乳胶产品检测线自动供料分拣系统研究
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摘要
在安全套生产中,整个加工过程已经基本实现了自动化,但是在进行电检测的时候却仍需人工将安全套套在检测仪器上,这极大地降低了生产效率,增加了工人的劳动强度,成为整个生产过程实现全面自动化的瓶颈。为此,亟需设计一套自动上料系统来实现上料功能,以便提高整套生产线的生产效率,降低生产成本,提高企业竞争力。
安全套材质特殊,柔性大,因此它在料斗中的状态各异,很难形成统一的排列状态,这给它的自动上料带来了巨大困难。为实现安全套检测的自动上料这一功能,我们将整个过程分为四个步骤:1、从料斗中取料并放在第一级传送带上;2、通过摄像头拍摄安全套状态图像并进行椭圆检测,确定安全套前端在传送带上的位置;3、吸取安全套并放至第二级的圆环中,完成自动分拣;4、通过机械手拾取安全套并套在检测仪器上,实现自动上料。
本文的主要工作是对安全套自动上料系统进行研究,并对安全套的自动分拣部分进行详细设计。论文的主要内容包括四大部分:安全套自动上料系统的整体结构设计,并对主要零部件进行分析;图像检测系统的开发,重点是开发出能够检测出安全套前端圆环的图像处理算法;自动分拣气动系统设计,主要是设计了气动系统的回路并对真空分拣子系统进行了仿真;自动分拣控制系统设计及其实验,选择了PLC的型号、编写了PLC梯形图,并在此基础上做了自动分拣模块的实验。
In the production of condom, although the whole process has basically achieved automation, but the condom is put on the testing instrument artificially in electricity detection, which greatly reduces the production efficiency, increases the labor intensity, and becomes a bottleneck to achieve comprehensive automation of the whole production process. Therefore, it is urgent to design a set of automatic feeding system to realize feeding function, so as to improve the efficiency of the whole production line, reduce production cost and enhance the competitiveness of enterprises.
The condom has special material and large flexibility, so it varies in the state of the hopper, and it is difficult to form a unified state, which brings enormous difficulties for the automatic feeding. To realize the automatic feeding for condom detection, the whole process is divided into four steps: 1、take materials from hopper and put them on the first level conveyor belt; 2、shoot the state image of condom through the camera and do the ellipse detection to determine the front position of condom on the conveyor belt; 3、pick up the condom and put it on the second level ring to finish automatic sorting; 4、pick the condom by manipulator and put it on the instrument to realize automatic feeding.
It is the main task of the paper to design the automatic feeding equipment for condom and design the part of the condom automatic sorting in detail. The main contents of the paper consist of four major components: the overall structure design of the condom automatic feeding system and the analysis of the main components; the development of image detection system, the key that developing the image processing algorithms which can detect the condom ring; the design of the automatic sorting pneumatic system, designing mainly the circuit of the pneumatic system and simulating the subsystem of the vacuum sorting; the design of the automatic sorting control system and the experiment, selecting the type of PLC、compiling the PLC ladder, doing the experiment of the automatic sorting on the basis of these content.
安全套材质特殊,柔性大,因此它在料斗中的状态各异,很难形成统一的排列状态,这给它的自动上料带来了巨大困难。为实现安全套检测的自动上料这一功能,我们将整个过程分为四个步骤:1、从料斗中取料并放在第一级传送带上;2、通过摄像头拍摄安全套状态图像并进行椭圆检测,确定安全套前端在传送带上的位置;3、吸取安全套并放至第二级的圆环中,完成自动分拣;4、通过机械手拾取安全套并套在检测仪器上,实现自动上料。
本文的主要工作是对安全套自动上料系统进行研究,并对安全套的自动分拣部分进行详细设计。论文的主要内容包括四大部分:安全套自动上料系统的整体结构设计,并对主要零部件进行分析;图像检测系统的开发,重点是开发出能够检测出安全套前端圆环的图像处理算法;自动分拣气动系统设计,主要是设计了气动系统的回路并对真空分拣子系统进行了仿真;自动分拣控制系统设计及其实验,选择了PLC的型号、编写了PLC梯形图,并在此基础上做了自动分拣模块的实验。
In the production of condom, although the whole process has basically achieved automation, but the condom is put on the testing instrument artificially in electricity detection, which greatly reduces the production efficiency, increases the labor intensity, and becomes a bottleneck to achieve comprehensive automation of the whole production process. Therefore, it is urgent to design a set of automatic feeding system to realize feeding function, so as to improve the efficiency of the whole production line, reduce production cost and enhance the competitiveness of enterprises.
