A visual camera robot

Abstract

The present invention relates to the field of machine vision technology, and discloses a visual photography robot, comprising: a frame; a photography unit, the photography unit comprising a shell with a receiving cavity, a three-dimensional laser scanner, and a 2D camera for obtaining a planar image signal; the three-dimensional laser scanner and the 2D camera are respectively installed in the receiving cavity; a control unit, the control unit is electrically connected to the photography unit; a mechanical arm, the mechanical arm drives the frame to move and / or rotate; wherein, there are multiple photography units, the multiple photography units are respectively fixed on the frame and respectively used to obtain scanning signals and image signals of different areas, and the control unit is used to simultaneously obtain scanning signals and image signals of multiple photography units. The present invention simultaneously scans multiple different areas on the vehicle body and calculates the spatial data of the vehicle body on the hanger, and guides the coating system to operate normally after comparison with the reference template, effectively improving the visual positioning efficiency and coating efficiency.

Description

Technical Field

[0001] This invention relates to the field of machine vision technology, and in particular to a vision-based photographing robot. Background Technology

[0002] With the advancement of technology, robotics has been widely applied in various fields, replacing traditional manual labor, greatly liberating a large amount of labor, and improving product qualification rates and production efficiency. In the automotive manufacturing industry, some car factories use robots to replace manual labor in applying degreasing agents or reinforcing agents to the car body surface, significantly improving production efficiency. However, due to the deviation in the position of the car body on different hangers, the robot needs to locate the spatial position of the car body on the hanger before coating it, and compare it with the spatial position on the reference template to generate an offset. The offset guides the coating robot to complete the precise coating work. For example, the automated glue coating system and method for trucks disclosed in announcement number CN110052349A, and the automatic robotic spraying system for PVC glue on the bottom of automobiles disclosed in announcement number CN201157810Y, use a 3D vision system on the robot to scan the area of ​​the car body to be coated and calculate the actual size of the car body, guiding the robot to complete the precise coating operation. To improve the accuracy of the 3D vision system in scanning the car body, the robot needs to adjust the shooting angle and position of the 3D vision camera multiple times to scan multiple areas of the car body to reduce calculation errors. At the same time, the coating angle of the spray gun needs to be adjusted before coating, resulting in a large number of robot rotations and adjustments, and a long scanning and shooting time, which reduces the visual positioning efficiency and coating efficiency. Summary of the Invention

[0003] The purpose of this invention is to provide a visual imaging robot that can simultaneously scan multiple different areas on a vehicle body and calculate the spatial data of the vehicle body on the hanger. After comparing the data with a reference template, the robot guides the coating system to operate normally. This provides high accuracy and avoids the need for the robot to rotate and adjust the scanning angle multiple times, effectively improving visual positioning efficiency and coating efficiency.

[0004] To achieve the above objectives, the present invention provides a visual imaging robot, comprising:

[0005] Frame;

[0006] The imaging unit includes a housing with a cavity, a 3D laser scanner, and a 2D camera for acquiring planar image signals; the 3D laser scanner and the 2D camera are respectively installed in the cavity.

[0007] A control unit, which is electrically connected to the imaging unit;

[0008] A robotic arm that drives the frame to move and / or rotate;

[0009] The device comprises multiple imaging units, each fixed to the frame and used to acquire scanning signals and image signals from different areas. The control unit is used to acquire scanning signals and image signals from multiple imaging units simultaneously.

[0010] As a preferred embodiment, the photographing unit further includes a light source for providing shooting light to the 2D camera, the light source being fixed to the housing and adjacent to the 2D camera.

[0011] As a preferred embodiment, the housing has a first outer side wall, on which a first slot for scanning by the three-dimensional laser scanner and a second slot for capturing images by the 2D camera are provided, and the first slot and the second slot are respectively connected to the accommodating cavity.

[0012] As a preferred embodiment, the housing also has a third outer side wall that is smoothly connected to the first outer side wall, and the third outer side wall is threaded with a metal connecting piece for fixed connection with the frame.

