Simulation micro-touch automatic control system based on PLC and machine vision

Abstract

The invention provides a simulation micro-touch automatic control system based on a PLC and machine vision, and belongs to the technical field of processing equipment control, the simulation micro-touch automatic control system specifically comprises an HMI interface, a vision system, a PLC system, a pressure sensor and an execution mechanism, the HMI interface, the vision system, the pressure sensor and the execution mechanism are all in communication connection with the PLC system, and the PLC system is in communication connection with the PLC system. The HMI interface is used for model switching and parameter setting of a user, the visual system is used for image acquisition and processing, the pressure sensor is used for detecting the holding force of the micro-contact device to a product, the PLC system serves as a central control unit, and the PLC system controls the execution mechanism to achieve automatic feeding and discharging of the product, micro-touch action of the micro-contact device and force value judgment. The problems that micro-touch force value detection cannot be quantified and the labor cost is high are solved, and automatic detection of the micro-touch process is achieved.

Description

Technical Field

[0001] The present application relates to the field of processing equipment control, and in particular to an analog micro-touch automatic control system based on PLC and machine vision. Background Art

[0002] The micro-touch process is a typical process of the product. At present, this process is to manually use a micro-touch device to perform hole-by-hole inspection on the product. There are problems such as the micro-touch force value detection cannot be quantified, involving a large number of product types and quantities, and high labor costs. Summary of the invention

[0003] In view of this, the present application provides an analog micro-touch automatic control system based on PLC and machine vision to solve the problem that micro-touch force value detection cannot be quantified and the labor cost is high, and to realize automatic detection of micro-touch processes.

[0004] The present application provides a PLC and machine vision-based analog micro-touch automatic control system that adopts the following technical solutions:

[0005] A simulated micro-touch automatic control system based on PLC and machine vision, comprising an HMI interface, a visual system, a PLC system, a pressure sensor and an actuator, wherein the HMI interface, the visual system, the pressure sensor and the actuator are all connected to the PLC system for communication; the HMI interface is used for users to switch models and set parameters; the visual system performs image acquisition and processing; the pressure sensor is used to detect the holding force of a micro-tactile device on a product; the PLC system serves as a central control unit; and the PLC system controls the actuator to realize automatic loading and unloading of products, micro-touch action of the micro-tactile device and force value judgment.

[0006] Optionally, the HMI interface includes a touch screen, a data processing unit and a switch, the data processing unit is used to store product models, the number of holes, micro-touch positions and micro-touch force values, the touch screen is used as an interactive interface, model switching, parameter setting and system debugging are achieved through the touch screen, and the switch is used for communication between the HMI interface and the PLC system.

[0007] Optionally, the visual system includes an industrial camera, an industrial computer, a light source and a light source controller. The PLC system sends light source control signals and image acquisition signals to the industrial camera and the light source controller. After receiving the signals, the light source controller controls the switch of the light source. The machine vision software in the industrial computer performs image acquisition and processing, stores the image processing results, and sends the hole position coordinate data to the PLC system.

[0008] Optionally, the PLC system includes a controller, an input / output expansion module, an AD conversion module and a communication interface, wherein the input / output expansion module expands the IO points of the controller body and together with the communication interface realizes control of the actuator; the AD conversion module is used to convert the analog data of the pressure sensor into digital data for the controller to read and process.

[0009] Optionally, the actuator includes a speed regulating motor, a servo motor, a servo controller, a cylinder and a solenoid valve;

[0010] The speed regulating motor is used to drive the conveyor belt to transport the tested product to realize automatic loading and unloading;

[0011] The servo controller controls the servo motor to drive the micro-tactile device to move to the micro-tactile position according to the hole position coordinate data sent by the PLC system, and drives the micro-tactile device to perform up and down micro-tactile actions; during the micro-tactile process, the PLC system obtains the micro-tactile force value in real time by reading the data of the pressure sensor, and determines whether it is qualified;

[0012] The solenoid valve controls the extension and retraction of the cylinder according to the IO control signal of the PLC system to achieve the clamping and limiting of the product.

