3D Virtual Encoder Control for Long Conveyor Position Tracking
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Solution Overview
Problem
Current mechanical encoder methods in industrial automation systems face inaccuracies, unwieldiness, decoupling issues, and lack of scalability, particularly when tracking the position of objects on long conveyor systems, due to backlash, lengthy electrical connections, and limitations in measuring relative motion.
Innovation Solution
A non-contact 'virtual' encoder system utilizing 3D sensing technology to generate continuous position and velocity measurements, mimicking quadrature signals from mechanical encoders, allowing for accurate tracking of objects along assembly lines without physical contact, enabling precise control of industrial automation machines.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If a rotary position encoder is attached to a drive shaft to measure linear position and velocity, then position tracking is achieved, but inaccuracies of several hundred millimeters occur due to backlash in drive motors, couplings, and conveyor chain assemblies
Solution Approach 1:
The patent replaces the mechanical encoder system with an optical measurement system. A camera captures images of coded patterns attached to objects on the conveyor, and image processing algorithms calculate position and velocity without mechanical contact. This substitution eliminates backlash issues inherent in mechanical encoders while maintaining measurement precision.
Solution Approach 2:
The patent introduces coded patterns as intermediaries between the object and the measurement system. These patterns serve as visual markers that the camera can track to determine position and velocity, replacing the direct mechanical coupling between encoder and conveyor while improving measurement reliability.
2Length of moving object
If a conveyor segment hundreds of meters long is used, then long-distance transport is achieved, but unwieldy electrical connections hundreds of meters long are required between the drive shaft's encoder and the robot
Solution Approach 1:
The patent replaces the electrical connection system with an optical measurement system. Instead of transmitting position data through lengthy electrical cables from a mechanical encoder, the system uses a camera to capture images and process them locally to determine object position, eliminating the need for complex electrical infrastructure over long distances.
Solution Approach 2:
The patent creates visual copies (images) of the coded patterns on objects and processes these copies to extract position information. This copying approach allows position measurement without physical or electrical connection to the moving objects, simplifying the system for long conveyor applications.
3Measurement precision
If a rotary encoder is fixed to a drive shaft, then position measurement is achieved, but relative motion between the conveyor and objects cannot be measured due to decoupling
Solution Approach 1:
The patent replaces the drive-shaft-fixed mechanical encoder with an optical system that independently tracks each object. The camera captures images of coded patterns on individual objects, allowing measurement of each object's position and motion relative to the conveyor, thereby capturing relative motion that mechanical encoders miss.
Solution Approach 2:
The patent creates visual copies of coded patterns on each object and processes these independently. This allows the system to measure position and motion of each object separately, capturing relative motion between objects and conveyor that would be invisible to a mechanical encoder fixed to the drive shaft.
4Device complexity
If few drive shafts are available in a conveyor assembly, then mechanical simplicity is maintained, but scalability to multiple assembly stations is limited
Solution Approach 1:
The patent replaces the mechanical encoder infrastructure with an optical measurement system that can be deployed at multiple stations independently. Cameras and image processing systems can be installed at any location along the conveyor without requiring additional drive shafts or mechanical modifications, enabling easy scalability.
Solution Approach 2:
The patent divides the measurement function into independent segments that can be deployed at multiple stations. Each station can have its own camera and processing system, allowing modular scaling along the conveyor line without requiring a centralized mechanical encoder system tied to drive shaft locations.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The virtual encoder system achieves higher accuracy and robustness, allowing for precise assembly and inspection tasks on moving objects, and can be easily scaled for multiple stations along a conveyor line, overcoming the limitations of mechanical encoders.
Implementation Method 1
beams of radiation intersect an object in the field of view of the 2D sensor, and some radiation from those beams is reflected by that object back to the 2D sensor
Data Source
AI summary
A method and system are provided for controlling an industrial automation machine using non-contact (virtual) position encoding. The system and method can be used to determine the position of an object under assembly on a conveyor system without mechanical coupling to a line or drive mechanism of the line.