In the production process of lithium batteries, the products should be automatically removed from the production line, sent to the testing place for visual inspection by the intelligent image processing system, and then the qualified products are sent to a specific packaging container, and the unqualified products are sent to another container. This is the final step in the production of batteries in the production of batteries by Sonnenschein, the largest battery manufacturer in Europe, before packaging, and there are several stations in the entire battery production process with palletizing robots from Baigra. Although the functions of these robots are not exactly the same, the same trailer is used to facilitate the operation of products at different stations. In this article, we will briefly introduce the final appearance inspection and the palletizing robot with visual inspection system as an example.
A standard batch supply mechanism consists of a lifting section of the pallets, a horizontal movement section of the pallets and a 2D XZ robot. It is driven by a linear motion unit to move up and down arbitrarily accurately. During the operation, the top first pallet is raised to a certain height higher than the horizontal motion axis and then stops, and then the horizontal axis moves to the first pallet, so that the carriage with it is under the first pallet. The lifting shaft is then lowered so that the first pallet is on the carriage of the horizontal axis. The lifting shaft is then raised by 10 mm, and the horizontal axial return movement brings the pallet in front of the 2D XZ robot. The XZ 2D robot first transfers the parts in the first row one by one, and then puts them back in place after the transfer is finished. When one row of parts has been processed, the horizontal axis of motion moves forward again so that the parts in the second row are in a position that the robot can grasp. And so on, after the final row of parts has been processed, the horizontal axis of motion returns the pallet to its original position on the lifting axis. Then process the parts of the next pallet and so on until all the parts on the final pallet are processed.
The feeding system has up to 14 pallets at a time, and the size of each pallet is 320*250*35mm, equipped with 100 batteries, and the weight of each battery is 10 grams. Using a suction claw that grabs five batteries at a time, five parts are transferred, inspected, and put back into the tray every 5 seconds on average. It takes 4 seconds to change the pallet each time, and the positioning accuracy of each moving part is 0.1mm.
The lifting shaft is made of two PAS42BB gantry structure, and the maximum load can reach 80 kg. Two PAS41BR are used for the horizontal axis of movement, and the maximum load can be up to 20 kg. The X-axis of the XZ 2D robot is PAS42BB, and the Z-axis is LM-A41BB. Movement speed up to 60 m/min. The claws are suction cups that catch five parts at a time.
The visual inspection system uses the smart camera of Germany VC company VC4466C colorful smart camera, equipped with CCD sensor, the resolution is 1024*768 pixels, progressive scanning output signal, and 20 frames of images per second. The exposure time is from 5us to 20s, which can be set by software. With TI DSP, 8000 MIPS (= million operations per second) can be performed per second. It comes with 4MB of flash memory and 64MB of data storage. It has 4 programmable inputs and 4 programmable outputs, 1 RS232 interface, SXGA video output and optional Ethernet output. Its overall volume is 110*50*35mm, the overall weight is 250 grams, and the power supply is 24VDC.
The template matching algorithm is selected to quickly check the following data of the battery:
1. Whether the appearance color is consistent;
2. Whether the drawings are unclear and incomplete;
3. Whether there is any fault in the text.
The teaching method is selected to absorb the qualified battery as the standard template, and then compare the images of the battery each time, so as to complete the above detection function. The advantage of VC4466C colorful smart camera is that it does not consume DSP resources when the camera is exposed to read a new image, and the DSP can be used to complete the template matching processing job. It takes 50 ms to acquire an image, and 100 ms to complete a template match. All one smart camera system can complete the inspection of 5 batteries.
The whole robot system uses the TLCC CAN bus control system of Begra, and the movement of each axis is controlled by CANBus. Based on the results of the inspection from the VC4466C smart camera, the TLCC puts the battery back in its original place or puts it in the non-conforming product box. The TLC5 series of intelligent drivers are selected for all kinds of motion axes, which accept motion commands from TLCC. The planetary reducer equipped with each shaft is the PLE series fine planetary reducer of Neugart company in Germany. The whole system selects 4 PLE series fine planetary reducers and 4 programmable, intelligent servo drive system TLC534 with motion control function.
This article introduces the structure and operation process of a large-scale feeding robot. It can be composed of Cartesian coordinate robots for loading and unloading, and the transfer robot is very suitable for many kinds of use, and the cost is lower than other robots, high efficiency, and is widely used in the production of cosmetics, food, mobile phones, sensors, toys, appearances, etc. in Europe.
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