[0013] Optionally, the communication interface includes an EtherCAT interface, and the EtherCAT interface is used to connect the PLC system and the servo controller to achieve communication between the PLC system and the servo controller.

[0014] Optionally, the communication interface also includes a Modbus TCP network port, and the HMI interface, visual system, and pressure sensor are all connected to the PLC system via a network cable and a Modbus TCP network port.

[0015] To summarize, the present application includes the following beneficial technical effects: the control system adopts a combination of software and hardware to realize automatic loading and unloading of products, image acquisition and processing, automatic micro-touch and judgment, etc., which improves the traditional operation method. Through HM I, machine vision, PLC, and mutual cooperation, the automatic detection of micro-touch processes can be realized. It has good versatility, high operating speed, and good stability. It solves the problem that micro-touch force value detection cannot be quantified, reduces the labor cost of the process, realizes the automatic detection of micro-touch processes, and improves the automation level of the production process. BRIEF DESCRIPTION OF THE DRAWINGS

[0016] In order to more clearly illustrate the technical solutions of the embodiments of the present application, the drawings required for use in the embodiments will be briefly introduced below. Obviously, the drawings described below are only some embodiments of the present application. For ordinary technicians in this field, other drawings can be obtained based on these drawings without paying creative work.

[0017] Figure 1 It is a schematic diagram of the structural block diagram of the simulated micro-touch automatic control system of this application.

[0018] Figure 2 It is a schematic diagram of the composition of the HMI interface of this application.

[0019] Figure 3 It is a schematic diagram of the composition of the visual system of this application.

[0020] Figure 4 It is a schematic diagram of the composition of the PLC system of this application.

[0021] Figure 5 This is a schematic diagram of the structure of the execution agency of this application.

[0022] Explanation of the accompanying drawings: 1. HMI interface; 2. Vision system; 3. PLC system; 4. Actuator; 5. Pressure sensor; 11. Touch screen; 12. Switch; 21. Industrial camera; 22. Industrial computer; 23. Light source; 24. Light source controller; 31. Controller; 32. Input and output expansion module; 33. AD conversion module; 34. Modbus TCP network port; 35. EtherCAT interface; 41. Speed ​​control motor; 42. Servo motor; 43. Servo controller; 44. Solenoid valve; 45. Cylinder. DETAILED DESCRIPTION

[0023] The embodiments of the present application are described in detail below with reference to the accompanying drawings.

[0024] The following describes the implementation methods of the present application through specific examples, and those skilled in the art can easily understand other advantages and effects of the present application from the contents disclosed in this specification. Obviously, the described embodiments are only a part of the embodiments of the present application, rather than all the embodiments. The present application can also be implemented or applied through other different specific implementation methods, and the details in this specification can also be modified or changed in various ways based on different viewpoints and applications without departing from the spirit of the present application. It should be noted that, in the absence of conflict, the following embodiments and the features in the embodiments can be combined with each other. Based on the embodiments in the present application, all other embodiments obtained by ordinary technicians in the field without making creative work belong to the scope of protection of the present application.

[0025] It should be noted that various aspects of the embodiments within the scope of the appended claims are described below. It should be apparent that the aspects described herein can be embodied in a wide variety of forms, and any specific structure and / or function described herein is merely illustrative. Based on the present application, it should be understood by those skilled in the art that an aspect described herein can be implemented independently of any other aspect, and two or more of these aspects can be combined in various ways. For example, any number of aspects described herein can be used to implement the device and / or practice the method. In addition, other structures and / or functionalities other than one or more of the aspects described herein can be used to implement this device and / or practice this method.

[0026] It should also be noted that the illustrations provided in the following embodiments are only schematic illustrations of the basic concept of the present application. The illustrations only show the components related to the present application rather than being drawn according to the number, shape and size of the components in actual implementation. In actual implementation, the type, quantity and proportion of each component may be changed at will, and the component layout may also be more complicated.

