CN115157506A - Lens pouring method capable of accurately detecting and controlling liquid level - Google Patents
Lens pouring method capable of accurately detecting and controlling liquid level Download PDFInfo
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- CN115157506A CN115157506A CN202210731619.4A CN202210731619A CN115157506A CN 115157506 A CN115157506 A CN 115157506A CN 202210731619 A CN202210731619 A CN 202210731619A CN 115157506 A CN115157506 A CN 115157506A
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- 239000007788 liquid Substances 0.000 title claims abstract description 59
- 238000000034 method Methods 0.000 title claims abstract description 26
- 238000002347 injection Methods 0.000 claims description 15
- 239000007924 injection Substances 0.000 claims description 15
- 230000008569 process Effects 0.000 claims description 15
- 238000001514 detection method Methods 0.000 claims description 8
- 239000002390 adhesive tape Substances 0.000 claims description 6
- 238000007789 sealing Methods 0.000 claims description 3
- 238000004891 communication Methods 0.000 abstract description 3
- 238000005266 casting Methods 0.000 description 7
- 238000010586 diagram Methods 0.000 description 3
- 230000004044 response Effects 0.000 description 3
- 230000008901 benefit Effects 0.000 description 2
- 238000004519 manufacturing process Methods 0.000 description 2
- 230000004048 modification Effects 0.000 description 2
- 238000012986 modification Methods 0.000 description 2
- 230000009467 reduction Effects 0.000 description 2
- 239000013589 supplement Substances 0.000 description 2
- 239000012780 transparent material Substances 0.000 description 2
- 230000000007 visual effect Effects 0.000 description 2
- 238000011179 visual inspection Methods 0.000 description 2
- 230000009286 beneficial effect Effects 0.000 description 1
- 230000005540 biological transmission Effects 0.000 description 1
- 230000005574 cross-species transmission Effects 0.000 description 1
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- 239000011347 resin Substances 0.000 description 1
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C39/00—Shaping by casting, i.e. introducing the moulding material into a mould or between confining surfaces without significant moulding pressure; Apparatus therefor
- B29C39/02—Shaping by casting, i.e. introducing the moulding material into a mould or between confining surfaces without significant moulding pressure; Apparatus therefor for making articles of definite length, i.e. discrete articles
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C39/00—Shaping by casting, i.e. introducing the moulding material into a mould or between confining surfaces without significant moulding pressure; Apparatus therefor
- B29C39/22—Component parts, details or accessories; Auxiliary operations
- B29C39/44—Measuring, controlling or regulating
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29L—INDEXING SCHEME ASSOCIATED WITH SUBCLASS B29C, RELATING TO PARTICULAR ARTICLES
- B29L2011/00—Optical elements, e.g. lenses, prisms
- B29L2011/0016—Lenses
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Abstract
The invention relates to a lens pouring method for accurately detecting and controlling liquid level, wherein a control device comprises an FPGA module, a lens mold, a backlight source, a control valve, a pouring head, a cross piece and a camera; wherein the transverse sheet is arranged close to the lens mould, and the contact part of the transverse sheet and the lens mould is positioned at the uppermost part of the lens mould; the backlight source and the camera are respectively arranged on two sides of the lens mold; the pouring head is arranged close to the lens mold, the pouring head is connected with a hose, and the control valve is arranged on the hose; the FPGA module is respectively in communication connection with the control valve and the camera; the transverse sheet is tightly attached to the edge of the lens mold and is in a grid shape; through set up the edge of grid form on the horizontal piece, make liquid level and fence contrast, guarantee that the FPGA module can accurately discern the image that sets up in axial camera collection.
Description
Technical Field
The invention relates to the field of lenses, in particular to a lens pouring method for accurately detecting and controlling liquid level.
