Market Application BackgroundWith the deepening of the intelligent transformation of the manufacturing industry, micro-material handling in fields such as 3C electronics, PCB, food packaging, pharmaceuticals, cosmetics, and automotive parts is undergoing a transformation in production modes. Traditional mechanical vibration feeding and single-picking/labeling methods can no longer meet the current market demands for high precision, high efficiency, and flexible production. The industry is rapidly transitioning from large-scale single-product production to customized small-batch production of multiple varieties.

Multi-Nozzle Visual Loading and Unloading Technology Introduction:

Materials are placed in a flexible vibrating tray to disperse, combined with third-party vision systems to perform preliminary identification and matching of materials in the flexible vibrating tray, generating coordinates for acceptable materials (OK). The machine synchronously runs to the coordinates of the OK materials, where multiple nozzles will adsorb the materials. During the process of placing materials onto the tray, visual capture is used to achieve positional correction, ultimately placing the materials in the tray.Currently, the types of materials that the loading and unloading system needs to handle are becoming increasingly complex, including packaging materials with smart identifiers such as QR codes, barcodes, anti-counterfeiting codes, as well as various precision electronic components and miniature hardware parts.This diversified material handling demand poses higher requirements for visual recognition accuracy, mechanical positioning accuracy, and system flexibility.

▲ Common Loading and Unloading Materials ▲

Common Traditional Visual Loading and Unloading Solutions on the Market:Typically, during the material pickup process, the gripper or suction cup of the robotic arm causes slight positional shifts in the materials being grabbed, and this error can affect the overall placement accuracy. To avoid this issue, industrial cameras are usually employed to capture the position of the materials during the movement of the workpiece, allowing for positional correction.Currently, most loading and unloading solutions without visual capture adopt the “Industrial Computer + Machine Vision + PLC + Touch Screen” scheme, and also only use fixed capture methods during positional correction, meaning that the device stops at the photo point to allow the camera to take a picture before continuing to operate. This scheme increases the waiting time during motion, reducing the efficiency of the loading and unloading process and severely impacting productivity.

▲ V/t Diagram of Equipment When Using Traditional Fixed Capture Scheme ▲

Positive Motion Technology’s Multi-Nozzle Visual Loading and Unloading Solution:

Addressing the pain points of traditional solutions, Positive Motion Technology has launched a multi-nozzle visual loading and unloading solution based on the ultra-high-speed PCIe EtherCAT motion control card PCIE464M.

When the motion mechanism reaches the preset photo area, the motion control card precisely triggers the industrial camera to execute multi-position visual capture operations through high-speed digital IO ports. Combined with third-party vision, it completes parallel image acquisition and feature recognition at multiple nozzle stations in a short time, and provides sub-pixel-level positioning data in real-time feedback to the motion controller.The system can simultaneously complete multi-axis position compensation and angle correction, achieving high-speed continuous capture operations. This solution can improve overall efficiency by more than 12% compared to traditional fixed capture methods.

▲ V/t Diagram of Equipment When Using Positive Motion Solution for Flying Capture ▲

PCIE464M Motion Control Card Solution for Multi-Nozzle Loading and Unloading

Positive Motion Multi-Nozzle Visual Loading and Unloading Solution Design

16DI: Connects to origin, limit sensors, as well as switch signals, encoders, etc.;

16DO: High-speed output ports connect to industrial camera’s hardware trigger input and glue dispensing valves;

EtherCAT Interface: Connects to EtherCAT bus drivers, controlling the motion of other axes; simultaneously expands EtherCAT IO modules, with EtherCAT cycles as fast as 125us;

8 Channel Single-Ended Pulse Output: Connects to pulse drivers;

RS232 Communication Interface: Connects to light source controllers;

EtherNET Interface: Gigabit network port, connects to area array cameras that support the Gige protocol, enabling visual positioning and correction applications.