The condom has special material and large flexibility, so it varies in the state of the hopper, and it is difficult to form a unified state, which brings enormous difficulties for the automatic feeding. To realize the automatic feeding for condom detection, the whole process is divided into four steps: 1、take materials from hopper and put them on the first level conveyor belt; 2、shoot the state image of condom through the camera and do the ellipse detection to determine the front position of condom on the conveyor belt; 3、pick up the condom and put it on the second level ring to finish automatic sorting; 4、pick the condom by manipulator and put it on the instrument to realize automatic feeding.
It is the main task of the paper to design the automatic feeding equipment for condom and design the part of the condom automatic sorting in detail. The main contents of the paper consist of four major components: the overall structure design of the condom automatic feeding system and the analysis of the main components; the development of image detection system, the key that developing the image processing algorithms which can detect the condom ring; the design of the automatic sorting pneumatic system, designing mainly the circuit of the pneumatic system and simulating the subsystem of the vacuum sorting; the design of the automatic sorting control system and the experiment, selecting the type of PLC、compiling the PLC ladder, doing the experiment of the automatic sorting on the basis of these content.
引文
[1]陈佩云,章以钧.制造业综合自动化现状和今后发展[J].中国机械工程,1996,6(3):1-5
[2]朱新星.中国制造业现状及发展对策[J.科技信,2007,(1):164
[3]吴贵生,杨志刚.制造业在我国经济中的地位和作用[J].机械职业教育,2002,(3):3-4
[4]张祥国.简论分拣及分拣系统[J].物流技术,2002,(10):9-10
[5]李娜娜.卷烟配送中心自动分拣系统的规划设计研究[D].[硕士学位论文].长沙:中南大学控制科学与工程系,2008
[6]韩新宅.邮政自动化分拣技术[M].北京:北京邮电大学出版社,1997,1-4
[7]国家机械工业局行业管理司,国家国内贸易局设备成套管理局.中国机电产品大辞典[M].北京:机械工业出版社,1999,470
[8]王波.自适应棉纺异纤分拣装置的研制[D].[硕士学位论文].青岛:青岛科技大学检测技术及其自动化装置专业,2009
[9] Hartmut KIECKHOEFER, Jan BAAN, Arjan MAST, etal. Image processing techniques for ultrasonic inspection [J].17th World Conference on Nondestrrctive Testing, 2008
[10]陈建宏,林绍义.基于激光的特种汽车镀膜玻璃自动化检测[J].重庆工学院学报,2009,23(8):24-28
[11] Diez Aznar,Jose Manuel.New methodology for the programation of PLC in control systems based in Grafcet[J].Universidad Politecnica De Valencia,2000,12:25-27
[12] Farsi M.Application of a PLC as a cell controller using a communication network [J].IEE COLLOQ DIG, 1995, 112:3/1-3/4
[13]姚国年,卫军胡.基于PLC高压水倒空控制系统的设计[J].机床与液压,2010,20(38):72-74
[14] Gang Liu, Robert M.Haralick, Two practical issues in Canny’s edge detector implementation [J].Proceedings of 15th International Conference on Pattern Recognition, 2000, 3: 676-678
[15]刘丽华.基于PLC控制的教学型旋盖气动机械手设计[J].液压与气动,2010,(3):51-53
[16] C.G.Rafael, E.W.Richard. Digital Image Processing [M]. Second Edition.Beijing: Publishing house of electronics industry, 2002.1-6
[17]陶跃珍.基于机器视觉的啤酒瓶瓶口缺陷检测系统的研究[D].[硕士学位论文].武汉:湖北工业大学测试计量技术与仪器专业,2007
