Automatic calibration and detection device of plug-in machine and working method of automatic calibration and detection device

Abstract

The invention discloses an automatic calibration and detection device of a plug-in machine and a working method thereof, and the device comprises a top image collection module which comprises a top camera and a top light source which are disposed above a circuit board; the bottom image acquisition module comprises a bottom camera and a bottom light source which are arranged below the circuit board; the external image acquisition module comprises an external camera, an external light source and an external reflector which are arranged on the side of the circuit board; and the grabbing device comprises a grabbing mechanism and a moving module. Through three-way calibration of the top image acquisition module, the bottom image acquisition module and the external image acquisition module, the calibration accuracy can be improved, errors possibly generated by manual calibration are avoided, and the calibration process is simplified. The invention relates to the technical field of component inserter calibration and detection.

Description

Technical Field

[0001] The present application relates to the technical field of calibration and detection of a plug-in machine, and particularly relates to an automatic calibration and detection device for a plug-in machine and its working method. Background Art

[0002] In the field of electronic manufacturing, as one of the core devices of an automatic equipment line, the accuracy and efficiency of component insertion of a special-shaped plug-in machine directly affect the quality of products and the production efficiency. In order to avoid the occurrence of defective insertion phenomena such as bending of the pins of electronic components during the automatic plug-in process, thereby reducing the possibility of subsequent repair of the circuit board, improving the calibration accuracy of the plug-in machine is crucial for ensuring the efficiency and quality of the plug-in operation.

[0003] In the prior art, by setting a reference jig and a series of calibration steps, the aim is to improve the calibration accuracy and efficiency of the plug-in machine. Generally, through the following steps: calibration of the Z-axis origin offset of the plug-in head, calibration of the PCB camera and the component camera, calibration of the machine origin offset, calibration of the flying shot offset of the component camera, calibration of the PCB origin and the track width, calibration of the R-axis offset and the center, calibration of the XY-plane correction, calibration of the Z-axis head offset, calibration of the picking position, and manual simulation of each step of insertion.

[0004] However, this method involves multiple independent calibration steps, which not only increases the complexity of the operation but also may affect the calibration efficiency. In addition, this method may have certain limitations when dealing with special-shaped electronic components, because the shape and structural complexity of special-shaped components may lead to recognition and positioning problems during the calibration process. This method may require a relatively high technical level and experience in actual operation, which has relatively high requirements for the training and skills of operators. Summary of the Invention

[0005] The present application aims to at least solve one of the technical problems existing in the prior art. For this purpose, the present application provides an automatic calibration and detection device for a plug-in machine, which can simplify the calibration process and improve the calibration efficiency.

[0006] The present application also provides a working method of an automatic calibration and detection device for a plug-in machine with the above structure.

[0007] According to an embodiment of the first aspect of the present application, the automatic calibration and detection device for a plug-in machine includes:

[0008] A top image acquisition module, which includes a top camera and a top light source arranged above the circuit board. The top camera captures the top mounting situation of the circuit board, and the top light source illuminates the top of the circuit board;

[0009] The bottom image acquisition module includes a bottom camera and a bottom light source disposed below the circuit board. The bottom camera captures the bottom mounting condition of the circuit board, and the bottom light source illuminates the bottom of the circuit board.

[0010] The external image acquisition module includes an external camera, an external light source, and an external mirror disposed on the side of the circuit board. The external mirror reflects the light of the external light source to the bottom of the circuit board and reflects the image of the bottom of the circuit board to the external camera.

[0011] The gripping device includes a gripping mechanism and a moving module. The gripping mechanism is connected to the moving module. The gripping mechanism is used to fix the calibration block, and the moving module is used to drive the gripping mechanism to move.

[0012] The automatic calibration and detection device of the plug-in machine according to the embodiment of the present application has at least the following beneficial effects: Through the three-party calibration of the top image acquisition module, the bottom image acquisition module, and the external image acquisition module, the calibration accuracy can be improved, the errors that may be generated by manual calibration can be avoided, and the calibration process can be simplified.

