无锡博而远智能装备有限公司

ALU-HDTJ 使用手册
版本：V01

ALU-HDTJ User Manual

 目录
1：安全注意事项 Safety Precautions ..................................................................................................3

2：设备基本参数 Equipment basic parameters .............................................................................6

2.1 设备基本信息 Equipment basic information........................................................................6

3：设备安装 Equipment installation ...................................................................................................7

3.1 设备进场定位 Equipment onsite positioning.......................................................................7

3.2 电源、气源连接 Power and air connection .........................................................................7

4 画面介绍 Screen Introduction ..........................................................................................................8

4.1 主界面介绍 Mian Screen Introduction ...................................................................................8

4.2 监控界面介绍 Introduction to Welding Monitoring Interface ......................................8

4.2.1 参数点检界面 Parameter inspection interface .... Error! Bookmark not defined.

4.2.2 稼动率监控界面 Monitoring interface of ground motion rate .............................8

4.2.3 产能监控界面 Capacity Monitoring Interface .............................................................9

4.2.4 状态监控界面 Status Monitoring Interface .......... Error! Bookmark not defined.

4.3 报警界面 Alarming Interface ................................................................................................... 10

4.3.1 实时报警界面 Real-time alarm interface ..................................................................... 10

4.3.2 操作日志界面 Operation log interface ........................................................................ 10

5：调试步骤 Debug steps .................................................................................................................... 12

1 / 25
 5.1 传输归正机构 Transmission alignment mechanism ........................................................ 13

6：视觉部分 Visual part ........................................................................................................................ 13

6.1 视觉介绍 Introduction to Vision ............................................................................................. 13

6.1.1 简介 Introduction.................................................................................................................. 13

6.1.3 成像调试 Imaging debugging......................................................................................... 14

6.1.4 阈值设置 Threshold setting.............................................................................................. 15

6.1.5 拼图设置 Jigsaw Set ............................................................................................................ 16

6.1.6 返修软件 Rework software .............................................................................................. 20

7：正常开机前准备 Preparing for normal startup ...................................................................... 20

7.1 确认设备基本情况 Confirm the basic status of the equipment .................................. 21

7.2 确认参数（配方、视觉）Confirm parameters ................................................................ 22

8：报警处理 Alarm handling .............................................................................................................. 22

8.1 报警汇总 Alarm condition summary .................................................................................... 22

8.2 驱动器报警部分 Drive Alarm Part ......................................................................................... 23

1.1.1 伺服驱动器常见报警 Common alarms of servo drives .......................................... 23

9：设备保养 Equipment maintenance ............................................................................................ 23

9.1 日常保养 Daily maintenance.................................................................................................... 23

9.2 周保养 Weekly maintenance ................................................................................................... 23

9.3 月保养 Monthly maintenance ................................................................................................ 23

2 / 25
10 附录 appendix .................................................................................................................................... 25

1：注意事项

 必须遵守手册内的安全事项，以及贴在机器上的安全标牌

的内容

The safety instructions in the manual and the contents of the

safety tags affixed to the machine must be followed

3 / 25
 不得擅自进行影响机器安全性的任何改造。如有需求，请

于本公司沟通

No modification affecting the safety of the machine shall be

carried out without authorization. If there is a need, please

contact our company

 为说明部分细节，部分图例中无安全护罩的，请确认实际

中是安装完整状态

To illustrate some of the details, some of the legends do not

have a safety shield, please confirm that the actual

installation is complete state

 为提升设备质量及可靠性，会对设备进行部分升级改造，

对此造成的差异本公司不另行通知，以实物为准

In order to improve the quality and reliability of the

equipment, part of the equipment will be upgraded, the

difference caused by the company without further notice,

subject to physical prevail.

