In the rapid development of industrial automation today, the
metal processing industry is facing the double challenge of
efficiency and precision. Especially in the field of copper strip
production, the traditional mechanical gripping is limited by
positioning errors, lack of flexibility and other issues, it is
difficult to meet the demand for high-precision, high-tempo
processing. The breakthrough application of 3D vision guidance
technology has successfully improved the automatic gripping
accuracy of copper strip to 0.1mm level, marking the new era
of millimeter-level precision control in intelligent manufacturing.
A technological breakthrough: from “mechanical
blind gripping” to “intelligent perception” of the leap
The traditional copper strip gripping mostly relies on fixed program control
robotic arm, the face of the incoming material position offset, strip
deformation and other working conditions, the actual gripping error is
often more than ± 2mm, resulting in the subsequent stamping, bending
process high scrap rate. 3D vision guidance system through three core
technologies to achieve subversive upgrades:
High-precision point cloud modeling: using laser line scanning and multimetric
vision fusion technology, generating more than 500,000 point cloud data per
second, real-time construction of three-dimensional profile model of the
plate and strip, with a resolution of 0.01mm thickness detection;
Dynamic position solving: based on deep learning algorithm, sub-millimeter
analysis of the edge curvature and surface flatness of the strip is completed
within 0.2 seconds, and the optimal gripping path is automatically generated;
Adaptive compensation mechanism: through the force control sensor and
visual feedback closed loop, dynamically correct the end attitude of the
robotic arm, eliminate vibration, temperature deformation and other
interference, to ensure that the gripping accuracy is stabilized within ± 0.1mm.
This technology makes the production line compatible with the mixed
flow production of copper plates and strips with different thicknesses of
0.1-6mm, shortening the changeover time from 30 minutes to 5 seconds,
and increasing the equipment utilization rate by 40%.
Second, application scenarios: cracking
the four core pain points of metal processing
In the whole process of copper strip processing, 3D vision guidance
technology is reconstructing the production paradigm:
1. Raw material loading
Traditional manual palletizing efficiency is low and easy to scratch the
board surface, 3D vision system can identify the interlayer gap and edge
alignment of the stacked strip, and guide the robotic arm to complete
the gripping with 0.1mm repeatable positioning accuracy, avoiding
double-sheet gripping accidents caused by interlayer adhesion, and
reducing the loss rate of raw materials by 90%.
2. Stamping molding station
For the alignment problem of stamping mold and strip, the system
compares CAD model and physical point cloud data in real time,
dynamically compensates for the deformation error of the sheet
after stretching, so that the deviation of the punching position is
controlled at ±0.08mm and the life of the mold is extended by 3 times.
3. Defect detection process
Integration of hyperspectral imaging technology, simultaneous detection
of oxidation spots, scratches and other micron-level defects in the
gripping process, the detection speed of 3m/s, compared with the
efficiency of manual visual inspection increased by 20 times, the
leakage rate reduced to less than 0.5%.
4. Finished product sorting and warehousing
Through 3D vision + RFID technology, automatic identification of
different batches, specifications of finished products, to achieve
24-hour unmanned sorting into the warehouse, warehouse density
increased by 60%, out of the warehouse accuracy rate of 100%.
Third, the impact of the industry: promote
copper processing into the “zero-defect
manufacturing” era
According to industry estimates, the large-scale application of 3D
vision guidance system can bring multi-dimensional value for
copper strip processing enterprises:
Quality upgrade: the improvement of gripping precision makes
the product size pass rate jump from 92% to 99.8%, and the yield
rate of high-end electronic copper foil exceeds 99.9%;
Cost optimization: after reducing manual intervention, a single
production line saves more than 800,000 yuan in labor costs every
year, and the value of scrap recycling increases by 2 million yuan;
Energy consumption control: precise gripping avoids ineffective
empty stroke, equipment energy consumption is reduced by 25%,
carbon emission is reduced by 15%;
Flexible production: support for small quantities of customized
orders for rapid switching, delivery cycle compressed to 1/3 of
the traditional model.
A large copper processing base of measured data shows that
after the deployment of 3D vision system, its annual output
of 50,000 tons of copper sheet and strip production line
integrated efficiency (OEE) from 68% to 89%, annual efficiency
gains of 32 million yuan.
Fourth, the future trend: 3D vision and
industrial meta-universe depth of integration
With the maturity of 5G and digital twin technology, 3D vision
guidance system is evolving from stand-alone intelligence to
full-link synergy:
Cloud synergy: compression of vision data processing time to within
50ms through edge computing, supporting real-time synchronization
of data from thousands of devices;
Self-learning evolution: building process knowledge graph, the system
can autonomously optimize the grasping strategy based on historical
data, and the iteration cycle is shortened by 70%;
Virtual commissioning: previewing the grasping scheme on the digital
twin platform, which reduces the commissioning cycle of a new
production line from 2 months to 1 week.
Experts predict that by 2028, the global market size of 3D vision in
the field of metal processing will exceed 12 billion U.S. dollars, of
which the proportion of high-precision gripping applications of
copper sheet and strip accounts for more than 35%, and become
the core engine to drive the upgrading of intelligent manufacturing.
Conclusion
The breakthrough of 0.1mm precision is not only a leap in technical
parameters, but also represents the qualitative change of industrial
automation from “function realization” to “ultimate optimization”.
3D vision guidance technology is redefining the standard paradigm
of copper strip production, injecting new intelligent and precise
technologies into the metal processing industry. 3D vision guidance
technology is redefining the standard paradigm of copper strip
production, injecting new kinetic energy of intelligence and
precision into the metal processing industry. Driven by “Industry 4.0”
and “Double Carbon Goal”, this production revolution triggered by
visual perception will continue to release the multiplier effect of cost
reduction and efficiency increase, and boost China's manufacturing
to the high end of the global value chain.