[0013] According to some embodiments of the present application, the top image acquisition module includes a first fixing bracket. The top camera and the top light source are both mounted on the first fixing bracket, and the first fixing bracket is connected to the gripping device.

[0014] According to some embodiments of the present application, the top camera is movably connected to the first fixing bracket. The top image acquisition module further includes a setscrew. The setscrew is threadedly connected to the first fixing bracket, and the end of the setscrew can contact the top camera. Screwing the setscrew can adjust the position and angle of the top camera.

[0015] According to some embodiments of the present application, the bottom image acquisition module further includes a housing. The housing is provided with opposite first and second openings. The bottom camera is mounted on the first opening, and the bottom light source is mounted in the second opening.

[0016] According to some embodiments of the present application, the bottom light source is a light strip and is attached to the edge of the second opening.

[0017] According to some embodiments of the present application, the bottom image acquisition module further includes a detection box. A first reflector and a second reflector are disposed in the detection box at an angle of 45 degrees. The image of the bottom of the circuit board is reflected by the first reflector to the second reflector and then reflected by the second reflector to the bottom camera.

[0018] According to some embodiments of the present application, the external image acquisition module further includes a transparent plate, the external mirror is disposed below the transparent plate, and the image at the bottom of the circuit board is projected onto the external mirror through the transparent plate.

[0019] According to some embodiments of the present application, the external image acquisition module further includes a calibration bracket, the transparent plate is mounted on the top of the calibration bracket, and the external mirror is fixedly mounted inside the calibration bracket.

[0020] According to some embodiments of the present application, the grasping mechanism is a suction cup, and the suction cup sucks the calibration block.

[0021] According to the working method of the second aspect embodiment of the present application, it is carried out for the above-mentioned automatic calibration and detection device of the plug-in machine, and includes the following steps:

[0022] Turn off the power of the plug-in machine and use the grasping mechanism to grasp the calibration block;

[0023] The moving module drives the grasping mechanism to move to the circuit board for calibration;

[0024] Turn on the top camera and the top light source, and the top camera takes pictures of the top mounting effect of the circuit board;

[0025] Turn on the external camera and the external light source, and the external camera takes pictures of the bottom mounting effect of the circuit board;

[0026] Perform position calibration on the captured images of the top camera and the external camera to obtain a first calibration result;

[0027] Turn on the bottom camera and the bottom light source, and the bottom camera takes pictures of the bottom mounting effect of the circuit board;

[0028] Perform position calibration on the captured images of the external camera and the bottom camera to obtain a second calibration result;

[0029] Compare the first calibration result and the second calibration result to determine the relationship between the top camera and the bottom camera, and complete the calibration work.

[0030] According to the working method of the embodiments of the present application, it has at least the following beneficial effects: comparing the first calibration result calibrated by the top image acquisition module and the external image acquisition module, and the second calibration result calibrated by the bottom image acquisition module and the external image acquisition module, using the external camera as a reference point to determine the relationship between the top camera and the bottom camera, quickly completing the calibration work, simplifying the calibration process while improving the calibration accuracy.

[0031] Additional aspects and advantages of the present application will be given in part in the following description, become apparent in part from the following description, or be learned through the practice of the present application. Description of the Drawings

[0032] The drawings are used to provide a further understanding of the technical solutions disclosed in the present application, and constitute a part of the specification. Together with the embodiments disclosed in the present application, they are used to explain the technical solutions of the present disclosure, and do not constitute a limitation to the technical solutions disclosed in the present application.

