Design And Experiment Of On-line Inspection And Error Compensation System For Door Panel Forming Production Line

With the development of domestic housing construction industry and the improvement of people’s living standards,the security door industry has been booming.The huge security door market promotes the rapid development of production and processing technology of the domestic steel security door,and has higher requirement about the quality of security door.The existing security door production line can’t satisfied the requirement of security door market,and it needs further improvement of the processing technique and automatic transformation to improve the production efficiency and product quality.According to the actual situation of the security door production line,this paper completed the design of the online detection and error compensation system applied to the security door panel forming production line.The system uses visual measurement technology to replace the traditional manual contact measurement,and solves the problems of low efficiency of manual detection and unstable results caused by inconsistent measurement benchmark.The system also designs an error compensation system,which applies the processing error compensation method of production line including single line processing error compensation and double line matching processing.It improves the processing accuracy and product consistency of door panel production line,and reduces the scrap rate of security door panel processing.The specific research contents are shown as follows:1)By analyzing the size of the security door panel and the design requirements of the detection system,the image acquisition scheme of the security door panel is designed,the selection of the vision acquisition module and the illumination module of the system is completed,and the system hardware structure is built.2)The measurement method of large-size plate based on connecting images with the reference bar is proposed.The reference bar used in this method is designed,and the projection deviation of mark points on the reference bar is analyzed and corrected,which ensures the accuracy of dimension measurement.The commonly used image processing algorithms are compared and analyzed,Gaussian filtering is selected to reduce noise,and Edge Drawing algorithm is selected to detects the edge of the door panel.In the edge point set division,the edge point set division method of direct extraction is proposed.And the weighted least square method is used to fit the door panel features.The average time to complete the visual measurement is 593 ms.3)The key positions of the door panel production line are analyzed,and the multi position error transfer model is simplified according to the analysis results.The mapping relationship between the processing error and the servo positioning distance is obtained by using the simplified error transfer model,which provides the basis for the on-line compensation of the processing error.The single line error compensation scheme and the double line matching processing scheme are designed to adjust and control the three working positions of hinge edge cutting,short edge cutting and peekhole punching.4)The design of online detection and error compensation system is completed and an experimental prototype is built.Based on the prototype,the key dimension measurement experiment and error compensation experiment of door panel are carried out.The experimental results show that the measurement accuracy of the system is within 0.5mm,and the error compensation can accurately control the servo positioning system of the key station,which satisfied the design requirements of the system.