Technology + Experience High innovation “first” high-performance visual motion controller solution

In the “Air conditioner inside automatic security check” project of Midea Air Conditioning Shunde Factory, the high-performance visual motion controller created by Gao Chuang starts from the actual needs of the air conditioning final assembly process, and realizes the deep integration of the operation control system and visual positioning and tracking at the bottom of the system architecture with the operation control technology and visual algorithm, and finally achieves the double breakthrough of servo frequency and operation accuracy. Thus, it can be widely used in dynamic operation scenarios such as internal security check.

531X305NTBAPG1 The biggest technical innovation highlight of this program is undoubtedly the first time that the Gaochuang transmission team has cleverly integrated the original vision controller and motion controller into a “high-performance visual motion controller”.

In this regard, Xiao Qiang explained: “This is not a simple 1+1=2, but based on a unified software platform, so that its own vision and motion control algorithm modules achieve deep integration, as if the machine is equipped with ‘eyes’ and’ brains’, so that they can work more accurately and more coordinated.”

At the same time, a high precision synchronous motion control technology based on dynamic visual servo is developed for continuous motion scenes. Simply put, the machine can maintain extremely high positioning accuracy and stability in the process of rapid movement, and finally achieve dynamic visual servo positioning accuracy ≤1.0mm, Angle <1.0°, and beat measurement accuracy <0.5% workpiece size.

Similarly, Gaotron’s unique advantages in algorithm research and development also give the solution a higher problem-solving ability. According to Zhou Jingwei, senior account manager of GaoChuang University, the motion following of the 2D camera requires a large 531X305NTBAPG1 number of algorithm applications to achieve, so that the motor can be controlled to follow the detection target while capturing the position of the terminal, and make the corresponding security check action.

“Compared to the 14-15 photos per second processing capacity of commercially available 2D cameras, the innovatively optimized High innovation 2D camera can achieve a high precision processing capacity of 30 photos per second. In the servo parameter tuning, Gaochuang adopts HDM algorithm based on frequency domain analysis of machine model, and realizes HDM algorithm based on PC, which has higher reliability and faster efficiency of self-tuning parameters. During the setting process, the movement distance of the target object is small, and there is no vibration and damage to the machine.”

For the successful application of this innovative program, Xiao Qiang can hardly hide his pride: “The successful application of high-performance visual motion controller in the automatic security check link of Midea air conditioning unit marks the key step of Gaochuang transmission in the field of visual motion controller from scratch and the industry leader!”

From scratch, with the strength of the industry “pioneers”

Based on rich technical reserves and solid project operation experience, Gaochuang Transmission quickly determined the high-performance visual motion controller solution in the “air conditioning automatic inspection” project, and built the air conditioning automatic inspection station from scratch for Midea Air conditioning Shunde factory within 3 months, solving the problem faced by the air conditioning industry for a long time.

531X305NTBAPG1 As the person in charge of the high-innovation aspect of the project, Xiao Qiang has a deep understanding of the difficulties in the process of “from scratch to existence” of the project: “The production line to be inspected is not only a single product, there will be mixed production or interspersing maintenance machines, and because the shell height of the maintenance machine is higher than that of the ordinary air conditioning machine, if the height of the security inspection equipment is not adjusted in time, it will cause damage to the maintenance machine.”

“The flexibility requirements of fast movement and mixed line production test the precision identification and rapid adjustment capabilities of our automated security solution, prompting us to further optimize the inspection process to ensure that each internal machine can safely and accurately complete the inspection.” Zhou Jingwei said.

In the process of project implementation, the team also encountered the problem of increasing internal resistance caused by the material of the tooling ground wire. Due to the need to use high-voltage electricity in the detection, the scheme originally used copper chain as the ground wire for detection. However, it is found that the internal resistance of copper chain in actual use is much higher than the standard range of 0.2 euros, which leads to excessive internal resistance and a large number of false positives.

In order to effectively solve this problem, the Gaochuang team fully 531X305NTBAPG1 understood and analyzed the customer’s production line needs, and finally decided to use the combination of copper wire + copper tube as a new ground wire material. This improvement not only significantly reduces the internal resistance, reduces the occurrence of false positives, but also improves the accuracy and stability of the detection.

Relying on Gao Chuang high-performance vision motion controller solution, Midea Air conditioning successfully built the “air conditioning automatic inspection” station, and officially put into operation in January 2024. Through the visual real-time guidance system, the station ensures that the probe of the security detector is quickly and accurately inserted into the terminal of the internal machine, while overcoming the core difficulties, and supports the automatic security check of different types of air conditioners in the production line. And the final actual operation results also let the United States, Gaochuang team surprises:

The results show that the station can achieve the tracking and positioning error within 1.5mm and the production line security check rhythm of less than 7s at the conveyor belt peak speed of 150mm/s, the success rate of alignment is more than 99.9%, the control response time is only 1ms, the visual operation and control interaction time is less than 100us, and 100% non-missed detection is achieved.

“Compared with the average manual inspection time of 9-10 seconds, the automatic security station can reduce the inspection time by one-third, which not only greatly improves the inspection efficiency, but also effectively reduces the production cost and achieves the goal of reducing costs and increasing efficiency.” Zhong Zhuwei gave full recognition to the automation transformation project of Gaochuang transmission. “The professional and innovative spirit demonstrated by the Gaocon transmission team during the project is impressive, and its automation solution not only has excellent performance, but also fully adjusted and optimized according to the actual needs of Midea air conditioning, which not only ensures product safety and high quality, but also significantly improves the efficiency of the production line.”