[18] Azeddine Beghdadi, Ammar Khellaf.A Noise-filtering Method Using a Local Information Measure[J].IEEE Transactions on Image Processing. 1997, 6(6):879-882
[19]林宁,沙涛.基于数字图像处理的棉花异纤检测研究[J].电气电子教学学报,2010,32(2):41-42
[20] Fangwei Zhao, Christopher J.S.Desilva.Use of The Laplacian of Gaussian Operator in Prostate Ultrasound Image Processing[J]. Proceedings of the 20th Annual International Conference of the IEEE Engineering in Medicine and Biology Society.1998,20(2):812-815
[21] Stephane Mallat,Sifen Zhong. Characterization of Signals from Multiscale Edges[J]. IEEE Transactions on Pattern Analysis and Machine Intelligenc, 1992,14(7):710-732
[22]朱铮涛,姚钦.基于图像处理的液晶保护屏玻璃板在线尺寸检测[J].控制与检测,2010,(3):55-58
[23] Li-Te Fang, Hsin-Chia Chen, Sheng-Jyh Wang, etal. AUTOMATIC MURA DETECTION SYSTEM FOR LIQUID CRYSTAL DISPLAY PANELS[J].18th IPPR Conference on Computer Vision, Graphics and Image Processing, 2005: 826-832
[24] K.Takahashi, T.Kitamura, M.Takatoo, etal. Traffic Flow Measuring System by Image Processing [J].IAPR Workshop on Machine Vision Applications, 1996, 5: 245-248
[25] Chien -Tsai Tsai and Daw -Tung Lin. Automatic License Plate Recognition system [J].18th IPPR Conference on Computer Vision, Graphics and Image Processing, 2005: 610-612
[26] Harry H.Cheng, Benjamin D.Shaw, Joe Palen, etal. A Real-Time Laser-Based Detection System for Messurement of Delineations of Moving Vehicles.IEEE/ASME TRANSACTIONS ON MECHATRONICS, 2001, 6 (2): 170-187
[27]秦峰华.卷烟自动分拣机的性能优化与实现[D].[硕士学位论文].济南.山东大学系统工程,2007
[28]丘胜标.浅析卷烟分拣系统[J].科技创新导报,2009,12:213
[29]李增刚.ADAMS入门详解与实例[M].北京:国防工业出版社,2006,1-10
[30]冯浩.基于ANSYS的某车载骨架结构的有限元分析与优化[D].[硕士学位论文].武汉,华中科技大学机械设计及理论,2007
[31]牛跃文.基于ANSYS的矿用汽车车架有限元模态分析[J].煤矿机械,2007,28(4):98-100
[32]李腾腾,钟绍华.ANSYS的发动机连杆的模态分析[J].汽车工程师,2010,4:25-32
[33]陈凯,李胜利等.超声图像胎儿颅骨椭圆自动检测方法[J].中国图象图形学报,2009,14(12):2478-2482
[34] W Lu, J Tan. Detection of incomplete ellipse in images with strong noise by interative randomized Hough transform[J].Pattern Recognition, 2008, 41:1268-1269
[35]张德丰.详解MATLAB数字图像处理[M].北京:电子工业出版社,2010.134-137
[36] Bennett N, Burridge R, Saito N. A method to detect and characterize ellipses using Hough transform[J]. Transaction on Pattern Analysis Machine Intelligence, 1999,21(7):652-657
[37]张铮,王艳平,薛桂香.数字图像处理与机器视觉[M].北京:人民邮电出版社,2010,350-357
[38] Ho C T, Chen L H.A fast ellipse/circle detector using geometric symmetry [J]. Pattern Recognition,1995,28: 117-124
[39]陈超.MATLAB应用实例精讲[M].北京:电子工业出版社,2011,181-182
[40]张强,王正林.精通MATLAB图像处理[M].北京:电子工业出版社,2009,17-18
[41]郭维强,蒲如平,韩秀杰,等.真空发生器抽吸机理与性能的分析研究[J].真空,2003,6:54-56
[42]曹玉平,阎祥安.气压传动与控制[M].天津:天津大学出版社,2010,172-173
[43]江帆,黄鹏.Fluent高级应用与实例分析[M].北京:清华大学出版社,2008,25-35
[44] John Abrahamson, Roger Jones, Andy Lau, etal. Influence of entry duct bends on the performance of return-flow cyclone dust collectors [J]. Powder Technology, 2002, 7: 123
[45]张世伟,温燕修,韩进.真空拾取器拾取动作响应时间与影响因素的分析[J].真空科学与技术学报,2010,30(1):92-94