[0033] Figure 1 It is a three-dimensional view of the automatic calibration and detection device of the plug-in machine according to the embodiment of the first aspect of the present application;

[0034] Figure 2 It is a three-dimensional view of the top image acquisition module in the automatic calibration and detection device of the plug-in machine according to the embodiment of the first aspect of the present application;

[0035] Figure 3 It is a three-dimensional view of the external image acquisition module in the automatic calibration and detection device of the plug-in machine according to the embodiment of the first aspect of the present application;

[0036] Figure 4 It is a three-dimensional view of the bottom image acquisition module in the automatic calibration and detection device of the plug-in machine according to the embodiment of the first aspect of the present application;

[0037] Figure 5 It is a three-dimensional view of the detection box in the automatic calibration and detection device of the plug-in machine according to the embodiment of the first aspect of the present application;

[0038] Figure 6 It is a cross-sectional view of the detection box in the automatic calibration and detection device of the plug-in machine according to the embodiment of the first aspect of the present application.

[0039] Reference numerals: 1 - grasping device, 2 - top image acquisition module, 3 - bottom image acquisition module, 4 - external image acquisition module, 5 - feeding tray, 6 - first fixing bracket, 7 - top camera, 8 - top light source, 9 - grasping mechanism, 10 - calibration bracket, 11 - external light source, 12 - external camera, 13 - second fixing bracket, 14 - external reflector, 15 - transparent plate, 16 - bottom camera field of view, 17 - bottom light source, 18 - housing, 19 - fixing block, 20 - bottom camera, 21 - detection box, 22 - first reflector, 23 - second reflector. Detailed Description of the Embodiments

[0040] The embodiments of the present application will be described in detail below. Examples of the embodiments are shown in the drawings, where the same or similar reference numerals denote the same or similar elements or elements having the same or similar functions throughout. The embodiments described below with reference to the drawings are exemplary only for explaining the present application and should not be construed as limiting the present application.

[0041] In the description of the present application, it should be understood that descriptions involving orientation, such as up, down, front, back, left, right, etc., indicating orientations or positional relationships, are based on the orientations or positional relationships shown in the accompanying drawings, and are only for the convenience of describing the present application and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, be constructed and operated in a specific orientation, and therefore should not be understood as a limitation on the present application.

[0042] In the description of this application, "several" means more than one, "more" means more than two, "greater than", "less than", "exceed", etc. are understood to exclude the number itself, and "above", "below", "within", etc. are understood to include the number itself. If there is a description of "first" or "second", it is only used for the purpose of distinguishing technical features, and cannot be understood as indicating or implying relative importance or implicitly indicating the number of the indicated technical features or implicitly indicating the order of the indicated technical features.

[0043] In the description of this application, unless otherwise clearly defined, terms such as setting, installing, connecting, etc. should be understood in a broad sense, and technicians in the relevant technical field can reasonably determine the specific meanings of the above terms in this application based on the specific content of the technical solution.

[0044] In the description of the present application, the description with reference to the terms "one embodiment", "some embodiments", "illustrative embodiments", "examples", "specific examples", or "some examples" means that the specific features, structures, materials, or characteristics described in conjunction with the embodiment or example are included in at least one embodiment or example of the present application. In this specification, the schematic representation of the above terms does not necessarily refer to the same embodiment or example. Moreover, the specific features, structures, materials, or characteristics described may be combined in any one or more embodiments or examples in a suitable manner.

[0045] In the field of electronic manufacturing, special-shaped plug-in machines are one of the core equipment of the automated equipment line. The accuracy and efficiency of plug-in directly affect the quality of the product and the efficiency of production. In order to avoid the occurrence of poor plug-in phenomena such as bent pins of electronic components during the automatic plug-in process, thereby reducing the possibility of subsequent rework of circuit boards, improving the calibration accuracy of the plug-in machine is crucial to ensure the efficiency and quality of the plug-in operation.

[0046] In the prior art, reference fixtures and a series of calibration steps are set to improve the calibration accuracy and efficiency of the insertion machine. Generally, the following steps are performed: Z-axis origin offset calibration of the insertion head, calibration of the PCB camera and component camera, machine origin offset calibration, component camera flying offset calibration, PCB origin and track width calibration and R-axis offset and center calibration, XY surface correction calibration, Z-axis head offset calibration, material pickup position calibration, and manual simulation of each step of insertion.