Background
The production of resin lenses requires the casting of a mold, wherein the casting process can be accomplished manually by an operator or automatically by the apparatus. In the manual operation process, an operator is required to enable the pouring head to be close to the mold, the opening and closing of the pouring head are manually controlled, the liquid in the mold is controlled to be injected, and the filled mold is required to be full, not overflow and free of bubbles. The manual pouring requires much labor and time, and the operator is required to keep attentive all the time, which is easy to fatigue. Therefore, in most of the production enterprises with higher modernization degree, the device is adopted to automatically complete the pouring. In the automatic pouring process of the device, the camera is used for collecting images, the liquid level height of the mold in the images is identified, and then the opening and closing of the pouring head are controlled, wherein the camera can be arranged in the main shaft direction or the side shaft direction of the mold. However, no matter the main shaft measures the liquid level or the side shaft measures the liquid level, because only one projection line is arranged at the liquid level, even if the main shaft direction light supplement or the side shaft direction light supplement is carried out, the liquid level is still not obvious, the image identification is easy to make mistakes, and the pouring is failed.
On the other hand, the traditional pouring head adopts a direct-opening and direct-closing control valve, the closing time of the control valve is extremely harsh in actual operation, and the response time of the control valve is ideally required to be in the ms level, so that the traditional control valve is difficult to realize accurate full stop.
In view of the foregoing, there is a need for a lens casting apparatus that can be accurately identified and precisely controlled.
Disclosure of Invention
The invention aims to overcome the defects in the prior art, and provides a lens pouring method for accurately detecting and controlling liquid level, which is simple in structure and convenient to use.
A lens pouring liquid level control device based on FPGA visual detection comprises an FPGA module, a lens mold, a backlight source, a control valve, a pouring head, a cross piece and a camera; wherein the transverse sheet is arranged close to the lens mould, and the contact part of the transverse sheet and the lens mould is positioned at the uppermost part of the lens mould; the backlight source and the camera are respectively arranged on two sides of the lens mold; the pouring head is arranged close to the lens mold, the pouring head is connected with a hose, and the control valve is arranged on the hose; the FPGA module is respectively in communication connection with the control valve and the camera; the transverse sheet is tightly attached to the edge of the lens mould and is in a grid shape.
Further, the lens mold is disc-shaped, the central axis direction of the lens mold is taken as the main axis direction, and the radial direction is taken as the side axis direction; the lens mould comprises a left mould, a right mould and a film, wherein the left mould and the right mould are symmetrically arranged, a set distance is arranged between the left mould and the right mould at intervals, the film is arranged between the left mould and the right mould for sealing, and the film is arranged on the side surfaces of the left mould and the right mould; an injection port is reserved when the edge of the film is sealed; the left die and the right die are in a circular sheet shape and both made of transparent materials.
Further, the cross pieces are triangular prisms; the transverse sheet presses the film, and the film is pressed on the left die and the right die; the transverse sheet keeps a set angle with the vertical direction.
Further, the pouring head is arranged at the position of an injection port on the side surface of the left die and the right die; the pouring head is vertically opposite to the injection opening; one end of the pouring head, which is far away from the lens mold, is connected with a hose, and the hose is used for guiding liquid.
Further, the control valve comprises a steering engine, a cam and a fixing piece, wherein the fixing piece comprises a U-shaped groove, and the hose penetrates through the U-shaped groove of the fixing piece; the cam is arranged at the output end of the steering engine and can rotate along with the rotation of the output end of the steering engine; the cam is positioned in the U-shaped groove of the fixing piece.
Further, the backlight source and the camera are both arranged in the direction of a side shaft of the lens mold; the backlight sets up in the one side that is close to the horizontal plate, and the camera sets up in the one side that is close to the pouring head.
