| Automotive electronics technology is one of the core technologies in the modern automotive industry.The number of sensors in the vehicle can reflect the electronic level of the car from the side.As one of the most important components of automobile electronic control system,automobile speed sensor is responsible for the collection and detection of the information of the driving status of the vehicle.Hall speed sensor is widely used for its high sensitivity,high response frequency and strong anti-interference ability.In recent years,with the rapid development of computer technology,sensor technology and image processing technology,machine vision technology and photoelectric technology have made great progress,advanced measurement technology is gradually adopted in industrial manufacture.As a brand-new and efficient non-contact detection technology,machine vision detection technology has the characteristics of high resolution accuracy,high efficiency,no contact with the detected object,safety and reliability,which is helpful to improve the level of production automation and flexibility.Therefore,using machine vision technology to improve the efficiency and quality of sensor manufacture will become an inevitable way.This paper in-depth analyze and study the application of mechanical structure design,machine vision technology and PLC control technology in automatic production equipment of speed sensor.The contents mainly include:1.The overall design of the sensor wire harness color and solder joint quality inspection platform.The design of mechanical structure functional and inspection process.The analysis and selection of the visual system hardware(industrial camera,camera,light,etc.),the electrical control components(PLC,servo,valve island,I/O interface card system),the Visual Studio2015,Open eVison and STEP 7 Basic.2.Theoretical calculation and selection of actuators in mechanical structure(sliding cylinder,swinging cylinder,servo motor).The freedom analysis,force analysis and locking force calculation of the wedge-shaped locking mechanism.Solidworks 3D modeling software was used to model and assemble the light source rotation mechanism,feeding mechanism,lens moving mechanism,servo motion mechanism and locking mechanism.3.Analyzing and studying the image preprocessing technologies applied in the vision detection system,including digital image types,color space,color space conversion,image denoising,image enhancement,image segmentation,image morphological algorithm,image feature extraction and other technologies.Matlab is used to simulate the collected images,comparative analysis of processing effect of each algorithm.The median filtering algorithm,gray scale transformation algorithm,otsu segmentation algorithm,open operation and closed operation algorithm,color feature,shape feature,geometric feature were used for image preprocessing.4.Using Visual Studio2015 C and Open eVison dynamic link library to design visual detection system program,including camera connection,image acquisition,image processing,image detection program and visual system interface;using STEP 7 Basic to design HMI.5.Designing the testing procedure and experimental scheme and conduct on-site testing and debugging experiments.After analyzing and evaluating the detection data,it is concluded that the misdiagnosis rate of color detection is 0 and the misdiagnosis rate of solder joint quality detection is 4.67%,which all meet the expected detection accuracy requirements of the detection platform and meet the requirements of the actual detection manufacture.The studied visual inspection platform in this paper combines the current advanced machine vision technology with mechanical structure design and electrical control technology to realize the automation of the manufacture of speed sensor,improve the detection accuracy and production efficiency of wire harness and solder joint,and ensure the quality of the sensor produced. |
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