[0013] As a preferred embodiment, the frame is a square frame structure formed by sequentially splicing several metal profiles, and multiple photographing units are sequentially arranged on the outer peripheral sidewalls of the frame.

[0014] As a preferred embodiment, the robotic arm is a six-degree-of-freedom robotic arm.

[0015] As a preferred embodiment, the multiple imaging units are located on the same plane.

[0016] As a preferred embodiment, the number of the photographing units is 4 to 6, and the multiple photographing units are arranged at relative intervals.

[0017] As a preferred embodiment, the system also includes a base for supporting the robotic arm.

[0018] Compared with existing technologies, the visual imaging robot of this invention has the following advantages:

[0019] The visual imaging robot of this invention is internally equipped with multiple imaging units. Each imaging unit includes a 3D laser scanner for scanning the vehicle body and a 2D camera for obtaining planar image signals. The combination of 3D laser scanning and 2D camera imaging improves the positioning accuracy of the vehicle body. Simultaneously, when the robotic arm swings to the scanning or imaging position, multiple imaging units simultaneously scan 3D data at different locations on the vehicle body and capture images at different locations for comparison with a reference template. The control unit simultaneously acquires the scanned data and captured images from multiple imaging units and performs calculations, avoiding multiple scans or images of the vehicle body by a single imaging unit. This effectively reduces the positioning time of the visual imaging robot, thereby improving coating efficiency. Furthermore, this invention sets up the spraying system independently outside the visual imaging robot. Therefore, the visual imaging robot does not need to control the movement or rotation of the spray gun in the spraying system, allowing the coating operation of the spraying system to be almost synchronous with the positioning operation of the visual imaging robot, thereby improving the overall efficiency of vehicle body positioning and coating. Attached Figure Description

[0020] Figure 1 This is a three-dimensional structural diagram of the visual imaging robot according to an embodiment of the present invention;

[0021] Figure 2 This is a schematic diagram of the structure of the imaging unit according to an embodiment of the present invention;

[0022] In the figure, 10 - frame; 2 - camera unit; 21 - housing; 211 - first outer side wall; 212 - second outer side wall; 213 - third outer side wall; 22 - first slot; 23 - second slot; 24 - data transmission terminal; 25 - power terminal; 27 - light source; 30 - robotic arm; 40 - metal connecting piece; 50 - base. Detailed Implementation

[0023] The specific embodiments of the present invention will be described in further detail below with reference to the accompanying drawings and examples. The following examples are for illustrative purposes only and are not intended to limit the scope of the invention.

[0024] In the description of this invention, it should be understood that the terms "center," "longitudinal," "lateral," "length," "width," "thickness," "upper," "lower," "front," "rear," "left," "right," "vertical," "horizontal," "top," "bottom," "inner," "outer," "clockwise," and "counterclockwise," etc., indicate the orientation or positional relationship based on the orientation or positional relationship shown in the accompanying drawings. They are only for the convenience of describing this invention and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation. Therefore, they should not be construed as limitations on this invention.

[0025] Furthermore, the terms "first" and "second" are used for descriptive purposes only and should not be construed as indicating or implying relative importance or implicitly specifying the number of technical features indicated. Thus, a feature defined as "first" or "second" may explicitly or implicitly include one or more of that feature. In the description of this invention, "a plurality of" means two or more, unless otherwise explicitly specified.

[0026] In this invention, unless otherwise explicitly specified and limited, the terms "installation," "connection," "linking," and "fixing," etc., should be interpreted broadly. For example, they can refer to a fixed connection, a detachable connection, or an integral part; they can refer to a mechanical connection or an electrical connection; they can refer to a direct connection or an indirect connection through an intermediate medium; they can refer to the internal communication of two components or the interaction between two components. Those skilled in the art can understand the specific meaning of the above terms in this invention according to the specific circumstances.