[0027] Additionally, in the following description, specific details are provided to facilitate a thorough understanding of the examples. However, it will be understood by those skilled in the art that the aspects described may be practiced without these specific details.

[0028] The embodiment of the present application provides a simulated micro-touch automatic control system based on PLC and machine vision.

[0029] like Figure 1 As shown, a simulated micro-touch automatic control system based on PLC and machine vision includes an HMI interface 1, a visual system 2, a PLC system 3, a pressure sensor 5 and an actuator 4. The HMI interface 1, the visual system 2, the pressure sensor 5 and the actuator 4 are all connected to the PLC system 3 for communication. The HMI interface 1 is used by the user to switch models and set parameters. The visual system 2 performs image acquisition and processing. The pressure sensor 5 is used to detect the holding force of the micro-tactile device on the product. The PLC system 3 serves as a central control unit. The PLC system 3 controls the actuator 4 to realize automatic loading and unloading of products, micro-touch action of the micro-tactile device and force value judgment.

[0030] Specifically, Figure 2 As shown, the HMI interface 1 includes a touch screen 11, a data processing unit, a switch 12 and software programming. The data processing unit is used to store product models, number of holes, micro-touch positions and micro-touch force values. The touch screen 11 is used as an interactive interface to achieve model switching, parameter setting and system debugging through the touch screen 11. The switch 12 is used for communication between the HMI interface 1 and the PLC system 3. Data storage, recording and other functions are realized through software programming.

[0031] like Figure 3 As shown, the visual system 2 includes an industrial camera 21, an industrial computer 22, a light source 23 and a light source controller 24. The industrial camera 21 and the industrial computer 22 are connected by a shielded network cable, the light source controller 23 and the light source 23 are connected by a control line, and the switch 12 and the industrial computer 22 are connected by a network cable, which is used to issue instructions on the HM I interface 1. The PLC system 3 sends a light source control signal and an image acquisition signal to the industrial camera 21 and the light source controller 24 according to the instructions. After receiving the signal, the light source controller 24 controls the switch of the light source 23; after the industrial computer 22 receives the signal, the machine vision software in the industrial computer 22 performs image acquisition and processing, and stores the image processing result and sends the hole position coordinate data to the PLC system 3.

[0032] like Figure 4 As shown, the PLC system 3 includes a controller 31, an input / output expansion module 32, an AD conversion module 33 and a communication interface. The input / output expansion module 32 is an IO point expansion of the controller 31 body and realizes the control of the actuator 4 together with the communication interface; the AD conversion module 33 is used to convert the analog data of the pressure sensor 5 into digital data for reading and processing by the controller 31. The PLC system 3 controls the light source controller 24 through the IO control signal.

[0033] like Figure 5 As shown, the actuator 4 includes a speed regulating motor 41, a servo motor 42, a servo controller 43, a cylinder 45 and a solenoid valve 44; the speed regulating motor 41 is used to drive the conveyor belt to transport the tested product to realize automatic loading and unloading; the servo controller 43 controls the servo motor 42 to drive the micro-touch device to move to the micro-touch position according to the hole coordinate data sent by the PLC system 3, and drives the micro-touch device to perform up and down micro-touch actions; during the micro-touch process, the PLC system 3 obtains the micro-touch force value in real time by reading the data of the pressure sensor 5, and determines whether it is qualified; the solenoid valve 44 controls the extension and retraction of the cylinder 45 according to the IO control signal of the PLC system 3 to realize the clamping and limiting of the product.

[0034] The communication interface includes a Modbus TCP network port 34 and an EtherCAT interface 35. The HMI interface 1, the visual system 2, and the pressure sensor 5 are connected to the PLC system 3 through a network cable and the Modbus TCP network port 34. The EtherCAT interface 35 is used to connect the PLC system 3 and the servo controller 43 to achieve communication between the PLC system 3 and the servo controller 43.

