3D Vision Calibration Target for Plane Parallelism Inspection
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Solution Overview
Problem
Existing 3D calibration techniques for vision systems are costly, time-consuming, and require meticulous maintenance, with no practical method to measure working plane orientation repeatability, and parallelism of robotic end-effector planes often relies on subjective and inaccurate manual setups.
Innovation Solution
A multi-layer 3D calibration target is used to eliminate the need for pre-calibration, allowing vision-based inspection and monitoring of orientation repeatability and parallelism by computing displacement differences between spatial locations and times, using a system that includes cameras, image sensors, and processors to analyze discrete calibration patterns with embedded ID codes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If traditional 3D calibration techniques are used, then calibration accuracy can be achieved, but the process becomes costly, time-consuming, and requires meticulous maintenance
Solution Approach 1:
The patent uses a disposable 2D calibration target instead of expensive, delicate 3D calibration objects. The 2D target can be easily replaced and does not require precise mechanical manufacturing tolerances, eliminating the need for costly and time-consuming 3D calibration while maintaining sufficient accuracy for the application
Solution Approach 2:
The patent extracts the essential calibration function from complex 3D objects and reduces it to a simple 2D pattern. By taking out only the necessary calibration elements (2D geometric patterns) and removing unnecessary 3D complexity, the system achieves calibration without the time and cost overhead of traditional 3D methods
2Measurement precision
If traditional 3D calibration techniques are used, then calibration accuracy can be achieved, but the process becomes costly and requires meticulous maintenance
Solution Approach 1:
The patent replaces expensive, precision-manufactured 3D calibration objects with inexpensive 2D printed or drawn patterns. These 2D targets can be manufactured at minimal cost using standard printing or drawing methods, eliminating the need for costly precision machining while providing sufficient calibration accuracy
Solution Approach 2:
The patent uses 2D copies or representations of calibration patterns instead of physical 3D objects. These 2D copies can be reproduced easily and cheaply through printing or digital display, replacing the need for expensive physical 3D calibration artifacts while maintaining the essential calibration functionality
3Ease of operation
If manual setup methods are used for parallelism, then flexibility is maintained, but accuracy and objectivity are compromised
Solution Approach 1:
The patent replaces manual mechanical alignment methods with automated vision-based measurement. The system uses cameras and image processing to automatically detect and measure parallelism, eliminating subjective human judgment while maintaining operational flexibility. The 2D calibration target works seamlessly with automated vision systems to provide objective, repeatable measurements
Solution Approach 2:
The patent implements automated feedback through vision systems that capture images of the 2D calibration target and compute parallelism measurements. This feedback loop provides real-time, objective data that guides adjustments, replacing subjective manual assessment with quantifiable, repeatable measurements that improve both accuracy and consistency
Data Source
AI summary
This invention provides a system and method for calibration of a 3D vision system using a multi-layer 3D calibration target that removes the requirement of accurate pre-calibration of the target. The system and method acquires images of the multi-layer 3D calibration target at different spatial locations and at different times, and computes the orientation difference of the 3D calibration target between the two acquisitions. The technique can be used to perform vision-based single-plane orientation repeatability inspection and monitoring. By applying this technique to an assembly working plane, vision-based assembly working plane orientation repeatability, inspection and monitoring can occur. Combined with a moving robot end effector, this technique provides vision-based robot end-effector orientation repeatability inspection and monitoring. Vision-guided adjustment of two planes to achieve parallelism can be achieved. The system and method operates to perform precise vision-guided robot setup to achieve parallelism of the robot's end-effector and the assembly working plane.