手機后蓋生產(chǎn)線視覺輔助定位及測量系統(tǒng)
1. Part to be inspected and cut / 被測工件
A mobile phone casing / 手機后蓋
2. System target / 系統(tǒng)目標
2.1. Heat & Press station/熱壓工位: to inspect the part defect including crease, or wrinkle; scratch and the direction of the carbon fiber/檢測熱壓后工件缺陷，包括皺痕，折痕，劃痕和碳素纖維方向
2.2. Press station/沖切工位:
l to get the part position relative to robot coordinate system, then feedback the part position to abb robot/沖切前檢測并得到工件在機器人坐標系里的位置偏差，并將測量結果反饋給abb機器人
l to inspect part dimension after press including length, width and hole diameter/沖切后檢測工件尺寸，包括長度，寬度和孔徑
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/加工前檢測并得到工件在機器人坐標系里的位置偏差，并將測量結果反饋給ABB機器人
l to inspect hole diameter/加工后檢測孔徑
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/加工前檢測并得到工件在機器人坐標系里的位置偏差，并將測量結果反饋給ABB機器人
l to inspect part dimension including injection feed boss, hole position and diameter/加工后檢測工件尺寸，包括料口柱，孔的位置和直徑
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/加工前檢測并得到工件在機器人坐標系里的位置偏差，并將測量結果反饋給ABB機器人
l to inspect part dimension including hole position and diameter/加工后檢測工件尺寸，包括孔的位置和直徑
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/加工前檢測并得到工件在機器人坐標系里的位置偏差，并將測量結果反饋給ABB機器人
l to inspect part dimension including opening width and depth/加工后檢測工件尺寸，包括開槽的寬度和深度
3. Enquiry and Solution / 測量要求及方案
Base on the system target we make a rough solution as below/基于以上系統(tǒng)需求我們初步制定了以下方案：
3.1. For Heat & Press station/熱壓工位:
Inspection enquiry/檢測要求:
Solution concept/檢測方案示意圖:
Load the part/放置工件到檢測位置:
Inspect/檢測狀態(tài):
System key component/系統(tǒng)主要零部件:
l One 10M pixels cameral/1個1000萬像素工業(yè)相機
l One Lens/1個透鏡
l One ring lighting install on the lens/1個環(huán)形光源，安裝在透鏡底部
l Adapter rings/轉接環(huán)
l One USB cable for connecting camera and PC/1根USB線纜用于連接相機和計算機
l One air cylinder for pushing the part to inspection position/1個帶導柱氣缸，用于將工件推到檢測位置
l One set of computer (PC, monitor, keyboard, mouse)/1套計算機，包括主機，顯示器，鍵盤和鼠標
l I/O card for I/O communication between robot and computer/I/O卡用于機器人和計算機之間的I/O通訊
l Mechanical parts for fixing camera and air cylinder/用于安裝相機和氣缸等的機械零件
3.2. For Press station/沖切工位
Inspection enquiry/檢測要求:
Solution concept/檢測方案示意圖:
Positioning inspection/沖切前工件位置檢測:
Dimension inspection after press/沖切后尺寸檢測:
System key component/系統(tǒng)主要零部件:
l One 10M pixels cameral/1個1000萬像素工業(yè)相機
l One Lens/1個透鏡
l One rectangle lighting install on the robot hand/一個矩形光源，安裝在機器人的末端
l Adapter rings/轉接環(huán)
l One USB cable for connecting camera and PC/1根USB線纜用于連接相機和計算機
l One set of computer (PC, monitor, keyboard, mouse)/1套計算機，包括主機，顯示器，鍵盤和鼠標
l I/O card for I/O communication between robot and computer/I/O卡用于機器人和計算機之間的I/O通訊
l Mechanical parts for fixing camera /用于安裝相機等的機械零件
3.3. For CNC1 station/CNC1工位
Inspection enquiry/檢測要求:
Solution concept/檢測方案示意圖:
Positioning inspection/加工前工件位置檢測:
Dimension inspection after CNC/加工后尺寸檢測:
System key component/系統(tǒng)主要零部件:
l One 10M pixels cameral/1個1000萬像素工業(yè)相機
l One Lens/1個透鏡
l One rectangle lighting install on the robot hand/一個矩形光源，安裝在機器人的末端
l One ring lighting install on the lens/一個環(huán)形光源，安裝在透鏡底部
l Adapter rings/轉接環(huán)
l One USB cable for connecting camera and PC/1根USB線纜用于連接相機和計算機
l One set of computer (PC, monitor, keyboard, mouse)/1套計算機，包括主機，顯示器，鍵盤和鼠標
l I/O card for I/O communication between robot and computer/I/O卡用于機器人和計算機之間的I/O通訊
l Mechanical parts for fixing camera /用于安裝相機等的機械零件
3.4. For CNC2 station/CNC2工位
Inspection enquiry/檢測要求:
Solution concept/檢測方案示意圖:
Positioning inspection/加工前工件位置檢測:
Dimension inspection after CNC/加工后尺寸檢測:
System key component/系統(tǒng)主要零部件:
l One 10M pixels cameral/1個1000萬像素工業(yè)相機
l One Lens/1個透鏡
l One rectangle lighting install on the robot hand/一個矩形光源，安裝在機器人的末端
l Adapter rings/轉接環(huán)
l One USB cable for connecting camera and PC/1根USB線纜用于連接相機和計算機
l One set of computer (PC, monitor, keyboard, mouse)/1套計算機，包括主機，顯示器，鍵盤和鼠標
l I/O card for I/O communication between robot and computer/I/O卡用于機器人和計算機之間的I/O通訊
l Mechanical parts for fixing camera /用于安裝相機等的機械零件
3.5. For CNC3 station/CNC3工位
Inspection enquiry/檢測要求:
Solution concept/檢測方案示意圖:
Positioning inspection/加工前工件位置檢測:
Dimension inspection after CNC/加工后尺寸檢測:
System key component/系統(tǒng)主要零部件:
l One 10M pixels cameral/1個1000萬像素工業(yè)相機
l One Lens/1個透鏡
l One rectangle lighting install on the robot hand/一個矩形光源，安裝在機器人的末端
l Adapter rings/轉接環(huán)
l One USB cable for connecting camera and PC/1根USB線纜用于連接相機和計算機
l One set of computer (PC, monitor, keyboard, mouse)/1套計算機，包括主機，顯示器，鍵盤和鼠標
l I/O card for I/O communication between robot and computer/I/O卡用于機器人和計算機之間的I/O通訊
l Mechanical parts for fixing camera /用于安裝相機等的機械零件
3.6. For CNC4 station/CNC4工位
Inspection enquiry/檢測要求:
Solution concept/檢測方案示意圖:
Positioning inspection/加工前工件位置檢測:
Dimension inspection after CNC/加工后尺寸檢測:
System key component/系統(tǒng)主要零部件:
l One 10M pixels cameral/1個1000萬像素工業(yè)相機
l One Lens/1個透鏡
l One rectangle lighting install on the robot hand/一個矩形光源，安裝在機器人的末端
l One ring lighting install on the lens/一個環(huán)形光源，安裝在透鏡底部
l Adapter rings/轉接環(huán)
l One USB cable for connecting camera and PC/1根USB線纜用于連接相機和計算機
l One set of computer (PC, monitor, keyboard, mouse)/1套計算機，包括主機，顯示器，鍵盤和鼠標
l I/O card for I/O communication between robot and computer/I/O卡用于機器人和計算機之間的I/O通訊
l Mechanical parts for fixing camera /用于安裝相機等的機械零件
4. System calibration/系統(tǒng)校準
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/為了實現(xiàn)準確測量，系統(tǒng)需要經(jīng)過校準。校準時需要用到一片專門用于視覺測量校準的校準片，校準步驟如下:
l the robot pick up the calibration plate just like a part/機器人拾取校準片，就像拾取一片工件一樣
l the robot move the calibration plate into the camera view at the focus level position/機器人將校準片移動到相機的事業(yè)范圍內，并且在相機的焦平面上
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./機器人將校準片移動到焦平面不同的位置，相機分別在每個位置拍取一張照片，總共需要拍40~50張照片
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. /軟件內部對照片做加準計算后完成系統(tǒng)的校準，包括相機的比例，以及機器人和相機之間的坐標關系。
Note/說明:
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. /系統(tǒng)校準只需要在系統(tǒng)安裝的時候做一次，在后續(xù)的使用過程中一般不需要再做校準，只有在機器人位置發(fā)生變化，或者相機位置發(fā)生變化后才需要重新做系統(tǒng)校準，或者其他會影響相機與機器人位置關系的因素發(fā)生改變后，才需要重新做系統(tǒng)校準。
5. Error analysis / 誤差分析
5.1. For positioning inspection/位置檢測
Errors can cause system errors include/對于每個工位加工前的位置檢測，會帶給系統(tǒng)誤差的因素有:
l Robot position repeatability/機器人的重復性定位精度
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. /本項目里將要使用的機器人為IRB 140， 根據(jù)官方參數(shù)表，本機器人的重復定位精度為0.03mm，由于本應用工件重量很輕，而且是固定型號（負載不變），我們估計機器人的實際重復定位精度為0.01~0.015mm，我們將使用這一數(shù)據(jù)來估算系統(tǒng)誤差。
l Camera measuring error/相機的坐標系標定和比例校準
The system calibration procedure please refer to chapter 4/系統(tǒng)校準說明和步驟詳見以上章節(jié)4。
After the calibration, the camera measuring error will be
So the total system measuring error for positioning inspection is
0.015+0.01=0.025mm
5.2. For dimension inspection/尺寸測量
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 /對于尺寸測量，由于所有的尺寸將由一張照片計算得到，機器人的定位精度及重復定位精度都不會給系統(tǒng)帶來明顯的影響，所以只有相機的測量誤差會對系統(tǒng)精度有重要影響:
The system calibration procedure please refer to chapter 4/系統(tǒng)校準說明和步驟詳見以上章節(jié)4。
After the calibration, the camera measuring error will be
So the total system measuring error for dimension inspection is
0.01mm