 设备适用于经过安全培训且合格的设备、工艺、操作人员，

其他未经许可人员严禁触碰，防止造成设备损坏与人员伤

Equipment for safety training and qualified equipment,

technology, operators, other unauthorized personnel are

strictly prohibited to touch, to prevent damage to

4 / 25
 equipment and casualties

当心卷入：设备运行中禁止触碰；

warning nip hand: No touching during equipment operation；

机器运转中禁止打开此门；

Do not open the door when the machine is running；

5 / 25
2：设备基本参数 Basic equipment parameters

2.1 设备基本信息 Basic equipment information

 外形尺寸：长 2200×宽 2000×高 1900mm

Dimensions: Length 2200 × Width 2000 × Height 1900 mm
 设备重量：2000KG
Equipment weight: 2000KG
 功率：峰值 10KW，平均功率约 5KW
Power: Peak 10KW, average power about 5KW
 电源：AC380V±5%，3P+1N+1PE(3 相 5 线制) 建议配线采用 6 平方主线
Power supply: AC380V ±5%, 3P+1N+1PE (3-phase 5-wire system)
recommends 6 square mainlines for distribution.
 气源：0.5-0.8Mpa 的干燥、干净压缩空气；用量：0.8m³/min
Air source: 0.5-0.8 Mpa dry, clean compressed air; Dosage:
0.8 m³ / min
 控制系统：PLC+触摸屏+CCD 视觉检测
Control system: PLC + touch screen + CCD visual inspection

6 / 25
3：设备安装 Installation of equipment

3.1 设备进场定位 Equipment onsite positioning

 设备进场前，升起地脚
Before the equipment comes into play, raise the ground
 设备进场时注意触摸屏悬臂，防止触摸屏损坏
Watch out for touch screen cantilevers when the device is in play to prevent
touch screen damage
 设备定位完成后，通过前后流水线调整设备水平、高度，调整完成后降
下地脚并锁紧
After the equipment positioning is completed, the level and height of the
equipment are adjusted through the front and rear assembly lines, and the
foot is lowered and locked after the adjustment is completed.

3.2 电源、气源连接 Power and gas connection

 电源进线采用三相五线制 6mm²线缆
Power supply with three-phase five-wire system 10 mm² cable
 需由专业电工操作，防止触电
Need to be operated by a professional electrician to prevent electric
shock
 需确保接线端子紧固，不可虚接
Need to ensure that the terminal is tight, not virtual connection

7 / 25
4 画面介绍 Screen Introduction

4.1 主界面介绍 Mian Screen Introduction

图1
① ：流水线对接信号显示
Pipelined docking signal aspect and indication
② ：设备运行时间统计及百分比时间分布
Equipment running time statistics and percentage time distribution
③ ：机构复位（整机初始化）
Mechanism Reset (Machine Initialization)
④ ：主要操作界面按钮
Main Operating Interface Button

4.2 监 控 界 面 介 绍 Introduction to Welding Monitoring

Interface

4.2.1 稼 动 率 监 控 界 面 Monitoring interface of ground

motion rate

：稼动率监控界面，图 15 所示 Monitoring interface for the rate of

8 / 25
movement, as shown in Figure 15

图 15 Figure 15
注：本页面为白班夜班各运行状态时间统计及占比 Note: this page is the running
status statistics and proportion of day shift night shift.

4.2.2 产能监控界面 Capacity Monitoring Interface

：产能监控界面，图 16 所示 Capacity monitoring interface, shown

in Figure 16

图 16 Figure 16
9 / 25
注：本页面为的白夜班产能统计页面 Note: This page is the white night shift
production capacity statistics page

4.3 报警界面 Alarming Interface

4.3.1 实时报警界面 Real-time alarm interface

：实时报警界面，图 19 所示 Real-time alarm interface, shown in Figure

19

图 19 Figure 19

注：本页面为实时报警界面，显示实时报警信息 Note: This page is a real-time alarm

interface, showing real-time alarm information

4.3.2 操作日志界面 Operation log interface

：操作日志界面，图 21 所示 Operation log interface, shown in Figure

21

10 / 25
 图 21 Figure 21

注：本页面为操作日志界面，显示按钮操作、参数更改等操作记录（参数更改
记录可显示更改前和更改后数据）Note: This page is the operation log interface,
showing the button operation, parameter change and other operation records
(parameter change records can show the data before and after the change)

11 / 25
5：调试步骤 Debug steps

5.1 传输归正机构 Transmission alignment mechanism

图 32
传输归正机构调整：
Transmission Correction Mechanism Adjustment:
1：调整短边归正处的浮球，使玻璃相对于传输水平
1: Adjust the float at the short side alignment so that the glass is relative to the
transmission level
2：将玻璃短边中心做标记，玻璃置于传输中心后，将玻璃短边中心与头尾焊接
托盘上中心线对齐后，升起前后归正气缸，确定四个归正轴位置参数
2：Mark the center of the short side of the glass, put the glass in the transmission
center, align the center of the short side of the glass with the center line of the head
and tail welding tray, raise the front and rear correction cylinder, and determine the
position parameters of the four correction axes.
3：测量玻璃短边至最近的传输型材距离，保持玻璃短边至最近的传输型材距离
一致，设定短边归正位置参数
3：Measure the distance from the short side of glass to the nearest transmission
profile, keep the distance from the short side of glass to the nearest transmission
profile consistent, set the short side correction position parameter