A lens pouring liquid level control method based on FPGA visual detection comprises the following steps:
step 1: after the adhesive tape is torn, the FPGA module sends a trigger signal to the camera head, the camera head is started, and images are collected and fed back in real time;
step 2: the FPGA module receives the image, identifies an injection area, and marks a stop area R1 and a deceleration area R2; after marking is finished, the transverse sheet is abutted against an injection port of an adhesive tape of the lens mold, and the FPGA module sends a full-open signal to the control valve;
and step 3: the control valve receives a full opening signal, the steering engine controls the cam to rotate, the cam does not extrude the hose, and the pouring head quickly injects liquid into the lens mold;
and 4, step 4: the camera collects images and transmits the images to the FPGA module;
and 5: the FPGA module receives image data, identifies and detects the image, and judges whether the liquid level reaches a deceleration area; if the liquid level has reached the deceleration zone, go to step 6; otherwise, returning to the step 4 after the time t1 is set at intervals;
step 6: the FPGA module gives a deceleration signal to the control valve; the control valve receives a deceleration signal, and the steering engine controls the cam to rotate by a set angle r1, so that the cam extrudes part of the hose;
and 7: the camera collects images and transmits the images to the FPGA module;
and 8: the FPGA module receives image data, identifies and detects the image, and judges whether the liquid level reaches a stop area; if the liquid level has reached the stop zone, go to step 9; otherwise, returning to the step 7 after the time t2 is set at intervals;
and step 9: the FPGA module gives a stop signal to the control valve; the control valve receives a stop signal, and the steering engine controls the cam to rotate by a set angle r2, so that the cam extrudes all the hoses; the film is cut, and the inlet is sealed with the film, and the process is completed.
Further, the identification process of the FPGA module in step 2 includes the following steps:
step 21: reading image data by the FPGA module, and carrying out binarization processing on the image; marking the coordinates of each pixel point in the image according to the line-field synchronizing signals image _ x and image _ y;
step 22: accumulating black points in pixel points of each line in the image according to the field synchronizing signal, and judging whether the number of the black points in each line is larger than a set value from bottom to top; if the number of black dots in the row is larger than the set value, recording the row as the upper boundary of the lens mold, and entering step 23; otherwise, after traversing the image, returning to step 21, wherein whether the image traversing is finished is judged according to the line synchronization signal;
step 23: scanning a line defined as the upper boundary of the lens mold in the image from left to right one by one, wherein the image _ x of the first pixel point from black to white is marked as the left boundary left of the lens mold, and then the image _ x of the pixel point from white to black is marked as the right boundary right of the lens mold;
step 24: providing a stopping area R1 in the area of the left and right borders, wherein the stopping area R1 is on the upper border of the lens mold; and setting a deceleration area R2, wherein the deceleration area R2 is below the stopping area R1 and keeps a set distance with the stopping area R1, and finishing the step.
Further, the stop region R1 and the deceleration region R2 in step 24 are rectangular regions having set lengths and widths, respectively.
Further, the process of the FPGA module performing image recognition detection in step 5 includes:
step 51: the FPGA module reads an image, performs binarization processing on the image, and marks coordinates of each pixel point in the image according to line-field synchronizing signals image _ x and image _ y;
step 52: judging whether the pixels in the deceleration region R2 are completely black or not, and if the pixels in the deceleration region R2 are completely black, entering step 6; otherwise, returning to the step 4 after the interval setting time t 1.
The invention has the beneficial effects that:
the grid-shaped edges are arranged on the transverse sheets, so that the liquid level is compared with the fence, and the FPGA module can accurately identify the image acquired by the camera arranged in the axial direction;
the control valve comprises the cam, so that the control valve can control the flow rate besides controlling the switch, and more accurate control is realized;
whether the liquid level reaches the deceleration region R2 and the stop region R1 or not is detected and identified through the FPGA module, the automatic control of the opening, the partial closing and the complete closing of the control valve is realized, the content of manual operation is reduced, and the operation precision is improved;
through setting up the regional R2 that slows down, combine the cam in the control valve, realize that the part is closed, make the liquid level reach the regional R2 that slows down after, the velocity of flow that the pouring head pours into liquid reduces, and the liquid level is controlled more easily, avoids liquid to spill over.
