An assembly docking vision inspection control system

Abstract

The application belongs to the technical field of machine vision detection, and particularly relates to an assembly butt joint vision detection control system, which comprises a dynamic vision imaging acquisition module, a real-time image preprocessing and feature solving module, a deviation data analysis decision module, a servo motion driving execution module, a high-speed real-time communication interaction module and a man-machine and data storage module; through bidirectional closed-loop linkage of visual acquisition, algorithm solving, decision control and servo execution, the application changes the traditional open-loop mode of assembly first, detection later and post-judgment into a closed-loop assembly mode of real-time detection, real-time difference calculation, real-time difference adjustment and dynamic verification, so that single fixed positioning is not needed in the assembly process, deviation is compensated through whole-process dynamic fine adjustment, the problem of disconnection between detection and execution mechanism is completely eliminated, and the first-time butt joint yield is significantly improved.

Description

Technical Field

[0001] This invention relates to the field of machine vision inspection technology, specifically to an assembly docking vision inspection and control system. Background Technology

[0002] Component assembly and docking is a core process in product manufacturing. The precision, consistency, and stability of assembly and docking directly determine the overall performance, service life, and safety and reliability of the product. As the manufacturing industry rapidly iterates towards high precision, automation, intelligence, and flexibility, the structure of product components is becoming increasingly complex, with miniaturized, irregularly shaped, and multi-curved surface components accounting for a continuous increase. At the same time, the industry has put forward more stringent standards for the positioning accuracy, inspection efficiency, yield rate, and batch production consistency of assembly and docking. Current vision inspection and control systems still face the following technical challenges: The real-time linkage between the detection and execution mechanisms is weak. The vision inspection module and the assembly drive mechanism are independent of each other, only completing post-event inspection and result display, without forming a closed-loop control. It is impossible to dynamically correct the workpiece posture and position based on real-time deviations. The docking process can only be positioned once, and deviations cannot be compensated for in real time, resulting in a low success rate of docking on the first attempt. It has poor adaptability to dynamic docking. While it performs reasonably well for static workpiece inspection, it suffers from image ghosting and positioning lag in moving and dynamic docking conditions. It cannot perform real-time inspection and deviation correction in sync with assembly movements, resulting in low reliability in dynamic operations.

[0003] Therefore, a vision inspection and control system for assembly docking is proposed to solve the problems mentioned above. Summary of the Invention

[0004] The purpose of this invention is to provide an assembly docking vision inspection and control system to solve the problems mentioned in the background art.

[0005] To achieve the above objectives, the present invention provides the following technical solution: an assembly docking vision inspection and control system, comprising a dynamic vision imaging acquisition module, a real-time image preprocessing and feature calculation module, a deviation data analysis and decision module, a servo motion drive execution module, a high-speed real-time communication interaction module, and a human-machine and data storage module; The signal output terminal of the dynamic visual imaging acquisition module is electrically connected to the input terminal of the real-time image preprocessing and feature calculation module. The deviation data output terminal of the real-time image preprocessing and feature calculation module is connected to the deviation data analysis and decision module. The deviation data analysis and decision module is bidirectionally connected to the servo motion drive execution module through the high-speed real-time communication interaction module. The human-machine interface and data storage module are bidirectionally connected to the deviation data analysis and decision module and the servo motion drive execution module, respectively.

[0006] Preferably, the dynamic visual imaging acquisition module uses a high-speed global shutter industrial camera in conjunction with a synchronous strobe supplementary light unit, abandoning the static acquisition mode of the rolling shutter camera, and synchronously acquiring images following the dynamic assembly motion trajectory of the workpiece. During the dynamic docking process of continuous workpiece movement and attitude fine adjustment, motion blur, blur, and frame delay problems are eliminated, ensuring that each frame image is a real-time and effective assembly feature image. The dynamic visual imaging acquisition module includes a high-speed global shutter industrial camera unit and a synchronous strobe light supplement unit.