[46]温燕修.直圆管道内两种流态下气体流动的模拟计算[D]:[硕士学位论文].沈阳:东北大学机械工程与自动化学院,2009
[47] PT Krasuski.Gas flux distributions from cylindrical tubes in molecular flow [J].Vacuum, 1990, v41:2129-2131
[48]熊幸明主编.电气控制与PLC[M].北京:机械工业出版社,2011,113-120
[49] YAN AiQing. The Method Selecting Type of PLC in Controlling System[J]. China Academic Journal Electronic Publishing House, 2011, 3:2612-2614
[50] Lu Hongzheng, Ying Zhiyuan, Liao T Warren. Simulation of programmable logic controller [J].Computers&Industrial Engineering,1992,23(1-4): 351-354
[51] Ram Bala, Lai Steven H-Y. Development of a program generator for programmable logiccontrollers[J].Computers&Industrial Engineering,1991,11(4):227-248
[52] Rehg, James A. Structured PLC Programming with Sequential Function Charts[C].2001 ASEE Annual Conference & Exposition,2001:24-27
[2]朱新星.中国制造业现状及发展对策[J.科技信,2007,(1):164
[3]吴贵生,杨志刚.制造业在我国经济中的地位和作用[J].机械职业教育,2002,(3):3-4
[4]张祥国.简论分拣及分拣系统[J].物流技术,2002,(10):9-10
[5]李娜娜.卷烟配送中心自动分拣系统的规划设计研究[D].[硕士学位论文].长沙:中南大学控制科学与工程系,2008
[6]韩新宅.邮政自动化分拣技术[M].北京:北京邮电大学出版社,1997,1-4
[7]国家机械工业局行业管理司,国家国内贸易局设备成套管理局.中国机电产品大辞典[M].北京:机械工业出版社,1999,470
[8]王波.自适应棉纺异纤分拣装置的研制[D].[硕士学位论文].青岛:青岛科技大学检测技术及其自动化装置专业,2009
[9] Hartmut KIECKHOEFER, Jan BAAN, Arjan MAST, etal. Image processing techniques for ultrasonic inspection [J].17th World Conference on Nondestrrctive Testing, 2008
[10]陈建宏,林绍义.基于激光的特种汽车镀膜玻璃自动化检测[J].重庆工学院学报,2009,23(8):24-28
[11] Diez Aznar,Jose Manuel.New methodology for the programation of PLC in control systems based in Grafcet[J].Universidad Politecnica De Valencia,2000,12:25-27
[12] Farsi M.Application of a PLC as a cell controller using a communication network [J].IEE COLLOQ DIG, 1995, 112:3/1-3/4
[13]姚国年,卫军胡.基于PLC高压水倒空控制系统的设计[J].机床与液压,2010,20(38):72-74
[14] Gang Liu, Robert M.Haralick, Two practical issues in Canny’s edge detector implementation [J].Proceedings of 15th International Conference on Pattern Recognition, 2000, 3: 676-678
[15]刘丽华.基于PLC控制的教学型旋盖气动机械手设计[J].液压与气动,2010,(3):51-53
[16] C.G.Rafael, E.W.Richard. Digital Image Processing [M]. Second Edition.Beijing: Publishing house of electronics industry, 2002.1-6
[17]陶跃珍.基于机器视觉的啤酒瓶瓶口缺陷检测系统的研究[D].[硕士学位论文].武汉:湖北工业大学测试计量技术与仪器专业,2007
[18] Azeddine Beghdadi, Ammar Khellaf.A Noise-filtering Method Using a Local Information Measure[J].IEEE Transactions on Image Processing. 1997, 6(6):879-882
[19]林宁,沙涛.基于数字图像处理的棉花异纤检测研究[J].电气电子教学学报,2010,32(2):41-42
[20] Fangwei Zhao, Christopher J.S.Desilva.Use of The Laplacian of Gaussian Operator in Prostate Ultrasound Image Processing[J]. Proceedings of the 20th Annual International Conference of the IEEE Engineering in Medicine and Biology Society.1998,20(2):812-815
[21] Stephane Mallat,Sifen Zhong. Characterization of Signals from Multiscale Edges[J]. IEEE Transactions on Pattern Analysis and Machine Intelligenc, 1992,14(7):710-732
[22]朱铮涛,姚钦.基于图像处理的液晶保护屏玻璃板在线尺寸检测[J].控制与检测,2010,(3):55-58