[0027] In this invention, unless otherwise explicitly specified and limited, "above" or "below" the second feature can include direct contact between the first and second features, or contact between the first and second features through another feature between them. Furthermore, "above," "over," and "on top" of the second feature includes the first feature directly above or diagonally above the second feature, or simply indicates that the first feature is at a higher horizontal level than the second feature. "Below," "below," and "under" the second feature includes the first feature directly below or diagonally below the second feature, or simply indicates that the first feature is at a lower horizontal level than the second feature.

[0028] like Figures 1-2 As shown, a preferred embodiment of the present invention provides a visual imaging robot, comprising: a frame 10, an imaging unit 2, a control unit (not shown), and a robotic arm 30. The imaging unit 2 includes a housing 21 with a cavity, a 3D laser scanner (not shown), and a 2D camera (not shown) for acquiring planar image signals; the 3D laser scanner and the 2D camera are respectively installed within the cavity; the control unit is electrically connected to the imaging unit 2; the robotic arm 30 drives the frame 10 to move and / or rotate; there are multiple imaging units 2, each fixed to the frame 10 and used to acquire scanning signals and image signals from different areas; the control unit simultaneously acquires the scanning signals and image signals from multiple imaging units 2.

[0029] Based on the above structure, when the robotic arm 30 controls the frame 10 to swing to the scanning or photographing position, multiple photographing units 2 simultaneously scan the three-dimensional data of different positions on the vehicle body and take images of different positions for comparison with the reference template. The control unit simultaneously acquires the data scanned and the images taken by multiple photographing units 2 and performs calculations, avoiding the use of one photographing unit 2 to scan or photograph the vehicle body multiple times, effectively reducing the positioning time of the visual photographing robot on the vehicle body, thereby improving the coating efficiency.

[0030] Furthermore, the 3D laser scanner of this invention is a major component of existing 3D laser scanning systems. Utilizing the principle of laser ranging, it records the 3D coordinates, reflectivity, and texture information of a large number of dense points on the surface of the object being measured, enabling rapid reconstruction of the 3D model of the target object and various graphic data such as lines, surfaces, and volumes. Typically, a 3D laser scanner includes a laser, receiver, time counter, a motor-controlled rotatable filter, control circuit board, microcomputer, CCD sensor, and software system. The working principle of the 3D laser scanner for scanning a vehicle body to obtain its dimensions is as follows: First, the mounting holes on the vehicle frame and the windshield's adhesive nails are selected as feature holes. The laser emits an inclined laser beam that illuminates the periphery of the feature hole, forming a light spot. The laser beam is scattered or reflected to form a reflected light beam, which is received by the receiver. The CCD sensor in the 3D laser scanner detects the angle of the reflected light beam and calculates the height distance between the imaging unit and the light spot. When the suspended vehicle body shifts, the measured height distance changes, thus achieving laser measurement of the feature hole's displacement, and subsequently calculating the RX / RY / Z data of the laser scanning position.

[0031] Furthermore, the 2D camera of the present invention is used to capture planar images of the feature holes and obtain X / Y / RZ data of the feature holes. Then, the X / Y / RZ data is transmitted to the control unit. The control unit simultaneously acquires the scanning data and image data of multiple imaging units for calculation and finally obtains the data (X / Y / Z / RX / RY / RZ) of the vehicle body frame. The data of the vehicle body frame is compared with the reference template for correction. Then, the corrected frame data is transmitted to the coating robot and the coating robot is guided to complete the coating work.

[0032] Furthermore, the imaging unit of the present invention also includes a light source 27 for providing shooting light to the 2D camera. The light source 27 is fixed on the housing 21 and adjacent to the 2D camera. Since the planar images captured by the 2D camera are easily affected by the ambient light, images captured in complete darkness are relatively dim, affecting the accuracy of subsequent analysis. Therefore, the housing 21 is provided with a light source 27, which provides shooting light when the 2D camera is shooting, ensuring the clarity of the 2D camera image. To avoid the light source 27 affecting the scanning work of the 3D laser scanner on the vehicle body frame, the light source 27 of the present invention is preferably a flash. When the 3D laser scanner is working, the light source 27 does not emit an illumination beam, but when the 2D camera is shooting, the light source 27 provides an illumination beam, ensuring the clarity of the 2D camera image.