[0047] However, this method involves multiple independent calibration steps, which not only increases the complexity of the operation but also may affect the calibration efficiency. In addition, there may be certain limitations when this method is applied to handling special-shaped electronic components, because the shape and structural complexity of special-shaped components may lead to identification and positioning problems during the calibration process. This method may require a relatively high technical level and experience in actual operation, which places high demands on the training and skills of operators.

[0048] In response to this, the automatic calibration and detection device for a plug-in machine in the first aspect embodiments of the present application can improve the calibration accuracy, avoid errors that may occur in manual calibration, and simplify the calibration process through the three-way calibration of the top image acquisition module 2, the bottom image acquisition module 3, and the external image acquisition module 4. In addition, the present application also proposes a working method for the automatic calibration and detection device for the above plug-in machine, which compares the first calibration result calibrated by the top image acquisition module 2 and the external image acquisition module 4, and the second calibration result calibrated by the bottom image acquisition module 3 and the external image acquisition module 4, and determines the relationship between the top camera 7 and the bottom camera 20 with the external camera 12 as the reference point, quickly completing the calibration work and improving the calibration accuracy while simplifying the calibration process.

[0049] Referring to Figure 1 , the automatic calibration and detection device for a plug-in machine in the first aspect embodiments of the present application includes a grasping device 1, a top image acquisition module 2, a bottom image acquisition module 3, and an external image acquisition module 4. Among them, the grasping device 1 is used to grasp the calibration block. After moving the calibration block to a predetermined position, each camera also takes the calibration block into the image, and the position of the circuit board pins is detected based on the position of the calibration block. The top image acquisition module 2 is used to capture the top image of the circuit board, and both the bottom image acquisition module 3 and the external image acquisition module 4 are used to capture the bottom image of the circuit board. On the one hand, by setting the external image acquisition module 4, the field of view of the camera can be expanded to assist in calibration. On the other hand, by comparing the calibration results of the top image acquisition module 2 and the bottom image acquisition module 3, and the calibration results of the bottom image acquisition module 3 and the external image acquisition module 4, the relationship between the top image acquisition module 2 and the bottom image acquisition module 3 can be confirmed with the external image acquisition module 4 as the calibration reference, completing the camera calibration of the plug-in machine.

[0050] Specifically, the grasping device 1 includes a grasping mechanism 9 and a moving module. The grasping mechanism 9 is connected to the moving module. The grasping mechanism 9 is used to fix the calibration block, and the moving module is used to drive the grasping mechanism 9 to move. For the grasping mechanism 9, it can adopt a mechanical claw to fix the calibration block by clamping; or as in this embodiment, the grasping mechanism 9 is a suction cup, and the suction cup is connected to an external vacuum extraction device through a pipeline. The vacuum extraction device extracts air, enabling the suction cup to suck the calibration block.

[0051] Referring to Figure 2 , the top image acquisition module 2 includes a top camera 7 and a top light source 8 disposed above the circuit board. The top camera 7 captures the top mounting condition of the circuit board, and the top light source 8 illuminates the top of the circuit board. Further, the top image acquisition module 2 further includes a first fixing bracket 6. Both the top camera 7 and the top light source 8 are mounted on the first fixing bracket 6, and the first fixing bracket 6 is connected to the grasping device 1. Thus, the entire top image acquisition module 2 can move together with the grasping device 1. It should be noted that the top camera 7 is movably connected to the first fixing bracket 6, and its position can be adjusted. The top image acquisition module 2 further includes a setscrew. The setscrew is threadedly connected to the first fixing bracket 6, and the end of the setscrew can contact the top camera 7. Thus, when the setscrew is screwed, the end of the setscrew can approach or move away from the top camera 7. Furthermore, by screwing the setscrew, the position and angle of the top camera 7 can be adjusted, facilitating the adjustment of the top camera 7 during subsequent calibration.