[0007] Preferably, the real-time image preprocessing and feature calculation module is equipped with a lightweight high-speed vision algorithm, which completes the feature analysis of dynamic images in milliseconds and outputs multi-dimensional error data of workpiece docking offset, gap deviation, and attitude tilt angle in real time. It continuously transmits real-time deviation parameters to the decision module, providing data support for dynamic real-time compensation and attitude fine-tuning. The real-time image preprocessing and feature calculation module includes an image receiving and buffering unit, a lightweight high-speed algorithm calculation unit, and a multi-dimensional deviation data output unit.

[0008] Preferably, the deviation data analysis and decision module receives the deviation data calculated by vision in real time, has a built-in dynamic deviation threshold judgment model and adaptive compensation algorithm, and intelligently generates control commands for position fine-tuning, posture correction and speed adaptation based on the real-time docking deviation. It participates in the assembly process control throughout the process, judges in real time whether the current assembly deviation exceeds the standard, and continuously outputs dynamic compensation commands. The deviation data analysis and decision-making module includes a deviation data receiving unit, a threshold judgment and model calculation unit, an adaptive compensation instruction generation unit, and a two-way data interaction unit.

[0009] Preferably, the servo motion drive execution module serves as the execution terminal for assembly docking. It receives real-time adjustment instructions from the decision module and completes dynamic fine-tuning and displacement compensation of the workpiece position, pitch, and yaw attitude. The module transmits its own motion parameters, servo status, and displacement stroke back to the decision module in real time, forming a two-way feedback mechanism. Based on the dynamic deviation detected by vision in real time, it adaptively corrects the assembly trajectory, continuously offsets docking errors, and significantly improves the success rate of docking in one go. The servo motion drive execution module includes an instruction receiving and parsing unit, a servo drive unit, an action execution unit, and a status parameter feedback unit.

[0010] Preferably, the high-speed real-time communication interaction module adopts the industrial Ethernet high-speed bus communication protocol to replace the low-speed serial port communication, which greatly reduces the data transmission delay and realizes microsecond-level interaction of visual data, deviation commands and servo status data. The high-speed real-time communication and interaction module includes an industrial Ethernet bus unit, a protocol parsing unit, and a multi-channel data forwarding unit.

[0011] Preferably, the human-machine interface and data storage module is responsible for system parameter configuration, data recording of the entire assembly process, deviation trend analysis and status visualization, real-time synchronous display of deviation changes and execution adjustment status during dynamic docking, and storage of detection data and compensation parameters for each assembly, supporting subsequent traceability and parameter optimization; The human-machine and data storage module includes a human-machine interaction operation unit, a real-time status visualization unit, a data storage unit, and a deviation trend analysis unit.

[0012] Compared with the prior art, the beneficial effects of the present invention are: 1) This application transforms the traditional open-loop mode of assembly first, inspection later, and judgment after the fact into a closed-loop assembly mode of real-time inspection, real-time error calculation, real-time error adjustment, and dynamic verification through a two-way closed-loop linkage of visual acquisition, algorithm calculation, decision control, and servo execution. During the assembly process, there is no need for single fixed positioning, and the deviation is compensated by dynamic fine adjustment throughout the process, which completely eliminates the problem of disconnection between the detection and execution mechanism and significantly improves the first-time docking yield. 2) This application achieves delay-free dynamic detection following assembly motion through high-speed global shutter dynamic imaging, millisecond-level real-time algorithm calculation and high-speed bus synchronous communication, eliminating motion trailing and frame lag problems. It can synchronously complete deviation identification and attitude correction during the continuous dynamic docking of workpieces, solving the technical problem that traditional systems are only suitable for static detection and have poor reliability in dynamic operations. Attached Figure Description

[0013] Figure 1 This is a diagram showing the module composition of this system; Figure 2 This is a diagram showing the unit composition of the dynamic visual imaging acquisition module; Figure 3 This is a diagram showing the unit composition of the real-time image preprocessing and feature calculation module. Figure 4 This is a diagram showing the unit composition of the deviation data analysis and decision-making module; Figure 5 This is a diagram showing the unit composition of the servo motion drive execution module; Figure 6 This is a diagram showing the unit composition of a high-speed real-time communication and interaction module. Figure 7 This is a diagram showing the unit composition of the human-machine interface and data storage module. Detailed Implementation

[0014] The technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.