12 / 25
6：视觉部分 Visual part

6.1 视觉介绍 Introduction to Vision

6.1.1 简介 Introduction

博而远EVA点烫机视觉软件系统是运行在Windows下的应用软件，该软件集成
了数据采集和自动控制于一体。
The visual software of EVA spotironing machine is an application software
running on Windows. The software integrates data acquisition and automation.
软件逻辑：组件经过拍照工位拍摄图像，OW_PREWD 获取图像发送给AI 检测
并同时传输条码给PLC，将结果展示到 GUI。组件经过返修工位 OW_REPAIR 从
PLC 获取条码，调取对应图片展示供员工查看。如果NG 则报警。
Software logic: The component takes the image through the camera station, OW
_ PREWD obtains the image and sends it to the AI detection and transmits the barcode
to the PLC at the same time, and displays the result to the GUI. The component gets
the bar code from the PLC after the repair station OW _ REPAIR, and fetches the
corresponding picture display for the staff to view. If NG then alarm.

图36 系统主界面

13 / 25
 软件流程图 Software flow chart

6.1.2 成像调试 Imaging debugging

镜头光圈拧到 4，焦距根据现场情况而定
Lens aperture screwed to 4, focal length depending on scene
DS 软件涉及到的调试：
硬件：触发使能、存档
图像：采集下面精准编辑的高度（修改完应用）、曝光中 us 为单位的参数
专业：LineScan 下面的 IinternalLineRate（行频）
触发使能勾选后可以手动触发拍照，检测成像效果。高度 20000 以下，尽量
降低减少浪费。曝光越低噪点越少，视成像而定，行频大小取决过检测点速度，
同一速度下同一块组件，行频越高，拉伸越长（点烫机拍照运行速度要求 500）
参考参数：高度 1800，曝光 150，行频 4000
The DS software involves debug:
Hardware: trigger enable, archive
Image: Capture the height of the precise editing below (modified application), the

14 / 25
parameters in us in the exposure
Professional: IinternalLineRate (line frequency) below LineScan
The trigger enables you to manually trigger the photo after checking to detect the
imaging effect. Height below 20000, try to reduce waste. The lower the exposure,
the less noise, depending on the imaging, line frequency size depends on the speed of
the detection point, the same speed of the same piece of components, the higher the
line frequency, the longer the stretch (point hot camera running speed requirements
of 500)
Reference parameters: altitude 1800, exposure 150, line frequency 4000

6.1.3 阈值设置

使用方法：打开 C:\YC\admin_main_gui\admin_main.exe
Usage: Open C:\ YC\ admin _ main _ gui\ admin _ main.exe
缺陷说明 Dxplaination of defects
缺陷名称 可调参数
Name of defect Adjustable parameter
虚焊 置信度 最小长度（面积）超过则为 OK 如设定 200，检
出 250 则为 OK
Virtual welding If the minimum length (area) exceeds the minimum reliability, it is
OK if 200 is set, 250 is OK
中间虚焊 置信度 最小长度（面积）超过则为 OK 同虚焊
Middle virtual welding The minimum length (area) of reliability exceeds OK with virtual
welding
焊偏 置信度
Welding bias Confidence
焊短 置信度
Short weld Confidence
中间焊短 置信度
Middle welding short Confidence
焊条长 置信度
Length of electrode Confidence
中间焊条长 置信度
Middle electrode length Confidence
无汇流条 置信度
No bus bar Cidence
无焊带 置信度
Solderless belt Cidence
串间距 最小长度 最大长度 在最小最大范围内为 OK 如设定 最小 1
最 2 检出为 2.5 则为 NG
String spacing Minimum length Maximum length is OK in the minimum maximum
range If the minimum 1 most 2 detection is set to 2.5 then NG

15 / 25
汇流条间距 最小长度 最大长度 在最小最大范围内为 OK 同串间距
Busbar spacing Minimum length Maximum length is OK within the minimum
maximum range
爬电距离 最小长度 最大长度 在最小最大范围内为 OK 同串间距
Creepage distance Minimum length Maximum length is OK within the minimum maximum
range

6.1.4 拼图设置 Jigsaw Set

6.1.5.1 拼图界面 Puzzle Interface

6.1.5.2 切图范围 Cut Graph Range

切图范围为原图的 x 轴，用画图工具打开原图找到两边 x 坐标（左下角可以

看到坐标），
如图中组件的 x 轴范围为 2200 到 16500。
Cut the scope of the original map of the x axis, with the drawing
tool to open the original map to find the x coordinates on both sides
(you can see the coordinates in the lower left corner),
The x-axis range of the components shown is 2200 to 16500.