[0052] Referring to Figure 3 , the external image acquisition module 4 includes an external camera 12, an external light source 11, and an external mirror 14 disposed on the side of the circuit board. The external mirror 14 reflects the light of the external light source 11 to the bottom of the circuit board and reflects the image of the bottom of the circuit board to the external camera 12. Thus, the adjustment of the optical path is achieved through the external mirror 14, enabling the external image acquisition module 4 to adapt to the narrow space inside the plug-in machine.

[0053] Referring to Figure 4 , the bottom image acquisition module 3 includes a bottom camera 20 and a bottom light source 17 disposed below the circuit board. The bottom camera 20 captures the bottom mounting condition of the circuit board, and the bottom light source 17 illuminates the bottom of the circuit board.

[0054] Further, the bottom image acquisition module 3 further includes a housing 18. The housing 18 is provided with opposite first and second openings. The bottom camera 20 is mounted to the first opening through a fixing block 19, and the bottom light source 17 is mounted in the second opening. By providing the housing 18, the lens of the bottom camera 20 can be protected, reducing the risk of external dust invading the lens. At the same time, the housing 18 is also used to define the size of the field of view 16 of the bottom camera.

[0055] Specifically, the bottom light source 17 is a light strip and is attached to the edge of the second opening. On the one hand, it can ensure that the bottom light source 17 emits light normally to illuminate the bottom of the circuit board, and on the other hand, it reduces the space occupied by the bottom light source 17.

[0056] In some embodiments, there are a relatively large number of feed trays 5 in the plug-in machine, which will occupy the space at the bottom of the circuit board. In this regard, referring to Figure 5 and Figure 6, the bottom image acquisition module 3 further includes a detection box 21. A first reflector 22 and a second reflector 23 are arranged in the detection box 21 at a 45-degree angle. The image at the bottom of the circuit board is reflected by the first reflector 22 to the second reflector 23, and then reflected by the second reflector 23 to the bottom camera 20. Thus, by reflecting the optical path through the detection box 21, the installation position of the bottom camera 20 can be changed, so as to avoid the feeder tray 5 of the plug-in machine.

[0057] Furthermore, the external image acquisition module 4 further includes a transparent plate 15. The image at the bottom of the circuit board is projected onto the external reflector 14 through the transparent plate 15. The function of the transparent plate 15 is to prevent dust, preventing external dust from contaminating the external reflector 14 and affecting the reflection effect.

[0058] Specifically, the external image acquisition module further includes a calibration bracket 10 and a second fixing bracket 13. The transparent plate 15 is installed on the top of the calibration bracket 10, and the external reflector 14 is arranged below the transparent plate 15 and fixedly installed inside the second fixing bracket 13.

[0059] A working method in the second aspect of this embodiment is carried out for the above-mentioned automatic calibration and detection device of the plug-in machine, including the following steps:

[0060] S100. Turn off the power of the plug-in machine, and use the grasping mechanism 9 to grasp the calibration block;

[0061] S200. The moving module drives the grasping mechanism 9 to move to the circuit board for calibration;

[0062] S300. Turn on the top camera 7 and the top light source 8, and the top camera 7 takes pictures of the top mounting effect of the circuit board;

[0063] S400. Turn on the external camera 12 and the external light source 11, and the external camera 12 takes pictures of the bottom mounting effect of the circuit board;

[0064] S500. Perform position calibration on the captured images of the top camera 7 and the external camera 12 to obtain the first calibration result;

[0065] S600. Turn on the bottom camera 20 and the bottom light source 17, and the bottom camera 20 takes pictures of the bottom mounting effect of the circuit board;

[0066] S700. Perform position calibration on the captured images of the external camera 12 and the bottom camera 20 to obtain the second calibration result;

[0067] S800. Compare the first calibration result and the second calibration result to determine the relationship between the top camera 7 and the bottom camera 20, and complete the calibration work.