Drawings
FIG. 1 is a general structural diagram of a first embodiment of the present invention;
FIG. 2 is a schematic view of a conventional cross piece and lens mold combination;
FIG. 3 is a schematic view of a combination of a cross piece and a lens mold according to a first embodiment of the present invention;
FIG. 4 is a binarized image of a conventional cross-piece and lens mold side axis direction image;
FIG. 5 is a binarized image of a cross-piece and lens mold side axis direction image according to a first embodiment of the present invention;
FIG. 6 is a schematic diagram of a control valve according to a first embodiment of the present invention;
FIG. 7 is an overall flowchart of a first embodiment of the present invention;
FIG. 8 is a flowchart illustrating the total computation of the FPGA module according to a first embodiment of the present invention;
FIG. 9 is a flowchart illustrating the FPGA recognition image in step 2 according to the first embodiment of the present invention;
FIG. 10 is a schematic diagram of a stopping region R1 and a decelerating region R2 according to a first embodiment of the invention;
FIG. 11 is a schematic view of the liquid level over the deceleration region R2 according to the first embodiment of the present invention;
fig. 12 is a schematic flow chart of an FPGA control valve according to a first embodiment of the present invention;
the attached drawings indicate the following: lens mould 1, backlight 2, control valve 3, steering wheel 31, cam 32, mounting 33, casting head 4, horizontal piece 5, camera 6, hose 7, traditional horizontal piece 8.
Detailed Description
The embodiments of the present invention are described below with reference to specific embodiments, and other advantages and effects of the present invention will be easily understood by those skilled in the art from the disclosure of the present specification. The invention is capable of other and different embodiments and of being practiced or of being carried out in various ways, and its several details are capable of modification in various respects, all without departing from the spirit and scope of the present invention. It should be noted that the features in the following embodiments and examples may be combined with each other without conflict.
It should be noted that the drawings provided in the following embodiments are only for illustrating the basic idea of the present invention, and the components related to the present invention are only shown in the drawings rather than drawn according to the number, shape and size of the components in actual implementation, and the type, quantity and proportion of the components in actual implementation may be changed freely, and the layout of the components may be more complicated.
The first embodiment is as follows:
as shown in fig. 1, a lens pouring liquid level control device based on FPGA visual inspection includes an FPGA module, a lens mold 1, a backlight 2, a control valve 3, a pouring head 4, a cross piece 5, and a camera 6. Wherein the transverse sheet 5 is arranged close to the lens mould 1, and the contact part of the transverse sheet 5 and the lens mould 1 is positioned at the uppermost part of the lens mould 1; the backlight source 2 and the camera 6 are respectively arranged at two sides of the lens mold 1; the pouring head 4 is arranged close to the lens mold 1, the pouring head 4 is connected with a hose 7, and the control valve 3 is arranged on the hose 7; the FPGA module is respectively in communication connection with the control valve 3 and the camera 6. The FPGA module is in this case arranged on the camera 6.
The lens mould 1 is disc-shaped, the central axis direction of the lens mould 1 is taken as the main shaft direction, and the radial direction is the side shaft direction, wherein the side shaft direction is vertical to the main shaft direction. The lens mould 1 comprises a left mould, a right mould and a film, wherein the left mould and the right mould are symmetrically arranged, a set distance is arranged between the left mould and the right mould at intervals, the film is arranged between the left mould and the right mould for sealing, and the film is arranged on the side surfaces of the left mould and the right mould. Wherein, an injection port is reserved when the edge of the film is sealed, and the injection port is used for injecting liquid between the left die and the right die. When the left and right molds are vertically arranged, the injection port of the film is positioned uppermost. The left die and the right die are circular sheets, and both are made of transparent materials, so that the liquid level can be observed conveniently.
As shown in fig. 2 to 5, the cross piece 5 is in a triangular prism shape, wherein one edge of the cross piece is provided with a uniform gap to form a grid shape, and the grid-shaped edge of the cross piece 5 is closely attached to the side surface of the lens mold 1. The cross piece 5 presses the film to press the film against the left and right dies, preventing the film from being separated from the sides of the left and right dies by a pulling force. The transverse sheet 5 keeps a set angle with the vertical direction, wherein the set angle ranges from 15 degrees to 75 degrees; in this case at an angle of 45 deg., in order that the cross piece 5 does not obstruct the vertically arranged pouring head 4. In actual operation, since the cross piece 5 is used for the film and the film injection port is located at the top, the contact part of the cross piece 5 and the lens mold 1 has a small distance from the top of the lens mold 1, which means that in the image in the side axis direction, the cross piece 5 and the image of the lens mold 1 are partially overlapped, and if the conventional cross piece 87 is used, the liquid level is blocked; in this embodiment, the edges of the cross pieces 5 are arranged in a grid shape, so that the liquid level in the overlapped area can be clearly displayed, and the accuracy of liquid level detection is ensured.