[23] Li-Te Fang, Hsin-Chia Chen, Sheng-Jyh Wang, etal. AUTOMATIC MURA DETECTION SYSTEM FOR LIQUID CRYSTAL DISPLAY PANELS[J].18th IPPR Conference on Computer Vision, Graphics and Image Processing, 2005: 826-832
[24] K.Takahashi, T.Kitamura, M.Takatoo, etal. Traffic Flow Measuring System by Image Processing [J].IAPR Workshop on Machine Vision Applications, 1996, 5: 245-248
[25] Chien -Tsai Tsai and Daw -Tung Lin. Automatic License Plate Recognition system [J].18th IPPR Conference on Computer Vision, Graphics and Image Processing, 2005: 610-612
[26] Harry H.Cheng, Benjamin D.Shaw, Joe Palen, etal. A Real-Time Laser-Based Detection System for Messurement of Delineations of Moving Vehicles.IEEE/ASME TRANSACTIONS ON MECHATRONICS, 2001, 6 (2): 170-187
[27]秦峰华.卷烟自动分拣机的性能优化与实现[D].[硕士学位论文].济南.山东大学系统工程,2007
[28]丘胜标.浅析卷烟分拣系统[J].科技创新导报,2009,12:213
[29]李增刚.ADAMS入门详解与实例[M].北京:国防工业出版社,2006,1-10
[30]冯浩.基于ANSYS的某车载骨架结构的有限元分析与优化[D].[硕士学位论文].武汉,华中科技大学机械设计及理论,2007
[31]牛跃文.基于ANSYS的矿用汽车车架有限元模态分析[J].煤矿机械,2007,28(4):98-100
[32]李腾腾,钟绍华.ANSYS的发动机连杆的模态分析[J].汽车工程师,2010,4:25-32
[33]陈凯,李胜利等.超声图像胎儿颅骨椭圆自动检测方法[J].中国图象图形学报,2009,14(12):2478-2482
[34] W Lu, J Tan. Detection of incomplete ellipse in images with strong noise by interative randomized Hough transform[J].Pattern Recognition, 2008, 41:1268-1269
[35]张德丰.详解MATLAB数字图像处理[M].北京:电子工业出版社,2010.134-137
[36] Bennett N, Burridge R, Saito N. A method to detect and characterize ellipses using Hough transform[J]. Transaction on Pattern Analysis Machine Intelligence, 1999,21(7):652-657
[37]张铮,王艳平,薛桂香.数字图像处理与机器视觉[M].北京:人民邮电出版社,2010,350-357
[38] Ho C T, Chen L H.A fast ellipse/circle detector using geometric symmetry [J]. Pattern Recognition,1995,28: 117-124
[39]陈超.MATLAB应用实例精讲[M].北京:电子工业出版社,2011,181-182
[40]张强,王正林.精通MATLAB图像处理[M].北京:电子工业出版社,2009,17-18
[41]郭维强,蒲如平,韩秀杰,等.真空发生器抽吸机理与性能的分析研究[J].真空,2003,6:54-56
[42]曹玉平,阎祥安.气压传动与控制[M].天津:天津大学出版社,2010,172-173
[43]江帆,黄鹏.Fluent高级应用与实例分析[M].北京:清华大学出版社,2008,25-35
[44] John Abrahamson, Roger Jones, Andy Lau, etal. Influence of entry duct bends on the performance of return-flow cyclone dust collectors [J]. Powder Technology, 2002, 7: 123
[45]张世伟,温燕修,韩进.真空拾取器拾取动作响应时间与影响因素的分析[J].真空科学与技术学报,2010,30(1):92-94
[46]温燕修.直圆管道内两种流态下气体流动的模拟计算[D]:[硕士学位论文].沈阳:东北大学机械工程与自动化学院,2009
[47] PT Krasuski.Gas flux distributions from cylindrical tubes in molecular flow [J].Vacuum, 1990, v41:2129-2131
[48]熊幸明主编.电气控制与PLC[M].北京:机械工业出版社,2011,113-120
[49] YAN AiQing. The Method Selecting Type of PLC in Controlling System[J]. China Academic Journal Electronic Publishing House, 2011, 3:2612-2614
[50] Lu Hongzheng, Ying Zhiyuan, Liao T Warren. Simulation of programmable logic controller [J].Computers&Industrial Engineering,1992,23(1-4): 351-354
[51] Ram Bala, Lai Steven H-Y. Development of a program generator for programmable logiccontrollers[J].Computers&Industrial Engineering,1991,11(4):227-248
[52] Rehg, James A. Structured PLC Programming with Sequential Function Charts[C].2001 ASEE Annual Conference & Exposition,2001:24-27