent needle tip calibration based on the position of the bent needle tip in the bent needle tip image.

2. The vision-based bent needle tip calibration device according to claim 1, characterized in that, The effective travel of the R-axis is 0 to 360 degrees. The clockwise direction of the rotating axis is set as positive, and the tip of the bent needle is rotated to the right and set as the 0 position of the rotating axis.

3. The vision-based bent needle tip calibration device according to claim 1, characterized in that, The rubber bucket bending needle tip device also includes a metal pad and a needle tube, wherein: The needle is mounted on the Z-axis of the moving platform; The curved needle tip is located below the needle tube, and the curved needle tip is locked onto the needle tube by the metal pad; The metal pad is screwed under the needle tube, and the metal pad has an opening in the middle so that the bent needle tip can pass through it and be snapped into the opening in the middle of the metal pad.

4. The vision-based bent needle tip calibration device according to claim 3, characterized in that, The back of the metal pad is made of a silver reflective material, which ensures that when the camera captures an image of the bent needle tip, the background appears white under the illumination of the white coaxial light source provided by the coaxial light source, thereby reducing noise.

5. A vision-based method for calibrating bent needle tips, characterized in that, The vision-based needle tip calibration device according to any one of claims 1 to 4, wherein the vision-based needle tip calibration method comprises: The glue bucket bending needle tip device is mounted on the automated mechanism device, and the glue bucket bending needle tip device includes a bending needle tip; The processing device sends control commands to the automated mechanism. The automated mechanism moves according to the control command, captures an image of the bent needle tip, and transmits it to the processing device. The processing device performs image processing on the bent needle tip image based on a preset image processing algorithm, identifies the position of the bent needle tip in the bent needle tip image, and performs bent needle tip calibration based on the position of the bent needle tip in the bent needle tip image.

6. The vision-based needle tip calibration method according to claim 5, characterized in that, The automated mechanism moves according to the control command, acquires an image of the bent needle tip, and transmits it to the processing device, including: Based on the angle of one revolution of the mobile platform's rotation axis, the plane on which the rotation axis rotates one revolution is divided into several rotation positions by a preset rotation angle. The preset rotation angle is the angle of one revolution of the mobile platform's rotation axis, which is divided equally by the number of rotation positions. Adjust the camera parameters, use the camera to acquire images of the bent needle tip at each rotation position, and transmit them to the processing device.

7. The vision-based needle tip calibration method according to claim 5, characterized in that, The vision-based bent needle tip calibration method also includes the processing device determining the calibration relationship between the camera center and the moving platform.

8. The vision-based needle tip calibration method according to claim 7, characterized in that, The processing device performs image processing on the bent needle tip image based on a preset image processing algorithm, identifies the position of the bent needle tip in the bent needle tip image, and performs bent needle tip calibration based on the position of the bent needle tip in the bent needle tip image, including: Based on the preset image processing algorithm and the calibration relationship between the camera center and the moving platform, the bent needle tip is searched from the bent needle tip image at each rotation position to obtain the searched bent needle tip result. Based on the results of the search for bent needle tips, the bent needle tips that were successfully found are calibrated.

Images