ALSONTECH 3D Vision empowers the Steel Industry by it's superior quality
1.Industry Background
high temperature
dusky
Strength
When you think of steel plants, do you think of these harsh production environments?
In the huge steel industry chain, the steel industry as a key midstream link, upstream carries non-ferrous metals, power and coal and other raw material industries, downstream connection machinery, real estate, home appliances and light industry, automobiles, ships and other industries, is an important pillar of the national economy, is the industrial food of the manufacturing industry.
In the future, large-scale steel enterprises will get rid of the labor-intensive low-value-added business model and achieve transformation and upgrading in the wave of intelligent manufacturing and Industry 4.0. In 2020, the World Economic Forum (WEF) released a new round of a new list of eighteen "lighthouse factories" in the global manufacturing sector. With the intelligent manufacturing achievements of the Shanghai Baosteel Co., Ltd. has become the only Chinese steel company selected, and the black light factory, unmanned production line and network management have subverted the public's traditional understanding of steel companies.
With mature 3D vision technology, ALSONTECH completed the smooth delivery of Baosteel pipe hoop processing station, helping to light the lighthouse. As part of automation, 3D vision plays a role in many aspects of the steel industry, which is presented below.
2. Application scenarios and cases
The ALSONTECH AT-S1000-01A series 3D vision system is selected to help users solve production pain points, reduce manual repetitive handling, and realize unmanned automatic machine tool loading and unloading for tubes/couplings of various specifications and sizes to ensure daily production capacity requirements.
The workpiece is highly reflective, and the 3D system adopts a linear laser solution, which can effectively identify and generate a complete and clear high-quality point cloud;
Some pipe walls are as thin as 2.5mm, and the system algorithm can eliminate the instability of traditional matching methods and improve the recognition accuracy.
There are many workpiece specifications, and the system can realize the rapid introduction of new products (<15min), reduce the requirements for operators;
Deep frame incoming materials, the robot may interfere with the pipe wall and frame wall when grasping, the system can carry out movement route planning to avoid the above risks, and further improve the basket cleaning rate;
Through a scan, the robot can be fed back the accurate grasping coordinates of multiple workpieces on the same layer, improving the overall feeding cycle and increasing the production capacity per unit time.
Steel bars are delivered in bundles, which require sticky labels and hanging tags to display information such as steel grade, furnace number, specification, length, etc. With the acceleration of the pace of production, manual positioning, high welding mark strength, repetitive labor, workers are easy to produce fatigue and boredom, which in turn leads to low work efficiency, marking position errors, while high dust, high noise and other harsh environments will also bring harm to employees, choose ALSONTECH C series grating structured light 3D vision system, It can help users reduce manpower input, avoid management risks, and realize 24-hour automated operations.
The steel bar bundle is not in place, the shape is different, the section of the steel bar is uneven, and the degree of rust is different, and the 3D system can accurately locate the outer end of the steel bar for welding mark, which is convenient for identification and use;
The system can carry out marking inspection to avoid repeated welding marks and wrong standards, and meet the requirements of > accuracy rate of 99.9%;
Grating structured light scheme, fast scanning cycle time, positioning beat <3s, to meet the requirements of the assembly line;
Protection grade IP65, industrial quality, not afraid of high dust, high noise and other harsh environmental influences. "
In large steel enterprises, the driving car will lift the fully loaded ladle to the designated station, and it is necessary to accurately grasp and place the fixed cylinder (cylinder pin) at the bottom of the ladle through the robot, and complete the automatic dumping of the ladle. In the past, users need to use multiple 2D cameras and depth ranging cameras to complete a disassembly process, equipment deployment investment, maintenance investment is more, operation steps are cumbersome, using ALSONTECH AT-S1000-04A 3D vision system, a set of equipment can meet the implementation of all process steps. Help users reduce costs and achieve efficient and intelligent production.
The light on site is very dim, and the 3D system adopts a line laser scanning scheme to obtain a complete and clear high-quality point cloud without the need for supplementary light measures;
Cylinder positioning needs 100% accuracy, no mistakes, the system adopts binocular structure, optimal baseline design, no temperature drift, to ensure stable and reliable positioning accuracy;
Small size, the robot can be easily installed on the final axis, and users do not need to erect additional installation mechanisms at complex production sites;
Complete function, while completing the positioning of the cylinder, the positioning of the seal installation position can be completed, further reducing user investment.
It is necessary to use the mold to form the steel after high temperature red and soft, and at the same time forging on the basis of red can eliminate or weaken the internal cracks, bubbles, slag inclusions, grain unevenness, segregation and other defects, so as to make the performance of steel products better. Even a dark brown workpiece can reach nearly 600°C. Taking the steel drum production site as an example, the user adopts ALSONTECH AT-S1000-01A 3D vision system to achieve automatic and safe production and stable operation.
The 3D system can complete the identification of workpieces in a high-temperature environment, generating clear, and dense point cloud data without defects;
The temperature is too high to make the surface of the workpiece shine and produce a certain reflection, and the line laser scheme can fight the reflection well;
Under reasonable installation and deployment, the system can ensure continuous operation, no temperature drift, stable identification accuracy, and no floating.
Any generation link is inseparable from the handling of raw materials, and the complex on-site production environment of steel companies urgently requires reliable automation solutions. Taking a steel company in Shandong Province as an example, through the deployment of ALSONTECH AT-S1000-01C-H 3D vision system on site, the repetitive, heavy and boring labor of multiple laborers was replaced by robots, and the feeding efficiency of raw materials was increased and the unit production capacity was improved.
The soft bags are stacked loosely, and the vision system adopts AI+3D positioning to achieve accurate grasping;
The site environment is dim and there is smoke and dust, which requires the 3D system to have high adaptability;
The feeding area is close to the high-temperature furnace, and the system can effectively adapt to temperature changes, without temperature drift, to ensure the stability of identification accuracy;
The system adopts a grating structured light scheme with high cycle time to effectively guarantee the feeding rate.
Picking & loading of round bars
ALSONTECH AT-S1000-04A 3D vision system
The bar can also be effectively identified close together, avoiding interference between the fixture and the frame
Round bar labeling
ALSONTECH AT-S1000-01C-H 3D vision system
Multiple specifications can be easily identified, guaranteeing 100% labeling rate
Rail marking
ALSONTECH AT-S1000-04A 3D vision system
Multiple specifications and different degrees of surface rust do not affect the identification, high adaptability
3. Industrial-quality 3D vision system
In view of the particularity of the production site in the steel industry, in addition to the basic accuracy, cycle requirements, qualified.3DThe visual system should have stability and high environmental adaptability, and cope with the multiple influences of temperature, humidity and illuminance, ALSONTECH has always pursued industrial quality to guide and constrain our R&D, design and manufacturing processes.
• The product shell is formed by CNC integrated processing, which is impact and corrosion resistant
• The key electronic components are selected from world-renowned brands, and quality control is required to reach the first-class level
• Protection level IP65, higher protection level products can be customized
• The self-developed SmartVision visual positioning operating system meets the requirements of complex processes
• The system is easy to use, easy to maintain, and can be mastered without excessive knowledge of automation programming
• Pre-sale, sale, after-sales full-process dedicated service, rapid response to on-site needs