[0015] Example: Please see Figure 1-7 The present invention provides a technical solution: An assembly docking vision inspection and control system includes a dynamic vision imaging acquisition module, a real-time image preprocessing and feature calculation module, a deviation data analysis and decision-making module, a servo motion drive execution module, a high-speed real-time communication interaction module, and a human-machine and data storage module. The signal output terminal of the dynamic visual imaging acquisition module is electrically connected to the input terminal of the real-time image preprocessing and feature calculation module. The deviation data output terminal of the real-time image preprocessing and feature calculation module is connected to the deviation data analysis and decision module. The deviation data analysis and decision module is bidirectionally connected to the servo motion drive execution module through the high-speed real-time communication interaction module. The human-machine interface and data storage module are bidirectionally connected to the deviation data analysis and decision module and the servo motion drive execution module, respectively.

[0016] The dynamic visual imaging acquisition module uses a high-speed global shutter industrial camera in conjunction with a synchronous strobe light unit, abandoning the static acquisition mode of the rolling shutter camera. It synchronously acquires images following the dynamic assembly motion trajectory of the workpiece. During the dynamic docking process of continuous workpiece movement and fine-tuning of posture, it eliminates motion blur, blur, and frame delay problems, ensuring that each frame image is a real-time and effective assembly feature image. The dynamic visual imaging acquisition module includes a high-speed global shutter industrial camera unit and a synchronous strobe lighting unit. The high-speed global shutter industrial camera unit includes a global shutter image sensor, a camera main control board, an image signal processing chip, a high-speed data output interface, a camera housing and mounting bracket, and a power supply module; the synchronous strobe lighting unit includes a high-frequency LED strobe light source, a light source driver board, a synchronous trigger circuit, a timing control chip, a light shield, a power supply component, and a light adjustment knob.

[0017] The high-speed global shutter industrial camera unit abandons the traditional static acquisition method of rolling shutter cameras and captures images synchronously following the dynamic assembly trajectory of the workpiece. The entire frame image is exposed at once, eliminating image ghosting and blurring problems in motion from the hardware source, ensuring that every frame image is clear and effective during dynamic docking. The synchronous strobe lighting unit is strictly synchronized with the trigger signal of the industrial camera, providing instantaneous supplementary lighting at the moment of camera exposure to improve the contrast and feature recognition of dynamic images; at the same time, it works in conjunction with the high-speed acquisition rhythm to eliminate frame delay and achieve synchronization of motion, image acquisition and supplementary lighting sequence. The real-time image preprocessing and feature calculation module is equipped with a lightweight high-speed vision algorithm, which completes the feature analysis of dynamic images in milliseconds and outputs multi-dimensional error data of workpiece docking offset, gap deviation, and attitude tilt angle in real time. It continuously transmits real-time deviation parameters to the decision module, providing data support for dynamic real-time compensation and attitude fine-tuning. The real-time image preprocessing and feature calculation module includes an image receiving and buffering unit, a lightweight high-speed algorithm processing unit, and a multi-dimensional deviation data output unit. The image receiving and buffering unit includes a high-speed data receiving interface, a large-capacity high-speed cache chip, a data bus, and a signal conditioning circuit; the lightweight high-speed algorithm processing unit includes an embedded industrial computing motherboard, a multi-core processing chip, algorithm storage flash memory, and onboard memory; the multi-dimensional deviation data output unit includes a digital signal output interface, a data encoding chip, and a differential signal transmission circuit.