[0068] The embodiments of the present application have been described in detail above with reference to the accompanying drawings. However, the present application is not limited to the above embodiments, and various changes can be made without departing from the spirit of the present application within the scope of knowledge possessed by those of ordinary skill in the art. In addition, the embodiments of the present application and the features in the embodiments can be combined with each other without conflict.

Claims

1. An automatic calibration and detection device for a plug-in machine, characterized in that Including: A top image acquisition module, which includes a top camera and a top light source arranged above the circuit board. The top camera captures the top mounting condition of the circuit board, and the top light source illuminates the top of the circuit board. A bottom image acquisition module, which includes a bottom camera and a bottom light source arranged below the circuit board. The bottom camera captures the bottom mounting condition of the circuit board, and the bottom light source illuminates the bottom of the circuit board. An external image acquisition module, which includes an external camera, an external light source, and an external reflector arranged on the side of the circuit board. The external reflector reflects the light of the external light source to the bottom of the circuit board and reflects the image of the bottom of the circuit board to the external camera. A grasping device, which includes a grasping mechanism and a moving module. The grasping mechanism is connected to the moving module. The grasping mechanism is used to fix the calibration block, and the moving module is used to drive the grasping mechanism to move.

2. The automatic calibration and detection device for the plug-in machine according to claim 1, wherein: The top image acquisition module includes a first fixing bracket. The top camera and the top light source are both mounted on the first fixing bracket, and the first fixing bracket is connected to the grasping device.

3. The automatic calibration and detection device of the plug-in machine according to claim 2, characterized in that: The top camera is movably connected to the first fixing bracket. The top image acquisition module further includes a setscrew. The setscrew is threadedly connected to the first fixing bracket, and the end of the setscrew can contact the top camera. By screwing the setscrew, the position and angle of the top camera can be adjusted.

4. The automatic calibration and detection device for the plug-in machine according to claim 1, wherein: The bottom image acquisition module further includes a housing, which is provided with opposite first and second openings. The bottom camera is mounted on the first opening, and the bottom light source is mounted in the second opening.

5. The automatic calibration and detection device for the plug-in machine according to claim 4, wherein: The bottom light source is a light strip and is attached to the edge of the second opening.

6. The automatic calibration and detection device for the plug-in machine according to claim 1, characterized in that: The bottom image acquisition module further includes a detection box, in which a first reflector and a second reflector are both placed at a 45-degree angle. The image of the bottom of the circuit board is reflected by the first reflector to the second reflector and then reflected by the second reflector to the bottom camera.

7. The automatic calibration and detection device for the plug-in machine according to claim 1, wherein: The external image acquisition module further includes a transparent plate. The external reflector is arranged below the transparent plate, and the image of the bottom of the circuit board is projected onto the external reflector through the transparent plate.

8. The automatic calibration and detection device for the plug-in machine according to claim 7, wherein: The external image acquisition module further includes a calibration bracket. The transparent plate is mounted on the top of the calibration bracket, and the external reflector is fixedly mounted inside the calibration bracket.

9. The automatic calibration and detection device for the plug-in machine according to claim 1, characterized in that: The grasping mechanism is a suction cup, and the suction cup sucks the calibration block.

10. A working method of an automatic calibration and detection device for the plug-in machine according to any one of claims 1 to 9, characterized in that, Including: Turn off the power of the plug-in machine and use the grasping mechanism to grasp the calibration block. The moving module drives the grasping mechanism to move to the circuit board for calibration. Turn on the top camera and the top light source, and the top camera captures the top mounting effect of the circuit board. Turn on the external camera and the external light source, and the external camera captures the bottom mounting effect of the circuit board. Perform position calibration on the captured images of the top camera and the external camera to obtain a first calibration result. Turn on the bottom camera and the bottom light source, and the bottom camera captures the bottom mounting effect of the circuit board. Perform position calibration on the captured images of the external camera and the bottom camera to obtain a second calibration result; Compare the first calibration result and the second calibration result to determine the relationship between the top camera and the bottom camera, and complete the calibration work.

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