ALSONTECH 3D vision applications in multiple engine manufacturing process

With the continuous promotion of the national dual carbon strategy, the goals of carbon peak before 2030 and carbon neutrality before 2060 are getting closer and closer. As a major fuel user, electrification of passenger cars has become an inevitable trend, "new energy","power battery" commercial vehicles, construction machinery, agricultural machinery equipment, aviation equipment, ships, large generatorsets and other equipment still need traditional engines to provide power for a longtime, and the engine manufacturing industry is optimizing the development of high-end, high-tech content such as further reducing fuel consumption, improving energy efficiency, and reducing carbon emissions.

Whether it is to meet the impact of electrification or improve their own quality, automation transformation is apreferred choice for engine manufacturers, only by continuously improving processing quality, reducing costs and increasing efficiency through intelligent manufacturing, and improving the degree of flexibility of production lines can we cope with risks such as changing and changing production brought about by market changes. The realization of flexible production lines, 3D vision will play an important role in it, has been andwill be applied in more machine substitution production scenarios.

3D vision applications in engine flexible manufacturing

3D vision guides CNC loading of engine blocks

Engine block has diverse structure, complex shape, inorder to ensure the quality of production, the machine tool is generally used for precision machining. Using 3D vision system to guide the robot to realize the d epalletizing of blanks or semi-finished product, so that the loading station to achieve flexibility.

• The above case adopts ALSONTECH AT-S1000-04A series 3Dvision camera, the line laser solution has good workpiece and environmental adaptability, and the small size is suitable for arm-mountedinstallation;

• Users only need to put in simple pallet loading stacking,no need to frequently customize and switch positioning fixtures or limit devices;

• According to the order demand, flexibly switch different types, different sizes, different surface characteristics of incoming materials;

• It is also well identified for black cylinders.

3D vision-guided unloading of engine block processing line

The processed cylinderhead is transported to the rear station by the conveyor belt, and the precise position of the workpiece can be obtained and the palletcan be accurately positioned through the 3D vision system, making the deployment of the unloading station more flexible.

• The above case adopts ALSONTECHAT-S1000-04A series 3Dvision camera, and theline laser solution has good workpiece and environmental adaptability, and the workstation is not affected when deployed by the window and under the lightstrip;

• The shape and color ofvarious pallets within the field of vision do not affect the recognition accuracy, and through 3D vision precise positioning, the utilization rate of the pallet is maximized, and there is noneed to make fixture limits for the pallet placement;

• The binocular structure can better ensure the accuracy and stability, guide the robot to grasp the workpiece and accurately place itin the pallet, and avoid damage such as bumps when the finished part is placed.

3D vision-guided engine bolt locking

The process execution of fasteners is very important for the quality of product assembly, especially for large multi-cylinder engines, manual tightening of bolts is heavy, personal experience, long hours of repetitive work distraction, etc. will become uncontrollable risks. The use of 3D vision system can realize the effective guidance of robot locking and improve the flexibility of the assembly locking station.

• The above case adopts AT-S1000-06C-S 3D vision camera, which has the characteristics of high precision and delicate point cloud, and meetsthe demanding requirements of low tolerance of the assembly process;

• The product adopts binocular structure, and the precisionoutput has high stability, ensuring that the site is not leakage and not tight;

• The 3D vision guided robot carries professional tightening guns and other mechanisms for locking to avoid manual interference factors, which can effectively improve the implementation efficiency and assembly yield of locking.

3D vision-guided bin picking of engine crankshafts

The shape of the crankshaft is spiral, which is more complex, difficult to customize the fixture, and the state of the workpieces stacked on top of each other in the materialbox also poses a challenge to identification. The use of 3D vision system can quickly realize the loading of different specifications of crankshafts, improve the utilization rate of the station, and realize the flexible production of the production line.

• The above case adopts AT-S1000-04Aseries 3D vision camera, which isinstalled by arm load according to the user's on-site deployment, effectively expanding the field of view through the arm span, and realizing rapid sorting and loading of workpieces;

• The same station canhandle a variety of incoming materials according to the order production arrangement, and the 3Dvision system can quickly switch according to different incoming material models, and can also quickly import new materials within two hours;

• The 3D vision system has a built-in complete obstacle avoidance grasping strategy, which effectively avoids the possible risk of bin wall collision when the fixture enters the bin.

3D vision-guided bin picking ofengine connecting rods

Connecting rod is an important spare parts of the engine, the production of incoming materials is mostly disorderly and scattered in the material box, the workpiece is relatively heavy, there are many models, the labor intensity of manual sorting and loading is very large, and the use of 3D vision system can effectively liberate labor and improve labor efficiency.

• The above case adopts ALSONTECHAT-S1000-01C-H3Dvision camera, which can effectively obtain delicatepoint cloud data, and the imaging and processing speed is fast, and the average capture time of a single piece is 3s;

• ALSONTECH provides users with a professional offline simulation programming operating environment – LightBinPick. Users can import 3D cameras, robot brands/models, workpiece digital models, material bins and other elements through the software, and build real grabbing scenarios by setting environmental parameters to simulate in the early stage of the project, users can quickly evaluate the feasibility of the project without a lot of manpower and material resources;

• In the implementation of disorderly sorting, the system realizes safe production through the implementation of various processing methods and grabbing strategies such as point cloud processing, deep learning, motion planning, and multi-grabbing position setting, and meets the high requirements of the workpiece clearance rate on site.

3D vision-guided CNC loading of engine cylinder sleeves

Cylinder liner is an important component of engine cylinder, processing links involve CNC machining, in the face of different specifications, colors, sizes of cylinder sleeves, the introduction of 3Dvision system can effectively guide the robot to achieve automatic loading, improve the flexibility of the processing station, increase the flexibility of production changeover.

• The above case adopts ALSONTECH AT-S1000-01A series 3D vision camera,which has a large field of view and large depth of field. It can meet the coverage of the user's large-size material bin, and the accuracy still meets the user's requirements for accurate grasping;

• The product adopts aline laser solution, which has good environmental adaptability, and the lightin the open environment has no effect on positioning recognition, and the user does not need to increase facilities such as shading darkroom;

• Cylinder sleeves are cylindrical workpieces of different specifications, the site adopts horizontal stacking or long itudinal placement in a variety of ways, 3D vision system can adopt different grasping strategies according to different placement methods to ensure that the horizontal workpiece stacking does not collapse, long itudinal workpiece grasping when the robotic arm and fixture do not collide with the bin wall, to achieve safe and efficient production.

• The 3D vision camera works in parallel with the robot,taking up no cycle time except for the first scan, and the loading efficiencyis greatly improved.

  ALSONTECH will continue to help the automation and flexible upgrading of manufacturing and processing industry production lines, provide industrial 3D vision products and solutions for the majority of automation users in process applications such as loading and unloading,