16 / 25
 6.1.5.3 每个图片的 X 轴移动参数 X-axis motion parameters for

each picture

微调 x 轴向右移动的参数，使三个图片对齐（负数向左，正数向右），下图为
最终效果。
Fine tune the x-axis to move the parameters to the right, so that the
three pictures aligned (negative to the left, positive to the right),
the final effect below.

6.1.5 返修软件 Rework software

{
"version": "jk", 基地名 Name of base
"port": 6000, 端口号 Port number

17 / 25
"prewd_url": "127.0.0.1:8080", prewd 的 ip 端口 Ip port of prewd
"scanner": {
"do_scan": false, 串口扫码枪 Serial scanning gun
"port_list": ["COM1"], 扫码枪 COM 口 Scanner COM port
"baudrate": 115200 波特率 Baud rate
},
"location": {
"axisX": "forward", x 轴坐标 填 reverse 反转
X axis coordinate fill reverse
"axisY": "forward" y 轴坐标 填 reverse 反转 Y-
axis coordinate fill reverse
},
"show_ng_pic": false, 是否只显示 ng 图片 Only display ng
images
"barcode_len": 18, 条码长度 Bar code length
"alarm_time": 2, 报警时间 Alarm time
"alarm_time": "NG 组件", NG 语音报警内容 可自定义
NG voice alarm content can be
customized
"plc": {
"do_plc": false, 是否连接 plc Connect to PLC
"type": "", plc 类型 三菱填 sl modbus 协议填 modbus
Plc type mitsubishi modbus protocol modbus
"ip": "", plc ip
"port": 502, plc 端口 PLC port
"income_address": "", 到位信号地址 In place signal address
"outcome_address": "", 放板信号地址 Release Signal Address
"barcode_address": "" 条码读取地址 Barcode Read Address

18 / 25
7 ： 正 常 开 机 前 准 备 Preparation before
normal operation.

7.1 确认设备基本情况 Confirm equipment basic

condition

 检查机器是否有报警 Check if the machine has an alarm

 检查焊接电源是否打开 Check whether the welding power source is turned
on

7.2 确 认 参 数 （ 配 方 、 视 觉 ） Validation parameters

(formulation, vision)

 确认当前生产组件版型 Confirm current production component version

 确认当前配方参数 Confirm current recipe parameters
 确认当前视觉参数选择 Confirm current visual parameter selection

8：报警处理 Alarm processing

8.1 报警汇总 Alarm summary

 气缸报警：Cylinder alarm：
检查对应气缸的光电，通过触摸屏查看是否随着气缸的动作做出对应的
状态变化
Check the photoelectric of the corresponding cylinder, through the touch
screen to see whether the corresponding change of state is made with the
movement of the cylinder
通过操作触摸屏是气缸进行动作，检查气缸是否跟随操作做出相应的动
作
Through the operation of the touch screen is the cylinder action, check
whether the cylinder to follow the operation to make the corresponding
action
 真空报警：Vacuum alarm：
检查对应的真空部分，汇流带位置是否有偏移 Check the corresponding
vacuum part, whether there is offset in the position of the bus band
19 / 25
 汇流带如未发生偏移，检查气管接头是否插紧 If the bus band is not offset,
check whether the tube connector is inserted tightly.
把气管拔出，堵住开口，查看真空表数值来确认气管有无破裂 Pull out the
trachea, block the opening, and check the vacuum gauge to see if the trachea is
ruptured.
检查真空表设定数值是否正常 Check the vacuum gauge setting value is
normal
 以上报警发生时，需确认触摸屏 IO 显示是否随光电、真空表的变化而变
化，以确认信号正常输入 When the above alarm occurs, you need to confirm
whether the touch screen IO display changes with the photoelectric, vacuum
meter changes, to confirm the signal normal input.