[0033] Further, refer to Figure 2 The housing 21 has a first outer side wall 211, on which a first slot 22 for scanning by a 3D laser scanner and a second slot 23 for capturing images by a 2D camera are provided. The first slot 22 and the second slot 23 are respectively connected to the receiving cavity. The area of ​​the first slot 22 depends on the lens area of ​​the 3D laser scanner, and the area of ​​the second slot 23 depends on the lens size of the 2D camera. By placing the lenses of the 3D laser scanner and the 2D camera on the same side of the housing 21, the 3D laser scanner and the 2D camera can collect point data or capture planar images of the same area of ​​the vehicle body, avoiding the trouble of selecting multiple different shooting positions and reducing the workload of calculation to reduce calculation errors. If the lenses of the 3D laser scanner and the 2D camera are not on the same side of the housing 21, when collecting point data or capturing planar images of the same area of ​​the vehicle body, the housing 21 needs to be rotated to adjust the scanning angle or shooting angle, which is more cumbersome and requires the installation of an angle adjustment mechanism on the housing 21, increasing the manufacturing cost.

[0034] Further, refer to Figure 2 The housing 21 also has a second outer wall 212 that is relatively far from the first outer wall 211. The second outer wall 212 is sequentially provided with a data transmission terminal 24 and a power terminal 25 that is electrically connected to the light source 27, the 2D camera, and the laser, respectively. The data transmission terminal 24 transmits the offset calculated by the imaging unit to the coating robot via a data cable, guiding the coating robot to complete the coating operation. The power terminal 25 is used to connect an external power supply, providing stable operating voltages to the light source 27 and the laser, respectively.

[0035] Further, refer to Figure 2The housing 21 also has a third outer side wall 213 that is smoothly connected to the first outer side wall 211. A metal connecting piece 40 for fixed connection with the frame 10 is threaded onto the third outer side wall 213. Preferably, the third outer side wall 213 has several mounting holes communicating with the accommodating cavity. The mounting holes may have internal threads, allowing bolts or screws to pass through the threaded holes and detachably connect the housing 21 to one side of the metal connecting piece 40. The metal connecting piece 40 is also threaded onto the frame 10, facilitating disassembly and replacement. Preferably, the angle between the third outer side wall 213 and the first outer side wall 211 is a right angle.

[0036] Furthermore, the frame 10 is a square frame structure assembled from several metal profiles, with multiple camera units 2 sequentially arranged on the outer perimeter sidewalls of the frame 10. The frame 10 is made of metal profiles, making it lightweight yet strong, and suitable for long-term use.

[0037] Preferably, the robotic arm 30 is a six-degree-of-freedom robotic arm 30. The six-degree-of-freedom robotic arm 30 can control the frame 10 to move along the X-axis, Y-axis, and Z-axis, rotate along the X-axis, Y-axis, and Z-axis, so as to allow the imaging unit 2 to scan or photograph any position on the vehicle body.

[0038] Preferably, for ease of disassembly and to improve aesthetics, multiple camera units 2 are located on the same plane.

[0039] Preferably, the number of photographing units 2 is 3 to 6, and the multiple photographing units 2 are arranged at intervals relative to each other. (Reference) Figure 1 The camera unit 2 is provided in three exemplary configurations. Several camera units 2 are controlled to operate according to different types of vehicle bodies, so that the visual camera robot of the present invention can be applied to various types of vehicle body positioning operations, thereby improving its versatility.

[0040] Furthermore, to enable the robotic arm 30 to move more freely and smoothly, the visual imaging robot of the present invention also includes a base 50 for supporting the robotic arm 30. The base 50 is preferably made of welded metal tubing, and the robotic arm 30 is fixed to the top of the base 50 so that the base 50 does not interfere with the movement trajectory of the robotic arm 30 when it is working.

