Solutionfor Casing Production Line Positioning & Inspection
1.Part to be inspected and cut /被测工件
A mobile phone casing / 手机后盖
2.System target /体系方针
2.1.Heat & Press station/热压工位: to inspect the part defect including crease, or wrinkle; scratch and the direction of the carbon fiber/检验热压后工件缺点，包孕皱痕，折痕，划痕和碳素纤维标的目的
2.2.Press station/冲切工位:
l to get the part position relative to robot coordinate system, then feedback the part position to abb robot/冲切前检验并获得工件正在机器人坐标系里的位置误差，并将丈量成果反馈给abb机器人
l to inspect part dimension after press including length, width and hole diameter/冲切后检验工件尺寸，包孕长度，宽度和孔径
2.3.CNC 1 station/CNC1工位:
l to get the part position relative to robot coordinate system, then feedback the part position to ABB robot/加工前检验并获得工件正在机器人坐标系里的位置毛病，并将丈量后果反馈给ABB机器人
l to inspect hole diameter/加工后检验孔径
2.4.CNC 2 station/CNC2工位:
l to get the part position relative to robot coordinate system, then feedback the part position to ABB robot/加工前检验并获得工件正在机器人坐标系里的位置误差，并将丈量后果反馈给ABB机器人
l to inspect part dimension including injection feed boss, hole position and diameter/加工后检验工件尺寸，包罗料口柱，孔的位置和直径
2.5.CNC 3 station/CNC3工位:
l to get the part position relative to robot coordinate system, then feedback the part position to ABB robot/加工前检验并获得工件正在机器人坐标系里的位置毛病，并将丈量成果反馈给ABB机器人
l to inspect part dimension including hole position and diameter/加工后检验工件尺寸，包孕孔的位置和直径
2.6.CNC 4 station/CNC4工位:
l to get the part position relative to robot coordinate system, then feedback the part position to ABB robot/加工前检验并获得工件正在机器人坐标系里的位置误差，并将丈量后果反馈给ABB机器人
l to inspect part dimension including opening width and depth/加工后检验工件尺寸，包罗开槽的宽度和深度
3.Enquiry and Solution / 丈量请求及计划
Base on the system target we make a rough solution as below/基于以上体系需求我们开端制订了以下计划：
3.1.For Heat & Press station/热压工位:
Inspection enquiry/检验规定:
Solution concept/检验计划示意图:
Load the part/安排工件到检验位置:
Inspect/检验状况:
System key component/体系次要零部件:
l One 10M pixels cameral/1个1000万像素工业相机
l One Lens/1个透镜
l One ring lighting install on the lens/1个环形光源，安装在透镜底部
l Adapter rings/转接环
l One USB cable for connecting camera and PC/1根USB线缆适用于毗连相机和计算机
l One air cylinder for pushing the part to inspection position/1个带导柱气缸，适用于将工件推到检验位置
l One set of computer (PC, monitor, keyboard, mouse)/1套计算机，包孕主机，显示器，键盘和鼠标
l I/O card for I/O communication between robot and computer/I/O卡适用于机械人和计算机之间的I/O通讯
l Mechanical parts for fixing camera and air cylinder/适用于安装相机和气缸等的机械零件
3.2.For Press station/冲切工位
Inspection enquiry/检验请求:
Solution concept/检验计划示意图:
Positioning inspection/冲切前工件位置检验:
Dimension inspection after press/冲切后尺寸检验:
System key component/体系重要零部件:
l One 10M pixels cameral/1个1000万像素工业相机
l One Lens/1个透镜
l One rectangle lighting install on the robot hand/一个矩形光源，安装在机器人的末了
l Adapter rings/转接环
l One USB cable for connecting camera and PC/1根USB线缆适用于毗连相机和计算机
l One set of computer (PC, monitor, keyboard, mouse)/1套计算机，包孕主机，显示器，键盘和鼠标
l I/O card for I/O communication between robot and computer/I/O卡适用于机械人和计算机之间的I/O通讯
l Mechanical parts for fixing camera /适用于安装相机等的机械零件
3.3.For CNC1 station/CNC1工位
Inspection enquiry/检验规定:
Solution concept/检验计划示意图:
Positioning inspection/加工前工件位置检验:
Dimension inspection after CNC/加工后尺寸检验:
System key component/体系关键零部件:
l One 10M pixels cameral/1个1000万像素工业相机
l One Lens/1个透镜
l One rectangle lighting install on the robot hand/一个矩形光源，安装在机器人的结尾
l One ring lighting install on the lens/一个环形光源，安装在透镜底部
l Adapter rings/转接环
l One USB cable for connecting camera and PC/1根USB线缆适用于毗连相机和计算机
l One set of computer (PC, monitor, keyboard, mouse)/1套计算机，包含主机，显示器，键盘和鼠标
l I/O card for I/O communication between robot and computer/I/O卡适用于机械人和计算机之间的I/O通讯
l Mechanical parts for fixing camera /适用于安装相机等的机械零件
3.4.For CNC2 station/CNC2工位
Inspection enquiry/检验请求:
Solution concept/检验计划示意图:
Positioning inspection/加工前工件位置检验:
Dimension inspection after CNC/加工后尺寸检验:
System key component/体系首要零部件:
l One 10M pixels cameral/1个1000万像素工业相机
l One Lens/1个透镜
l One rectangle lighting install on the robot hand/一个矩形光源，安装在机器人的结尾
l Adapter rings/转接环
l One USB cable for connecting camera and PC/1根USB线缆适用于毗邻相机和计算机
l One set of computer (PC, monitor, keyboard, mouse)/1套计算机，包孕主机，显示器，键盘和鼠标
l I/O card for I/O communication between robot and computer/I/O卡适用于机械人和计算机之间的I/O通讯