[0018] The image receiving buffer unit receives raw images transmitted from the front-end camera in real time and temporarily buffers the image data to avoid loss or congestion of high-speed data streams; The lightweight high-speed algorithm computing unit is equipped with a dedicated high-speed vision algorithm, which can complete preprocessing such as image noise reduction, feature extraction, and contour matching in milliseconds, and simultaneously calculate multi-dimensional error data such as workpiece offset, gap deviation, and attitude tilt angle. The multidimensional deviation data output unit continuously transmits real-time deviation parameters to the outside world and continuously pushes raw error data to the downstream decision-making module. The deviation data analysis and decision module receives deviation data calculated by vision in real time. It has a built-in dynamic deviation threshold judgment model and adaptive compensation algorithm. Based on the real-time docking deviation, it intelligently generates control commands for position fine-tuning, posture correction and speed adaptation. It participates in the assembly process control throughout the process, judges in real time whether the current assembly deviation exceeds the standard, and continuously outputs dynamic compensation commands. The deviation data analysis and decision-making module includes a deviation data receiving unit, a threshold judgment and model calculation unit, an adaptive compensation instruction generation unit, and a two-way data interaction unit. The deviation data receiving unit includes a multi-channel data receiving interface, a data decoding chip, and a signal filtering circuit; the threshold judgment and model calculation unit includes a main control CPU, an algorithm model storage chip, a logic operation circuit, and a parameter register; the adaptive compensation instruction generation unit includes an instruction encoding chip, a control signal generation circuit, and an instruction buffer; and the two-way data interaction unit includes a two-way communication interface, a data exchange chip, and a transmit / receive switching circuit.

[0019] The deviation data receiving unit receives multi-dimensional deviation data output by the vision module in real time and completes data parsing, classification and organization. The threshold judgment and model calculation unit has a built-in dynamic deviation threshold judgment model, which compares the real-time deviation with the allowable error range to determine whether the deviation exceeds the standard; The adaptive compensation command generation unit calls the adaptive compensation algorithm to intelligently generate three types of control commands: position fine-tuning, attitude correction, and running speed adaptation, based on different types and sizes of deviations. The two-way data interaction unit sends adjustment commands downwards on the one hand, and receives motion status and displacement data returned by the servo module on the other hand, forming a logical closed loop; The servo motion drive execution module serves as the execution terminal for assembly docking. It receives real-time adjustment commands from the decision module and completes dynamic fine-tuning and displacement compensation of the workpiece position, pitch, and yaw attitude. The module transmits its own motion parameters, servo status, and displacement stroke back to the decision module in real time, forming a two-way feedback mechanism. Based on the dynamic deviation detected in real time by vision, it adaptively corrects the assembly trajectory, continuously offsets docking errors, and significantly improves the success rate of docking in one go. The servo motion drive execution module includes an instruction receiving and parsing unit, a servo drive unit, an execution action unit, and a status parameter feedback unit. The instruction receiving and parsing unit includes a communication receiving interface, an instruction parsing chip, and a protocol decoding circuit; the servo drive unit includes a servo driver, a power amplifier circuit, a current / voltage sampling element, and an overload protection circuit; the execution action unit includes a servo motor, a reducer, a lead screw / rack, a linear slide, a rotary attitude mechanism, and a workpiece fixture; the status parameter feedback unit includes a displacement sensor, an attitude detection sensor, a speed / position acquisition chip, a status signal transmission circuit, and a data feedback interface. The instruction receiving and parsing unit receives adjustment instructions issued by the decision module and parses the position, attitude, and speed control logic; The servo drive unit drives the servo motor to operate; The actuator unit drives the workpiece to complete position fine-tuning, pitch, yaw attitude correction, displacement compensation, and real-time correction of the assembly docking trajectory; The status parameter feedback unit collects servo operating parameters, actual displacement stroke, and equipment working status in real time and sends them back to the decision module, forming a complete closed loop of visual inspection, decision issuance, servo execution, and status feedback. The high-speed real-time communication and interaction module adopts the industrial Ethernet high-speed bus communication protocol to replace the low-speed serial port communication, greatly compressing the data transmission delay and realizing microsecond-level interaction of visual data, deviation commands and servo status data. The high-speed real-time communication interaction module includes an industrial Ethernet bus unit, a protocol parsing unit, and a multi-channel data forwarding unit. The industrial Ethernet bus unit includes an industrial Ethernet switch, an Ethernet physical layer chip, shielded communication cables, and aviation connectors / network interface terminals; the protocol parsing unit includes a communication protocol processing chip, a protocol configuration storage chip, and a data verification circuit; the multi-channel data forwarding unit includes a data exchange chip, a multi-channel distribution circuit, and a signal relay module.