Pouring head 4 sets up in the sprue position of left mould and right mould side, and wherein pouring head 4 is vertical just to the sprue setting, guarantees that the liquid of pouring into can not spill, and on the other hand reduces the bubble that produces when liquid pours into. The end of the casting head 4 remote from the lens mould 1 is connected with a hose 7, and the hose 7 is used for guiding liquid.
As shown in fig. 6, the control valve 3 includes a steering engine 31, a cam 32, and a fixing member 33, wherein the fixing member 33 includes a U-shaped groove, and the hose 7 passes through the U-shaped groove of the fixing member 33. The cam 32 is arranged at the output end of the steering engine 31, and the cam 32 can rotate along with the rotation of the output end of the steering engine 31; the cam 32 is located in a U-shaped slot in the anchor 33. The plane where the rotation direction of the cam 32 is located is parallel to the flow direction of liquid in the hose 7, so that the cam 32 can play a role in squeezing the hose 7 when rotating, and the cam 32 rotates to control the circulation and the blockage of the liquid in the hose 7 in combination with the U-shaped groove structure of the fixing piece 33. In this embodiment the rudder unit 31 is screwed to the fixing member 33.
The backlight source 2 and the camera 6 are both arranged in the side axial direction of the lens mold 1, in this example, the backlight source 2 is arranged on the side close to the cross piece 5, and the camera 6 is arranged on the side close to the casting head 4; in some other embodiments, the backlight 2 may be disposed on a side close to the casting head 4, and the camera 6 may be disposed on a side close to the cross piece 5. The camera 6 is an image sensor controlled by the FPGA, and can realize rapid acquisition and high-speed transmission of images and reduce response delay.
In the implementation process, as the grid-shaped edges are arranged on the transverse sheet 5, the liquid level is compared with the fence, and the FPGA module can accurately identify the image collected by the camera 6 arranged in the axial direction; by arranging the control valve 3 to include the cam 32, the control valve 3 can control the flow rate in addition to controlling the opening and closing of the pouring head, and more accurate control can be realized.
As shown in fig. 7 and 8, a lens pouring liquid level control method based on FPGA visual inspection includes the following steps:
step 1: after the adhesive tape is torn, the FPGA module sends a trigger signal to the camera 6, and the camera 6 is started to acquire and feed back images in real time;
step 2: the FPGA module receives the image, identifies an injection area, and marks a stop area R1 and a deceleration area R2; after the marking is finished, the transverse sheet 5 is abutted against the injection port of the adhesive tape of the lens mold 1, and the FPGA module sends a full-open signal to the control valve 3;
and step 3: the control valve 3 receives a full-open signal, the steering engine 31 controls the cam 32 to rotate, so that the cam 32 does not extrude the hose 7, and the pouring head 4 quickly injects liquid into the lens mold 1;
and 4, step 4: the camera 6 collects images and transmits the images to the FPGA module;
and 5: the FPGA module receives image data, identifies and detects the image, and judges whether the liquid level reaches a deceleration area; if the liquid level has reached the deceleration zone, entering step 6; otherwise, returning to the step 4 after the time t1 is set at intervals;
and 6: the FPGA module gives a deceleration signal to the control valve 3; the control valve 3 receives a deceleration signal, and the steering engine 31 controls the cam 32 to rotate by a set angle r1, so that the cam 32 extrudes part of the hose 7;
and 7: the camera 6 collects images and transmits the images to the FPGA module;
and 8: the FPGA module receives image data, identifies and detects the image, and judges whether the liquid level reaches a stop area; if the liquid level has reached the stop zone, go to step 9; otherwise, returning to the step 7 after the time t2 is set at intervals;
and step 9: the FPGA module gives a stop signal to the control valve 3; the control valve 3 receives a stop signal, and the steering engine 31 controls the cam 32 to rotate by a set angle r2, so that the cam 32 extrudes all the hoses 7; the film is cut, and the inlet is sealed with the film, ending the process.