[0041] In summary, this invention provides a visual imaging robot, which internally includes multiple imaging units 2. Each imaging unit 2 includes a 3D laser scanner for scanning the vehicle body and a 2D camera for obtaining planar image signals. The combination of 3D laser scanning and 2D camera imaging improves the positioning accuracy of the vehicle body. Simultaneously, when the robotic arm 30 controls the frame 10 to swing to the scanning or imaging position, multiple imaging units 2 simultaneously scan 3D data at different locations on the vehicle body and capture images at different locations for comparison with a reference template. The control unit simultaneously acquires the scanned data and captured images from multiple imaging units 2 and performs calculations, avoiding multiple scans or images of the vehicle body by a single imaging unit 2. This effectively reduces the positioning time of the visual imaging robot on the vehicle body, thereby improving coating efficiency. Furthermore, this invention independently sets up the spraying system outside the visual imaging robot. Therefore, the visual imaging robot does not need to control the movement or rotation of the spray gun in the spraying system, allowing the coating operation of the spraying system to be almost synchronous with the positioning operation of the visual imaging robot, thereby improving the overall efficiency of vehicle body positioning and coating.

[0042] In the description of this specification, the references to terms such as "one embodiment," "some embodiments," "illustrative embodiment," "example," "specific example," or "some examples," etc., indicate that a specific feature, structure, material, or characteristic described in connection with that embodiment or example is included in at least one embodiment or example of the invention. In this specification, the illustrative expressions of the above terms do not necessarily refer to the same embodiment or example. Furthermore, the specific features, structures, materials, or characteristics described may be combined in any suitable manner in one or more embodiments or examples.

[0043] Although embodiments of the invention have been shown and described, those skilled in the art will understand that various changes, modifications, substitutions and alterations can be made to these embodiments without departing from the principles and spirit of the invention, the scope of which is defined by the claims and their equivalents.

Claims

1. A visual camera robot, characterized in that: include: Frame; A photographing unit, the photographing unit comprising a housing having a receiving cavity, a three-dimensional laser scanner, and a 2D camera for obtaining a planar image signal; the three-dimensional laser scanner and the 2D camera are respectively installed in the receiving cavity; The three-dimensional laser scanner includes a laser, a receiver, a time counter, a motor-controlled rotatable filter, a control circuit board, a microcomputer, a CCD sensor and a software system; The photographing unit further comprises a light source for providing photographing light to the 2D camera, wherein the light source is fixed on the housing and is adjacent to the 2D camera; A control unit, the control unit is electrically connected to the camera unit; A mechanical arm, wherein the mechanical arm drives the frame to move and / or rotate; There are multiple photographing units, which are respectively fixed on the frame and used to obtain scanning signals and image signals of different areas, and the control unit is used to simultaneously obtain scanning signals and image signals of the multiple photographing units.

2. The visual camera robot according to claim 1, characterized in that: The shell has a first outer wall, on which a first slot for the three-dimensional laser scanner to scan and a second slot for the 2D camera to take images are formed, and the first slot and the second slot are respectively connected to the accommodating cavity.

3. The visual camera robot according to claim 2, characterized in that: The shell further comprises a third outer side wall smoothly connected to the first outer side wall, and a metal connecting sheet for fixedly connecting to the frame is threadedly connected to the third outer side wall.

4. The visual camera robot according to any one of claims 1 to 3, characterized in that: The frame is a square frame structure formed by sequentially splicing a plurality of metal profiles, and a plurality of the camera units are sequentially arranged on the outer peripheral side wall of the frame.

5. The visual camera robot according to any one of claims 1 to 3, characterized in that: The robotic arm is a six-degree-of-freedom robotic arm.

6. The visual camera robot according to claim 1, characterized in that: The plurality of photographing units are located on the same plane.

7. The visual camera robot according to claim 6, characterized in that: The number of the photographing units is 3 to 6, and the plurality of photographing units are arranged at relatively intervals.

8. The visual camera robot according to claim 1, characterized in that: Also included is a seat for supporting the mechanical arm.

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