[0020] The industrial Ethernet bus unit adopts the industrial Ethernet high-speed bus protocol to replace the traditional low-speed serial communication, which greatly reduces data transmission latency. The protocol parsing unit uniformly parses the communication protocols of visual data, control commands, and servo status data, ensuring data interoperability and compatibility between different modules; The multi-channel data forwarding unit enables microsecond-level bidirectional interaction of visual deviation data, control commands, and servo status data, thus connecting the data links of the entire system. The human-machine interface and data storage module is responsible for system parameter configuration, data recording of the entire assembly process, deviation trend analysis and status visualization. It displays deviation changes and execution adjustment status in real time during the dynamic docking process, and stores the detection data and compensation parameters of each assembly to support subsequent traceability and parameter optimization. The human-machine interface and data storage module includes a human-machine interaction unit, a real-time status visualization unit, a data storage unit, and a deviation trend analysis unit. The human-machine interaction unit includes an industrial touchscreen display, physical function buttons, an operation command input circuit, and a parameter configuration knob; the real-time status visualization unit includes a display driver chip, a screen buffer chip, and a video signal transmission circuit; the data storage unit includes an industrial-grade solid-state drive, a Flash memory chip, and a data read / write control circuit; and the deviation trend analysis unit includes a data analysis and processing chip, a statistical calculation circuit, and a data retrieval interface.

[0021] The human-computer interaction unit completes operations such as system parameter configuration, function start / stop, and manual intervention; The real-time status visualization unit synchronously displays the real-time deviation, servo execution status, and equipment operating parameters during the docking process, intuitively presenting the entire closed-loop control process; The data storage unit completely stores the test data, compensation parameters, and operation logs of each assembly, supporting data traceability in the later stages; The deviation trend analysis unit performs statistical analysis on historical assembly data, providing a basis for equipment parameter iteration and process optimization.

[0022] The foregoing has shown and described the basic principles, main features, and advantages of the present invention. It will be apparent to those skilled in the art that the present invention is not limited to the details of the exemplary embodiments described above, and that the invention can be implemented in other specific forms without departing from its spirit or basic characteristics. Therefore, the embodiments should be considered exemplary and non-limiting in all respects. The scope of the invention is defined by the appended claims rather than the foregoing description. Therefore, all variations falling within the meaning and scope of equivalents of the claims are intended to be included within the present invention, and no reference numerals in the claims should be construed as limiting the scope of the claims.

[0023] Although embodiments of the invention have been shown and described, it will be understood by those skilled in the art that various changes, modifications, substitutions and alterations can be made to these embodiments without departing from the principles and spirit of the invention, the scope of which is defined by the appended claims and their equivalents.

Claims

1. A vision inspection and control system for assembly docking, characterized in that, It includes a dynamic visual imaging acquisition module, a real-time image preprocessing and feature calculation module, a deviation data analysis and decision-making module, a servo motion drive execution module, a high-speed real-time communication and interaction module, and a human-machine and data storage module; The signal output terminal of the dynamic visual imaging acquisition module is electrically connected to the input terminal of the real-time image preprocessing and feature calculation module. The deviation data output terminal of the real-time image preprocessing and feature calculation module is connected to the deviation data analysis and decision module. The deviation data analysis and decision module is bidirectionally connected to the servo motion drive execution module through the high-speed real-time communication interaction module. The human-machine interface and data storage module are bidirectionally connected to the deviation data analysis and decision module and the servo motion drive execution module, respectively.