[0035] The above is only a specific implementation of the present application, but the protection scope of the present application is not limited thereto. Any changes or substitutions that can be easily thought of by a person skilled in the art within the technical scope disclosed in the present application should be included in the protection scope of the present application. Therefore, the protection scope of the present application shall be based on the protection scope of the claims.

Claims

1. A simulated micro-touch automatic control system based on PLC and machine vision, characterized in that: The invention comprises an HMI interface (1), a visual system (2), a PLC system (3), a pressure sensor (5) and an actuator (4); the HMI interface (1), the visual system (2), the pressure sensor (5) and the actuator (4) are all connected to the PLC system (3) for communication; the HMI interface (1) is used by a user to switch models and set parameters; the visual system (2) performs image acquisition and processing; the pressure sensor (5) is used to detect the holding force of a micro-tactile device on a product; the PLC system (3) serves as a central control unit; the PLC system (3) controls the actuator (4) to realize automatic loading and unloading of products, micro-tactile action of the micro-tactile device and force value judgment.

2. The PLC and machine vision-based simulated micro-touch automatic control system according to claim 1 is characterized in that: The HMI interface (1) comprises a touch screen (11), a data processing unit and a switch (12); the data processing unit is used to store product models, the number of holes, micro-touch positions and micro-touch force values; the touch screen (11) serves as an interactive interface; model switching, parameter setting and system debugging are achieved through the touch screen (11); and the switch (12) is used for communication between the HMI interface (1) and the PLC system (3).

3. The PLC and machine vision-based simulated micro-touch automatic control system according to claim 1, characterized in that: The visual system (2) comprises an industrial camera (21), an industrial computer (22), a light source (23) and a light source controller (24); the PLC system (3) sends a light source control signal and an image acquisition signal to the industrial camera (21) and the light source controller (24); the light source controller (24) controls the switch of the light source (23) after receiving the signal; the machine vision software in the industrial computer (22) performs image acquisition and processing, stores the image processing result, and then sends the hole position coordinate data to the PLC system (3).

4. The PLC and machine vision-based simulated micro-touch automatic control system according to claim 3 is characterized in that: The PLC system (3) comprises a controller (31), an input / output expansion module (32), an AD conversion module (33) and a communication interface. The input / output expansion module (32) is used to expand the IO points of the controller (31) body and, together with the communication interface, to realize control of the actuator (4); the AD conversion module (33) is used to convert analog data of the pressure sensor (5) into digital data for the controller (31) to read and process.

5. The PLC and machine vision-based simulated micro-touch automatic control system according to claim 4 is characterized in that: The actuator (4) comprises a speed regulating motor (41), a servo motor (42), a servo controller (43), a cylinder (45) and a solenoid valve (44); The speed regulating motor (41) is used to drive the conveyor belt to transport the tested product to realize automatic loading and unloading; The servo controller (43) controls the servo motor (42) to drive the micro-tactile device to move to the micro-tactile position according to the hole position coordinate data sent by the PLC system (3), and drives the micro-tactile device to perform up and down micro-tactile actions; during the micro-tactile process, the PLC system (3) obtains the micro-tactile force value in real time by reading the data of the pressure sensor (5), and determines whether it is qualified; The solenoid valve (44) controls the extension and retraction of the cylinder (45) according to the IO control signal of the PLC system (3), thereby achieving the clamping and limiting of the product.

6. The PLC and machine vision-based simulated micro-touch automatic control system according to claim 5, characterized in that: The communication interface comprises an EtherCAT interface (35), and the EtherCAT interface (35) is used to connect the PLC system (3) and the servo controller (43) to achieve communication between the PLC system (3) and the servo controller (43).

7. The PLC and machine vision-based simulated micro-touch automatic control system according to claim 6, characterized in that: The communication interface also includes a Modbus TCP network port (34), and the HMI interface (1), the visual system (2), and the pressure sensor (5) are all connected to the PLC system (3) via a network cable and the Modbus TCP network port (34).

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