3D Sensor Registration for Industrial Workcell Safety Monitoring
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Solution Overview
Problem
Existing 3D sensor systems for industrial machinery face challenges in efficiently processing raw data for effective control outputs, requiring advanced data processing and configuration, which can be complex and time-consuming, and often result in safety hazards if not properly executed.
Innovation Solution
The implementation of a system that registers 3D sensors with respect to each other and with machinery in the workspace, using techniques such as global-optimization algorithms, computer-vision methods, and registration objects with distinctive 3D signatures, to establish a common reference frame for data processing and ensure accurate sensor alignment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If 3D sensors are used for monitoring workspace safety, then measurement precision and reliability are improved, but device complexity and data processing requirements increase
Solution Approach 1:
The system performs preliminary registration of 3D sensors to machinery and workspace before safety monitoring begins. Registration objects with distinctive 3D signatures are positioned in advance, and the control system pre-establishes coordinate transformations and reference frames, so that when monitoring starts, the sensors are already calibrated and aligned, reducing real-time processing complexity
Solution Approach 2:
Registration objects serve as intermediaries between the 3D sensors and the machinery/workspace. These objects with distinctive 3D signatures act as reference mediators that facilitate accurate sensor registration without requiring direct complex processing between sensors and machinery, simplifying the overall system complexity
2Manufacturing precision
If manual sensor configuration and registration is performed, then manufacturing precision can be achieved, but loss of time and productivity decrease
Solution Approach 1:
The control system automatically performs sensor registration and configuration tasks that would otherwise require manual intervention. The system uses the registration objects and automated algorithms to self-calibrate sensor positions and orientations, eliminating the need for manual configuration while maintaining high precision
Solution Approach 2:
The system changes the parameter of sensor registration from manual adjustment to automated computational determination. By using distinctive 3D signatures and global optimization algorithms, the registration parameters are automatically calculated and adjusted, dramatically reducing configuration time while maintaining precision
3Speed
If 3D sensor data is processed without proper registration, then processing speed increases, but measurement precision and safety reliability deteriorate
Solution Approach 1:
The system performs sensor registration and establishes coordinate transformations before safety monitoring begins. This preliminary setup ensures that when data processing occurs, the sensors are already properly aligned and referenced, allowing fast processing without sacrificing reliability
Solution Approach 2:
The control system continuously monitors the workspace and compares sensor data against the registered reference frames and safety zones. This feedback mechanism ensures that even with high-speed processing, the system maintains accuracy by constantly validating measurements against the pre-established registration data
Data Source
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AI summary
Various approaches to ensuring safe operation of industrial machinery in a workcell include disposing multiple image sensors proximate to the workcell and acquiring, with at least some of the image sensors, the first set of images of the workcell; registering the sensors to each other based at least in part on the first set of images and, based at least in part on the registration, converting the first set of images to a common reference frame of the sensors; determining a transformation matrix for transforming the common reference frame of the sensors to a global frame of the workcell; registering the sensors to the industrial machinery; acquiring the second set of images during operation of the industrial machinery; and monitoring the industrial machinery during operation thereof based at least in part on the acquired second plurality of images, transformation, and registration of the sensors to the industrial machinery.