Part.1 Industry Background
The rapid development of the automobile industry has put forward higher requirements for the automatic production of parts. With the increase of car sales, the traditional manual production mode has been difficult to meet the needs of mass production, and automated production is an inevitable trend.
Crankshaft is one of the key components of automobile engine, the production process is complicated, and the automation generation is relatively low. The crankshaft plays the role of converting reciprocating motion into rotary motion. It is usually made of high-strength alloy steel to withstand working conditions under high pressure and high temperature. Its production involves multiple production processes such as forging, machining, and polishing, and The crankshaft also needs to consider factors such as strength, stiffness, weight, balance and friction loss. The traditional manual production method is inefficient and difficult to achieve large-scale, standardized production and project replication.
The manufacturing process of the crankshaft requires high-precision machining and heat treatment. The traditional crankshaft loading and unloading is highly dependent on labor, with high work intensity, high repetition rate and low efficiency. Using machine vision technology with mechanical arms and grippers to replace manual loading work, it can quickly and accurately identify the status of disorderly incoming materials and implement grabbing and loading, providing enterprises with more efficient and safer solutions.
Part.2 Industry Pain Points
1. The production efficiency of manual operation is low and cannot meet the needs of mass production:
The traditional disorderly picking and loading of automobile crankshafts mainly relies on manual work and simple auxiliary machinery and equipment, but the weight of the crankshaft is heavy, difficult to transport, and the structure is cumbersome. There is a certain amount of reflection in some areas that may easily lead to the problem of stacking inspection reports, making The traditional manual mode is difficult to adapt to the high-capacity demand of today's automobile industry and has become one of the production bottlenecks;
2. The on-site working environment is harsh, full of noise, dust pollution and other unfavorable conditions, which will seriously affect the health of operators;
3. Grabbing is difficult, and quality and safety are difficult to guarantee:
The geometric shape of the crankshaft is complex, and it is often placed in an irregular state. It is difficult to grab it manually, which will easily lead to product damage and affect product quality and production safety;
4. The degree of automation is low, and the level of intelligence is preferred:
At present, although production automation is inevitable in the development of the times, the degree of mechanization in the grasping and assembly of crankshafts is still relatively low, and the application of intelligent equipment and systems in actual projects is seldom. There is a large room for improvement in the intelligent industry.
Part.3 Solution
In order to solve the pain points of the traditional crankshaft grasping system, the project uses Xianyang Technology's HY-M5 3D vision system, which uses algorithms to guide the robot to grasp the crankshaft and place it at a fixed point according to the 3D features, and guides the robot to quickly and accurately grasp the solution. The solution is stable and efficient. Precise operation is also possible.
1. Use 3D machine vision technology to realize accurate identification and positioning of the crankshaft. Scan crankshafts arranged in disorder through 3D vision sensors, obtain their 3D point cloud data, and analyze the geometric shape, spatial orientation, and attitude characteristics of crankshafts to achieve fast and accurate positioning;
2. Dynamic grasping path planning based on crankshaft positioning results. Based on the 3D visual positioning results, the system dynamically generates the best grabbing path in combination with the parameters of the robotic arm, and guides the robotic arm to stably grab the crankshaft;
3. The system supports the detection of dark and reflective objects, effectively solving the problem of crankshaft reflection. And the scanning speed of HY-M5 is 10-300Hz, the measurement accuracy is accurate to ±0.01mm, the field of view reaches 529x362-1164x979mm², and the large depth of field can capture the crankshaft from multiple angles and directions;
4. Modular design, with certain versatility. The system adopts a modular design, and the visual equipment, intelligent algorithm, path planning and robotic arm control are relatively independent, which is convenient for secondary development and promotion and application, and can be applied to more application scenarios, more working conditions and products.
Part.4 Program advantages
1. High precision: HY-M5 3D machine vision system ensures the accuracy and consistency of the crankshaft by providing high-precision crankshaft measurement data, and meets the design requirements and quality standards;
2. Strong anti-interference: HY-M5 3D machine vision system can solve the impact of reflection on the workpiece caused by sunlight, light and other factors;
3. Improve production efficiency: HY-M5 three-dimensional machine vision system can easily deal with crankshaft workpieces with different specifications and complex structures. Through non-contact measurement, it can effectively reduce potential damage and pollution, and greatly improve production efficiency;
4. Guarantee the safety of operators: HY-M5 three-dimensional machine vision system can prevent problems such as crankshaft collision, clamping and dropping parts, etc., which greatly improves the safety factor of work.