As shown in fig. 9-11, in step 2, the FPGA module first determines the left and right boundaries of the lens mold 1 and the mold gap between the left mold and the right mold according to the acquired image, wherein different set times t1 and t2 are set corresponding to different mold gaps, so that the time interval for controlling the camera 6 to acquire the image meets the corresponding injection requirement, and the computation amount of the FPGA module is reduced, thereby improving the response speed; in this example, t1 and t2 are set acquisition rates of the FPGA module, which are 16.7ms per frame, so t1 and t2 are maintained for 16.7ms. The identification process of the FPGA module comprises the following steps:
step 21: reading image data by the FPGA module, and carrying out binarization processing on the image; marking the coordinates of each pixel point in the image according to the line-field synchronizing signals image _ x and image _ y;
step 22: accumulating the black points in the pixel points of each line in the image according to the field synchronizing signal, and judging whether the number of the black points in each line is larger than a set value from bottom to top; if the number of black dots in the row is greater than the set value, recording the row as the upper boundary of the lens mold 1, and entering step 23; otherwise, after traversing the image, returning to step 21, wherein whether the image traversing is finished is judged according to the line synchronization signal;
step 23: scanning a line defined as the upper boundary of the lens mold 1 in the image from left to right one by one, wherein the image _ x of the first pixel point from black to white is marked as the left boundary left of the lens mold 1, and then the image _ x of the pixel point from white to black is marked as the right boundary right of the lens mold 1;
and step 24: setting a stopping area R1 in the area of the left and right borders, wherein the stopping area R1 is on the upper border of the lens mold 1; and setting a deceleration area R2, wherein the deceleration area R2 is below the stopping area R1 and keeps a set distance with the stopping area R1, and finishing the step.
The stop region R1 and the deceleration region R2 in step 24 are rectangular regions having set lengths and widths, respectively.
As shown in fig. 12, after the FPGA module receives the image data in step 5 and step 8, the FPGA module also sends the image data to the memory for caching. The process of the FPGA module for image recognition and detection in the step 5 comprises the following steps:
step 51: the FPGA module reads an image, performs binarization processing on the image, and marks coordinates of each pixel point in the image according to line-field synchronizing signals image _ x and image _ y;
step 52: judging whether the pixels in the deceleration region R2 are completely black or not, and entering the step 6 if the pixels in the deceleration region R2 are completely black; otherwise, returning to the step 4 after the time t1 is set.
The process of the image recognition and detection by the FPGA module in the step 8 comprises:
step 81: the FPGA module reads an image, performs binarization processing on the image, and marks the coordinates of each pixel point in the image according to line-field synchronization signals image _ x and image _ y;
step 82: judging whether the pixels in the stop region R1 are completely black or not, and if the pixels in the stop region R1 are completely black, entering the step 9; otherwise, returning to the step 7 after the interval setting time t 2.
It should be noted that, in this example, the FPGA module indirectly controls the control valve 3 by sending a control signal, and in some other embodiments, the FPGA module may directly control the control valve 3.
In the implementation process, whether the liquid level reaches a deceleration region R2 and a stop region R1 or not is detected and identified through the FPGA module, and the automatic control of the opening, the partial closing and the complete closing of the control valve 3 is realized; on the other hand, the speed reduction region R2 is arranged, and the cam 32 in the control valve 3 is combined to realize partial closing, so that after the liquid level reaches the speed reduction region R2, the flow speed of the liquid injected into the pouring head 4 is reduced, the liquid level is controlled more easily, and the liquid overflow is avoided.
The above description is only one specific example of the present invention and should not be construed as limiting the invention in any way. It will be apparent to persons skilled in the relevant art(s) that, having the benefit of this disclosure and its principles, various modifications and changes in form and detail can be made without departing from the principles and structures of the invention, which are, however, encompassed by the appended claims.
