Vision-based Precision Dispensing Control Solution

For planar dispensing applications using Cartesian mechanisms, this is a one-stop PC-based controller solution developed on the CODESYS software platform, including motion controller hardware and dispensing application software. The solution integrates motion control, vision, laser ranging, and other technologies, efficiently and precisely controlling the application of adhesive to the product surface or interior. Common applications include PCB pin encapsulation, red glue dispensing, chip underfill, thermal paste application, lens modules, voice coil modules, mobile phone casings, and screen dispensing.

The core of the entire control solution is the dispensing application software developed on the CODESYS software platform, which has the following main features:

1. Integrates common dispensing process control functions to meet most dispensing application scenarios

• Dispensing paths support vision-assisted teaching and DXF graphic import, supporting path planning methods including points, lines, arcs, circles, rectangles, bows, and spirals;

• Dispensing programs support modular editing such as subprogram blocks and arrays, allowing users to flexibly and conveniently create various dispensing paths quickly;

• In addition, the system supports common process control functions in dispensing applications, such as glue purging, automatic needle change calibration, needle cleaning, visual deviation correction, area height measurement compensation, weight-based processing compensation, and area NG detection.

2. The control system adopts a flexible configuration method to meet various control requirements

• Configurable point dispensing or line dispensing modes, suitable for various dispensing valve controllers for non-contact and contact dispensing;

• Supports access to multiple mainstream cameras and laser height sensors to achieve high-speed and high-precision dispensing;

• Flexibly define loading/unloading process actions according to different material handling procedures, quickly connecting upstream and downstream equipment on the production line.

This solution is a one-stop software+hardware complete dispensing control solution. The control system integrates common dispensing process control functions and allows flexible system configuration to meet various dispensing application requirements.

After the controller is connected to the dispensing equipment, debugging of the corresponding dispensing application can be performed, truly achieving plug-and-play and assisting equipment manufacturers in quickly implementing dispensing projects.

3D Five-Axis Dispensing Control Solution

As 3C products such as curved screen phones, smart earphones, smartwatches, and VR glasses become increasingly popular, the dispensing processes required for their production are becoming more complex. Cartesian dispensing robotic arms can no longer meet these demands, which is why 3D five-axis dispensing equipment is increasingly appearing on production lines.

A 3D five-axis dispensing system controls five axes to achieve spatial trajectory planning, enabling the robotic arm to precisely apply adhesive along the product's spatial trajectory in various postures. Key applications include dispensing on mobile phone frames, side dispensing, irregular/curved screen dispensing, and dispensing for various smart wearable products.

For 3D five-axis dispensing control systems, a dedicated motion controller has been developed based on the CODESYS software platform. Using five-axis linkage control technology, it can achieve precise dispensing for any spatial dispensing trajectory requirement on a product. The main features of the solution are:

1. Firstly, the system provides a flexible and open control platform

• Provides a complete API for five-axis control for user application development;

• PC-Based architecture, allowing flexible integration of vision and laser ranging technologies to achieve position calibration, compensation, and position picking in various postures required for five-axis applications.

2. Secondly, it utilizes five-axis control algorithms

• Adopts RTCP (Rotational Tool Center Point) technology algorithm, enabling follow control for various spatial irregular trajectories;

• The algorithm supports control of various AB-axis rotary table mechanisms, allowing corresponding control with simple parameter configuration based on different mechanical structures;

• Furthermore, the algorithm can control the processing speed of dispensing onto the workpiece to remain constant during trajectory following motion. The trajectory can also be segmented to set different processing speeds to meet the smooth processing requirements of various needs.

3. Additionally, it enables high-precision dispensing control.

By combining pre-dispense/post-dispense control, multi-axis comparison triggers, and spatial trajectory coordinate transformation functions, users can easily achieve high-precision dispensing control for irregularly shaped products at different speeds.

The demand for 3D five-axis dispensing systems will continue to grow, and the processes will become increasingly complex. A motion controller with a five-axis linkage control algorithm has been developed based on the CODESYS Runtime system and SoftMotion functions, aiming to assist equipment manufacturers in developing high-performance five-axis dispensing systems with its flexible, open, and precise five-axis control features.

Edge Control Solution

The edge control solution integrates automated machine vision, laser processing, on-the-fly processing, and informatized remote operation and maintenance, predictive maintenance, and other functions, merging IT and OT to achieve a control solution for flexible laser processing production and operation.

The core of the entire solution is an edge controller developed by Xinmai based on the CODESYS controller software development platform. This controller uses a 6th generation i5 as its CPU, equipped with a Windows system and the CODESYS Runtime real-time kernel. PLC programs, high-speed I/O control, motion control, and CNC processing are run within the CODESYS Runtime kernel, while machine vision positioning, human-machine interface, and informatized M2I analysis and processing software run within the Windows system.

In terms of overall application, the system is used in a laser processing equipment application case. The requirements for this case are:

Customized order dispatching is required based on demand, planning the laser-processed products according to orders.
Precise processing positioning is required, locating processing materials through vision.
Higher processing speed is required, completing processing without stopping the conveyor belt.
Equipment informatization is required to achieve global monitoring, remote operation and maintenance, predictive maintenance, and data analysis functions.

The edge controller accurately controls laser energy through analog control, enabling the following functions:

Supports CNC G-code functionality; after orders are entered into the database, processing paths are generated based on order information.
Supports machine vision for precise positioning, improving processing quality.
Supports on-the-fly processing, achieving processing while moving through encoder positioning and deviation correction, thereby improving processing efficiency.

Features of the complete solution

1. Compact Size, Powerful Performance

• Compact size, supporting up to i7 high-performance processors;

• Supports Windows 7/Windows 10 operating systems;

• Easily achieves machine vision and information processing with high-performance requirements.

2. High Scalability, Real-time Transmission

• Multiple industrial bus communication and I/O module expansion;

• EtherCAT distributed I/O and multi-axis control, with real-time communication as fast as 100μs.

3. High Integration, Efficient Operation

• Utilizes CODESYS multi-core solution;

• Seamlessly integrates IT and OT, supporting both PLC languages and high-level language algorithms;

• Achieves machine vision, motion control, distributed acquisition, laser processing, and data analysis, enabling flexible production and equipment maintenance.

4. Global Monitoring, Intelligent O&M

• Supports various informatization interfaces, data upload to databases and the cloud;