Motion Control Process Implementation

The PCIE464M motion control card sends commands to the drivers via the EtherCAT bus, driving the motors to execute motion control tasks. The system provides real-time feedback on motor position (MPOS) through encoders or grating rulers, combined with motion control algorithms to achieve precise position control. The camera is triggered to take precise shots at the target position, ensuring image acquisition accuracy and synchronization during high-speed motion, meeting the precise positioning requirements in high-speed flying capture scenarios.Application Action Flow of the Solution01

Tray Visual Positioning

The camera captures the materials in the vibrating tray for rough positioning, combined with third-party vision to calculate the pickup position coordinates and plan the pickup path;

Mechanism Loading and Pickup

Based on the calculated position, the suction nozzles of the motion axis move to the correct position to perform multiple nozzle pickups;

Lower Camera Multi-Position Visual Flying Capture

The picked materials move to the camera’s shooting point area, where the motion control card internally outputs precise position comparisons to trigger the camera for multiple nozzle material visual flying captures;

▲ Multi-Position Flying Capture Parameter Settings ▲

Multi-Position Localization and Correction

Combining third-party vision for visual analysis and processing of the captured material images, performing positional correction and adjustments;

Material Placement

During the movement to the placement position, angle and position compensation corrections are made, then arriving at the correct target position for multiple placements;

Return to Loading Position

After placement is complete, return to the loading position and prepare for the next pickup, cycling through the process.

Multi-Nozzle Loading and Unloading Application Process Flow

Advantages of the Solution Application

Applicable to support Windows XP/7/10/11, Linux and other operating systems, with wide applicability;

Unified open API function interface allows users to develop flexibly and efficiently;

PCIe interface is faster than PCI interface in terms of transmission efficiency, making it more suitable for high-speed and high-precision application scenarios;

PCIE464M onboard 16 in 16 out, no need for adapter boards, easy wiring;

Supports upper computer + RTBasic script language mixed development, greatly improving the real-time execution efficiency of commands;

EtherCAT synchronization cycles can be as fast as 125us, enhancing device productivity;

During the machine vision positioning correction process, flying capture technology is used to shorten the machine’s CT;

12 independent hardware position comparison outputs can achieve simultaneous visual flying captures at multiple points and positions, enhancing overall production efficiency by more than 10%;

Further enhance accuracy, with on-site measurements showing loading and unloading placement accuracy reaching ±0.02mm.

Hardware Configuration of the Solution

Product Type	Product Model	Manufacturer	Quantity
Motion Control Card	PCIE464M	Positive Motion	1
IO Expansion Coupler	ZMIO310-ECAT	Positive Motion	1
IO Expansion Input Module	ZMIO310-16DI	Positive Motion	3
IO Expansion Output Module	ZMIO310-16DO	Positive Motion	2
Camera	130W/500W pixels	–	2
Light Source	Ring/Area Light Source	–	2
PC+ Display + Mouse Keyboard	–	–	1
EtherCAT Bus Servo	1.5KW	–	2
EtherCAT Bus + Pulse Stepper Motor	–	–	8/12/16
XY1Y2Z Structure	–	–	1
Other Accessories	–	–	–

Ultra-High-Speed PCIe EtherCAT Motion Control Card

Targeting high-speed and high-precision intelligent equipment under the “PC + Motion Control Card” model, achieving multi-axis synchronous control and high-speed high-precision motion control!

Supports 6-64 axes of motion control, compatible with EtherCAT bus/pulse/stepper servo drivers;

Up to 16 axes of linked axes, with a minimum control cycle of 125us;

Standard configuration of 16 in 16 out, including 4 high-speed latch inputs, 4 high-speed PWM, and 12 high-speed hardware comparison outputs PSO;

Supports PWM output, 1D/2D/3D PSO hardware position comparison output, visual flying capture, continuous trajectory interpolation, etc.;

Supports power-off storage and power-off interruption, multiple encryption, providing safer program mechanisms;

Features one-dimensional and two-dimensional pitch compensation control for higher processing precision;

8 channels of single-ended pulse axes, 4 channels of single-ended encoder axes;

Supports 30+ robotic arm models’ forward and inverse kinematics algorithms, such as SCARA, Delta, UVW, 4-axis/5-axis RTCP…

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