Sheet Workpiece Alignment Using IoT Tilt Correction
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Solution Overview
Problem
Sheet workpieces in industrial manufacturing, such as LED panels and wafers, often experience processing errors due to rotation, translation, and deformation during machining, resulting from inaccurate grasping and alignment, which affects processing accuracy.
Innovation Solution
An Industrial Internet of Things (IoT) system that includes a user platform, service platform, management platform, and sensor network platform, utilizing a camera with fixed focal length for image capture, sharpness analysis to determine tilt data, and a tilt correction model to adjust the sheet workpiece to a completely horizontal state, enabling accurate horizontal and rotational adjustments through a bearing mechanism.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional suction cup grasping and fixing methods are used for sheet workpieces, then the workpiece can be held and positioned, but rotation, translation, and deformation occur during the process, resulting in processing errors
Solution Approach 1:
The system performs preliminary detection of the sheet workpiece's tilt angle and deformation state before processing. By capturing images with the detection camera and analyzing sharpness distribution, the system calculates the workpiece's actual orientation and deformation in advance, enabling pre-adjustment of the bearing mechanism to compensate for potential rotation, translation, and deformation during grasping and processing.
Solution Approach 2:
The system establishes a feedback loop where the detection camera continuously monitors the sheet workpiece's position and deformation state. The processing results from sharpness analysis are fed back to adjust the bearing mechanism's bearing plates, ensuring real-time compensation for any rotation, translation, or deformation that occurs during grasping and processing, thereby maintaining high processing accuracy.
2Manufacturing precision
If multiple adjustment operations are performed for tilt, horizontal position, and rotation of sheet workpieces, then alignment accuracy can be improved, but the adjustment process becomes complex and time-consuming
Solution Approach 1:
The system merges multiple adjustment operations (tilt adjustment, horizontal position adjustment, and rotation adjustment) into a single coordinated action. By detecting the workpiece's tilt angle and deformation state simultaneously and calculating comprehensive adjustment parameters, the bearing mechanism adjusts all three degrees of freedom in one operation, achieving high alignment accuracy while simplifying the adjustment process and reducing time consumption.
3Measurement precision
If traditional multiple-step detection and adjustment methods are used for sheet workpieces, then measurement accuracy can be maintained, but productivity decreases due to multiple operations
Solution Approach 1:
The detection camera captures the sheet workpiece's tilt angle and deformation state in a single preliminary detection operation before processing. By analyzing the sharpness distribution of the captured image, the system calculates all necessary adjustment parameters (tilt angle, horizontal position, rotation angle) in advance, eliminating the need for multiple detection and adjustment steps during processing, thereby maintaining measurement precision while significantly improving productivity.
Data Source
AI summary
An Industrial Internet of Things system, a control method and storage medium for monitoring sheet workpiece production are provided. The method comprises: obtaining a first target image on a production line; generating a sharpness matrix based on the first target image, calculating a tilt direction and a tilt angle of the target sheet workpiece as tilt data, and determining deformation data of the target sheet workpiece based on the first target image; determining a second target image through a tilt correction model; performing calibration and identification on the second target image, generating horizontal adjustment data and rotational adjustment data corresponding to the second target image, and calculating tilt adjustment data according to the tilt data; determining target adjustment clamping parameters; sending the horizontal adjustment data, the rotational adjustment data, the tilt adjustment data, and the target adjustment clamping parameters to the production line, and adjusting the target sheet workpiece.