2. The assembly docking vision inspection and control system according to claim 1, characterized in that: The dynamic visual imaging acquisition module uses a high-speed global shutter industrial camera in conjunction with a synchronous strobe light unit, abandoning the static acquisition mode of the rolling shutter camera. It synchronously acquires images following the dynamic assembly motion trajectory of the workpiece. During the dynamic docking process of continuous workpiece movement and fine-tuning of posture, it eliminates motion blur, blur, and frame delay problems, ensuring that each frame image is a real-time and effective assembly feature image. The dynamic visual imaging acquisition module includes a high-speed global shutter industrial camera unit and a synchronous strobe light supplement unit.

3. The assembly docking vision inspection and control system according to claim 1, characterized in that: The real-time image preprocessing and feature calculation module is equipped with a lightweight high-speed vision algorithm, which completes the feature analysis of dynamic images in milliseconds and outputs multi-dimensional error data of workpiece docking offset, gap deviation, and attitude tilt angle in real time. It continuously transmits real-time deviation parameters to the decision module, providing data support for dynamic real-time compensation and attitude fine-tuning. The real-time image preprocessing and feature calculation module includes an image receiving and buffering unit, a lightweight high-speed algorithm calculation unit, and a multi-dimensional deviation data output unit.

4. The assembly docking vision inspection and control system according to claim 1, characterized in that: The deviation data analysis and decision module receives deviation data calculated by vision in real time. It has a built-in dynamic deviation threshold judgment model and adaptive compensation algorithm. Based on the real-time docking deviation, it intelligently generates control commands for position fine-tuning, posture correction and speed adaptation. It participates in the assembly process control throughout the process, judges in real time whether the current assembly deviation exceeds the standard, and continuously outputs dynamic compensation commands. The deviation data analysis and decision-making module includes a deviation data receiving unit, a threshold judgment and model calculation unit, an adaptive compensation instruction generation unit, and a two-way data interaction unit.

5. The assembly docking vision inspection and control system according to claim 1, characterized in that: The servo motion drive execution module serves as the execution terminal for assembly docking. It receives real-time adjustment commands from the decision module and completes dynamic fine-tuning and displacement compensation of the workpiece position, pitch, and yaw attitude. The module transmits its own motion parameters, servo status, and displacement stroke back to the decision module in real time, forming a two-way feedback mechanism. Based on the dynamic deviation detected in real time by vision, it adaptively corrects the assembly trajectory, continuously offsets docking errors, and significantly improves the success rate of docking in one go. The servo motion drive execution module includes an instruction receiving and parsing unit, a servo drive unit, an action execution unit, and a status parameter feedback unit.

6. The assembly docking vision inspection and control system according to claim 1, characterized in that: The high-speed real-time communication and interaction module adopts the industrial Ethernet high-speed bus communication protocol to replace the low-speed serial port communication, greatly compressing the data transmission delay and realizing microsecond-level interaction of visual data, deviation commands and servo status data. The high-speed real-time communication and interaction module includes an industrial Ethernet bus unit, a protocol parsing unit, and a multi-channel data forwarding unit.

7. The assembly docking vision inspection and control system according to claim 1, characterized in that: The human-machine interface and data storage module is responsible for system parameter configuration, data recording of the entire assembly process, deviation trend analysis and status visualization. It displays deviation changes and execution adjustment status in real time during the dynamic docking process, and stores the detection data and compensation parameters of each assembly to support subsequent traceability and parameter optimization. The human-machine and data storage module includes a human-machine interaction operation unit, a real-time status visualization unit, a data storage unit, and a deviation trend analysis unit.

Images