8.2 驱动器报警部分 Drive Alarm Part

1.1.1 伺服驱动器常见报警 Common alarm for servo drive

1：E630：电机堵转 Motor blocking

处理方法：Method of treatment：
① ：检测动力线是否有断线情况 Check if the power line is broken
② ：检查上位机与伺服通讯线路是否受到干扰 Check if the communication
line between the host computer and the servo is disturbed.
③ ：检查机械因素是否有卡死、偶尔卡顿、偏心状况 Check if mechanical
factors are jammed, even Carton, eccentricity
2：E731：编码器电池失效 Encoder battery failure
处理方法：Method of treatment：
① ：H0D-20 设为 1，断电重启生效 H0D-20 set to 1, power off and restart in
effect
2：E740：编码器电池失效 Encoder battery failure
处理方法：Method of treatment：
① ：H0D-20 设为 1，断电重启生效 H0D-20 set to 1, power off and restart in
effect3：EE08：网络状态错误 Network Status Error
处理方法：Method of treatment：
① ：检测网线是否断开 Check whether the network is disconnected
② ：检测 PLC 是否正常运行 Check whether the PLC is working properly

20 / 25
 9：设备保养 Equipment maintenance

9.1 日常保养 Daily maintenance

9.2 周保养 Weekly maintenance

9.3 月保养 Monthly maintenance

D H J-H 保养维护计划表
保养类型 检查内容 计划时间 备注
1：清理切刀出汇流条残留
确保设备停机时清
2：抓取轴吸嘴清理
每日轮班时 理
3：残余汇流带清理
每日
4：确认设备安全光栅是否正常
如有异常，及时通
5：设备运行中有无异响 每日
知当班设备
1：清洁滑轨、丝杆，并加注润滑脂
每周 2：检查真空气路有无破损漏气，真空吸 每周
嘴有无堵塞
1：清洁滑轨、、滑块、丝杆，齿轮齿条
每月 、并加注润滑脂 每月
2：是否有损坏、缺少的部件
1：检查接线端子出螺丝有无松动
需由专业电工进行
2：检查电器件使用情况‘
检测清理
每年 3：清理电柜灰尘 每年
4：是否有损坏、缺少的部件
5：各机构加注润滑脂

DHJ-H Maintenance Schedule

Type of maintenance Check the content Planning time Remarks

21 / 25
 1: Clean up the

remnants of the cutter

Ensure
out of the bus bar
equipment is
2: Grab Shaft Suction
cleaned up
Nozzle Cleaning
During daily shifts when it is down
3: Residual Confluence

Clearance

daily 4: Confirm whether the

equipment safety

grating is normal

If there is any

5: There is no abnormal abnormality,

sound in the operation daily notify the

of the equipment equipment on

duty in time.

1: clean the slide rail,

screw rod, and add

grease
every week every week
2：Check whether the

vacuum gas path is

broken or leaking, and

22 / 25
 the vacuum suction

nozzle is blocked.

1：Clean the slide rail,

slide block, screw, rack

and pinion, and add

each month grease each month

2: Are there any

damaged or missing

parts?

1: check the terminal

out of the screw is not

Inspection and
loose
cleaning by a
2: Check the use of
professional
electrical parts
electrician
3: Clean the dust of the
every year every year
electric cabinet

4: Are there any

damaged or missing

parts

5: Fill the body with

grease

23 / 25
10 附录
附录 I：设计参考标准
1、GB 16754-2008/ISO 13850：2006 机械安全 急停 设计原则（ISO 13850：2006，
IDT）的 4 安全要求
2、GB5005-93 通用用电设备配电设计规范 第二章 电动机
3、GB/T 114048.6-1998 低压开关设备和控制设备 接触器和电动机
4、GB/T 14048.9-1998 低压开关设备和控制设备 辅助电器 第 1 部分：铜导体的
接线端子；第 2 部分：铜导体的保护导体接线端子排
5、GB/T 50054-95 低压电器设计规范 第 4 章：配电线的保护；第 5 章：配电线
路的铺设
6、电器安全工程 首都经济贸易大学出版社 杨有启 钮英建
7、GB/T 16499-1996 电气安全标准的导则
8、IEC 60947 低压开关设备和控制设备
9、IEC60204-1 机械安全机械用电设备一般要求 11 Electronic wquipment.
10、GB/T 1570.1-2007 机械安全 基本概念与设计通则 （ISO 12100-1：2003，IDT）
11、ISO 17398 安全色（2004-08-15）
12、GB 2894-1996 安全标志国家标准

24 / 25