Claims (4)
1. A lens pouring method capable of accurately detecting and controlling liquid level is characterized by comprising the following steps:
step 1: after the adhesive tape is torn, the FPGA module sends a trigger signal to the camera head, the camera head is started, and images are collected and fed back in real time;
and 2, step: the FPGA module receives the image, identifies an injection area, and marks a stop area R1 and a deceleration area R2; after marking is finished, the transverse sheet is abutted against an injection port of an adhesive tape of the lens mold, and the FPGA module sends a full-open signal to the control valve;
and step 3: the control valve receives a full-open signal, the steering engine controls the cam to rotate, the cam does not extrude the hose, and the pouring head quickly injects liquid into the lens mold;
and 4, step 4: the camera collects images and transmits the images to the FPGA module;
and 5: the FPGA module receives image data, identifies and detects the image, and judges whether the liquid level reaches a deceleration area; if the liquid level has reached the deceleration zone, go to step 6; otherwise, returning to the step 4 after the time t1 is set at intervals;
step 6: the FPGA module gives a deceleration signal to the control valve; the control valve receives a deceleration signal, and the steering engine controls the cam to rotate by a set angle r1, so that the cam extrudes part of the hose;
and 7: the camera collects images and transmits the images to the FPGA module;
and 8: the FPGA module receives image data, identifies and detects the image, and judges whether the liquid level reaches a stop area; if the liquid level has reached the stop zone, go to step 9; otherwise, returning to the step 7 after the time t2 is set at intervals;
and step 9: the FPGA module gives a stop signal to the control valve; the control valve receives a stop signal, and the steering engine controls the cam to rotate by a set angle r2, so that the cam extrudes all the hoses; cutting the film, sealing the injection opening with the film, and ending the process;
the process of the image recognition and detection by the FPGA module in step 8 includes:
step 81: the FPGA module reads an image, performs binarization processing on the image, and marks coordinates of each pixel point in the image according to line-field synchronizing signals image _ x and image _ y;
step 82: judging whether the pixels in the stop region R1 are completely black or not, and if the pixels in the stop region R1 are completely black, entering the step 9; otherwise, returning to the step 7 after the interval setting time t 2.
2. The lens pouring method for accurately detecting and controlling the liquid level according to claim 1, wherein the identification process of the FPGA module in the step 2 comprises the following steps:
step 21: reading image data by the FPGA module, and carrying out binarization processing on the image; marking the coordinates of each pixel point in the image according to the line-field synchronizing signals image _ x and image _ y;
step 22: accumulating the black points in the pixel points of each line in the image according to the field synchronizing signal, and judging whether the number of the black points in each line is larger than a set value from bottom to top; if the number of black dots in the row is larger than the set value, recording the row as the upper boundary of the lens mold, and entering step 23; otherwise, after traversing the image, returning to step 21, wherein whether the image traversing is finished is judged according to the line synchronization signal;
step 23: scanning a line defined as the upper boundary of the lens mold in the image from left to right one by one, wherein the image _ x of the first pixel point from black to white is marked as the left boundary left of the lens mold, and then the image _ x of the pixel point from white to black is marked as the right boundary right of the lens mold;
step 24: providing a stopping area R1 in the area of the left and right borders, wherein the stopping area R1 is on the upper border of the lens mold; and setting a deceleration area R2, wherein the deceleration area R2 is below the stopping area R1 and keeps a set distance with the stopping area R1, and finishing the step.
3. The lens pouring method for accurately detecting and controlling the liquid level according to claim 2, wherein the stop region R1 and the deceleration region R2 in step 24 are rectangular regions with a set length and width respectively.
4. The lens pouring method for accurately detecting and controlling the liquid level according to claim 1, wherein the image recognition and detection process of the FPGA module in the step 5 comprises the following steps:
step 51: the FPGA module reads an image, performs binarization processing on the image, and marks coordinates of each pixel point in the image according to line-field synchronizing signals image _ x and image _ y;
step 52: judging whether the pixels in the deceleration region R2 are completely black or not, and entering the step 6 if the pixels in the deceleration region R2 are completely black; otherwise, returning to the step 4 after the time t1 is set.
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| CN113021801B (en) | 2022-08-05 |
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| CN115256743A (en) | 2022-11-01 |
| CN115256743B (en) | 2023-12-08 |
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