l Mechanical parts for fixing camera /适用于安装相机等的机械零件
3.5.For CNC3 station/CNC3工位
Inspection enquiry/检验请求:
Solution concept/检验计划示意图:
Positioning inspection/加工前工件位置检验:
Dimension inspection after CNC/加工后尺寸检验:
System key component/体系次要零部件:
l One 10M pixels cameral/1个1000万像素工业相机
l One Lens/1个透镜
l One rectangle lighting install on the robot hand/一个矩形光源，安装在机器人的结尾
l Adapter rings/转接环
l One USB cable for connecting camera and PC/1根USB线缆适用于毗邻相机和计算机
l One set of computer (PC, monitor, keyboard, mouse)/1套计算机，包孕主机，显示器，键盘和鼠标
l I/O card for I/O communication between robot and computer/I/O卡适用于机械人和计算机之间的I/O通讯
l Mechanical parts for fixing camera /适用于安装相机等的机械零件
3.6.For CNC4 station/CNC4工位
Inspection enquiry/检验规定:
Solution concept/检验计划示意图:
Positioning inspection/加工前工件位置检验:
Dimension inspection after CNC/加工后尺寸检验:
System key component/体系首要零部件:
l One 10M pixels cameral/1个1000万像素工业相机
l One Lens/1个透镜
l One rectangle lighting install on the robot hand/一个矩形光源，安装在机器人的末尾
l One ring lighting install on the lens/一个环形光源，安装在透镜底部
l Adapter rings/转接环
l One USB cable for connecting camera and PC/1根USB线缆适用于毗连相机和计算机
l One set of computer (PC, monitor, keyboard, mouse)/1套计算机，包含主机，显示器，键盘和鼠标
l I/O card for I/O communication between robot and computer/I/O卡适用于机械人和计算机之间的I/O通讯
l Mechanical parts for fixing camera /适用于安装相机等的机械零件
4.System calibration/体系校准
In order to do measurement, the system has to be calibrated. There will be a special calibration plate for camera calibration and the calibration procedure will be/为了实现精确丈量，体系需求经由校准。校定时需求用到一片专门适用于视觉丈量校准的校准片，校准步调如下:
l the robot pick up the calibration plate just like a part/机器人拾取校准片，就像拾取一片工件一样
l the robot move the calibration plate into the camera view at the focus level position/机器人将校准片移动到相机的事业范围内，并且在相机的焦平面上
l the robot will move to different positions in the camera view range, and the camera will take picture for the calibration plate at each position. Totally there will be 40~50 pictures./机器人将校准片移动到焦平面差别的位置，相机分别在每一个位置拍与一张照片，统共需求拍40~50张照片
l software will do the calibration calculation internal, after the calibration is finished, the camera scale is calibrated, and also the system coordinate (between robot and camera) is calibrated. /软件内部对照片干加准测算后完成体系的校准，包罗相机的比例，和机械人和相机之间的坐标干系。
Note/阐明:
The system calibration is needed one time for system setup, during using normally no need to do calibration anymore, only when the robot position is changed, or camera position is changed, or something else will affect the relationship between robot and camera. /体系校准只需求正在体系安装的时分干一次，正在后续的使用过程中普通不需求再干校准，只有正在机器人位置产生变化，大概相机位置产生变化后才需求重新干体系校准，大概其他会危害相机取机器人位置干系的因素产生转变后，才需求重新干体系校准。
5.Error analysis / 偏差阐明
5.1.For positioning inspection/位置检验
Errors can cause system errors include/关于每一个工位加工前的位置检验，会带给系统误差的因素有:
l Robot position repeatability/机器人的重复性定位精度
The robot will be used for this project is IRB 140, and the position repeatability of this robot is 0.03mm according to the official data sheet. Since the part weight is very small and it is constant, we consider the robot position repeatability as 0.01~0.015mm for system error consideration. /本项目里将要运用的机械人为IRB 140，凭据官方参数表，本机械人的反复定位精度为0.03mm，因为本应用工件重量很轻，并且是固定型号（负载稳定），我们估量机械人的现实反复定位精度为0.01~0.015mm，我们将运用这一数据来预算系统误差。
l Camera measuring error/相机的坐标系标定和比例校准
The system calibration procedure please refer to chapter 4/体系校准阐明和步调详见以上章节4。
After the calibration, the camera measuring error will be about 10um/经由校准后，想几点额测量误差将在10um摆布。
So the total system measuring error for positioning inspection is about/所以定位丈量的系统误差约为:
0.015+0.01=0.025mm
5.2.For dimension inspection/尺寸丈量
since all the dimensions measurement will be done on one picture, the robot positioning error and repeatability error have no big effect on the dimension inspection, so only camera measuring error will be the main errors for system /关于尺寸丈量，因为所有的尺寸将由一张照片盘算获得，机器人的定位精度及反复定位精度都不会给体系带来较着的危害，所以只有相机的丈量误差会对体系精度有主要危害:
The system calibration procedure please refer to chapter 4/体系校准阐明和步调详见以上章节4。
After the calibration, the camera measuring error will be about 10um/颠末校准后，想几点额测量误差将在10um摆布。
So the total system measuring error for dimension inspection is about/所以尺寸丈量的系统误差约为:
0.01mm