solutionfor casing production line positioning & inspection
手机后盖生产线视觉辅助定位及测量系统
1.part to be inspected and cut /被测工件
a mobile phone casing / 手机后盖
2.system target /系统目标
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/检测热压后工件缺陷，包括皱痕，折痕，划痕和碳素纤维方向
2.2.press station/冲切工位:
l to get the part position relative to robot coordinate system, then feedback the part position toabbrobot/冲切前检测并得到工件在机器人坐标系里的位置偏差，并将测量结果反馈给abb机器人
l to inspect part dimension after press including length, width and hole diameter/冲切后检测工件尺寸，包括长度，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/加工前检测并得到工件在机器人坐标系里的位置偏差，并将测量结果反馈给abb机器人
l to inspect hole diameter/加工后检测孔径
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/加工前检测并得到工件在机器人坐标系里的位置偏差，并将测量结果反馈给abb机器人
l to inspect part dimension including injection feed boss, hole position and diameter/加工后检测工件尺寸，包括料口柱，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/加工前检测并得到工件在机器人坐标系里的位置偏差，并将测量结果反馈给abb机器人
l to inspect part dimension including hole position and diameter/加工后检测工件尺寸，包括孔的位置和直径
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/加工前检测并得到工件在机器人坐标系里的位置偏差，并将测量结果反馈给abb机器人
l to inspect part dimension including opening width and depth/加工后检测工件尺寸，包括开槽的宽度和深度
3.enquiry and solution /测量要求及方案
base on the system target we make a rough solution as below/基于以上系统需求我们初步制定了以下方案：
3.1.forheat & press station/热压工位:
inspection enquiry/检测要求:
solution concept/检测方案示意图:
load the part/放置工件到检测位置:
inspect/检测状态:
system key component/系统主要零部件:
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线缆用于连接相机和计算机
l one air cylinder for pushing the part to inspection position/1个带导柱气缸，用于将工件推到检测位置
l one set of computer (pc, monitor, keyboard, mouse)/1套计算机，包括主机，显示器，键盘和鼠标
l i/o card for i/o communication between robot and computer/i/o卡用于机器人和计算机之间的i/o通讯
l mechanical parts for fixing camera and air cylinder/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/检测要求:
solution concept/检测方案示意图:
positioning inspection/冲切前工件位置检测:
dimension inspection after press/冲切后尺寸检测:
system key component/系统主要零部件:
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，安装在机器人的末端
l adapter rings/转接环
l one usb cable for connecting camera and pc/1根usb线缆用于连接相机和计算机
l one set of computer (pc, monitor, keyboard, mouse)/1套计算机，包括主机，显示器，键盘和鼠标
l i/o card for i/o communication between robot and computer/i/o卡用于机器人和计算机之间的i/o通讯
l mechanical parts for fixing camera /用于安装相机等的机械零件
3.3.for cnc1 station/cnc1工位
inspection enquiry/检测要求:
solution concept/检测方案示意图:
positioning inspection/加工前工件位置检测:
dimension inspection after cnc/加工后尺寸检测:
system key component/系统主要零部件:
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，安装在机器人的末端
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线缆用于连接相机和计算机
l one set of computer (pc, monitor, keyboard, mouse)/1套计算机，包括主机，显示器，键盘和鼠标
l i/o card for i/o communication between robot and computer/i/o卡用于机器人和计算机之间的i/o通讯
l mechanical parts for fixing camera /用于安装相机等的机械零件
3.4.for cnc2 station/cnc2工位
inspection enquiry/检测要求:
solution concept/检测方案示意图:
positioning inspection/加工前工件位置检测:
dimension inspection after cnc/加工后尺寸检测:
system key component/系统主要零部件:
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，安装在机器人的末端
l adapter rings/转接环
l one usb cable for connecting camera and pc/1根usb线缆用于连接相机和计算机
l one set of computer (pc, monitor, keyboard, mouse)/1套计算机，包括主机，显示器，键盘和鼠标
l i/o card for i/o communication between robot and computer/i/o卡用于机器人和计算机之间的i/o通讯
l mechanical parts for fixing camera /用于安装相机等的机械零件
3.5.for cnc3 station/cnc3工位
inspection enquiry/检测要求:
solution concept/检测方案示意图:
positioning inspection/加工前工件位置检测:
dimension inspection after cnc/加工后尺寸检测:
system key component/系统主要零部件:
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，安装在机器人的末端
l adapter rings/转接环
l one usb cable for connecting camera and pc/1根usb线缆用于连接相机和计算机
l one set of computer (pc, monitor, keyboard, mouse)/1套计算机，包括主机，显示器，键盘和鼠标
l i/o card for i/o communication between robot and computer/i/o卡用于机器人和计算机之间的i/o通讯
l mechanical parts for fixing camera /用于安装相机等的机械零件
3.6.for cnc4 station/cnc4工位
inspection enquiry/检测要求:
solution concept/检测方案示意图:
positioning inspection/加工前工件位置检测:
dimension inspection after cnc/加工后尺寸检测:
system key component/系统主要零部件:
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，安装在机器人的末端
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线缆用于连接相机和计算机
l one set of computer (pc, monitor, keyboard, mouse)/1套计算机，包括主机，显示器，键盘和鼠标
l i/o card for i/o communication between robot and computer/i/o卡用于机器人和计算机之间的i/o通讯
l mechanical parts for fixing camera /用于安装相机等的机械零件
4.system calibration/系统校准
in order to do measurement, the system has to be calibrated.there will be a special calibration plate for camera calibrationand the calibration procedure will be/为了实现准确测量，系统需要经过校准。校准时需要用到一片专门用于视觉测量校准的校准片，校准步骤如下:
lthe 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
lthe 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
lthe 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不同的位置，相机分别在每个位置拍取一张照片，总共需要拍40~50张照片
lsoftware 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. /软件内部对照片做加准计算后完成系统的校准，包括相机的比例，以及机器人和相机之间的坐标关系。
note/说明:
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. /系统校准只需要在系统安装的时候做一次，在后续的使用过程中一般不需要再做校准，只有在机器人位置发生变化，或者相机位置发生变化后才需要重新做系统校准，或者其他会影响相机与机器人位置关系的因素发生改变后，才需要重新做系统校准。
5.error analysis /误差分析
5.1.for positioning inspection/位置检测
errors can cause system errors include/对于每个工位加工前的位置检测，会带给系统误差的因素有:
lrobot 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. /本项目里将要使用的机器人为irb 140，根据官方参数表，本机器人的重复定位精度为0.03mm，由于本应用工件重量很轻，而且是固定型号（负载不变），我们估计机器人的实际重复定位精度为0.01~0.015mm，我们将使用这一数据来估算系统误差。
lcamera measuring error/相机的坐标系标定和比例校准
the system calibration procedure please refer to chapter 4/系统校准说明和步骤详见以上章节4。
after the calibration, the camera measuring error will beabout 10um/经过校准后，想几点额测量误差将在10um左右。
so the total system measuring error for positioning inspection isabout/所以定位测量的系统误差约为:
0.015+0.01=0.025mm
5.2.for dimension inspection/尺寸测量
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 /对于尺寸测量，由于所有的尺寸将由一张照片计算得到，机器人的定位精度及重复定位精度都不会给系统带来明显的影响，所以只有相机的测量误差会对系统精度有重要影响:
the system calibration procedure please refer to chapter 4/系统校准说明和步骤详见以上章节4。
after the calibration, the camera measuring error will beabout 10um/经过校准后，想几点额测量误差将在10um左右。
so the total system measuring error for dimension inspection isabout/所以尺寸测量的系统误差约为:
0.01mm
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