Adaptive Bin Picking With Dual Vision for Robot Part Transfer
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Solution Overview
Problem
Manual operations in manufacturing processes, such as picking and placing heavy or large items, lead to inefficiencies, ergonomic stress, and potential injuries due to repetitive motions and the difficulty in using mechanical aids like cranes.
Innovation Solution
A conveyance system and method utilizing a robot with a vision system to identify items and determine pick and destination locations, along with adaptive trajectory planning, allowing for automated movement of items between a source and destination, including loose items with random orientations, using an end effector for picking and placing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If manual operations are used for picking and placing heavy or large items, then flexibility and ease of operation are maintained, but ergonomic stress, potential injuries, and inefficiency increase due to repetitive motions and difficulty in using mechanical aids
Solution Approach 1:
The patent replaces manual mechanical operations with an automated robotic system that uses vision guidance and adaptive trajectory planning. The robot performs picking and placing operations automatically, eliminating the need for human workers to manually handle heavy or large items, thereby resolving the contradiction between ease of operation and productivity.
Solution Approach 2:
The robotic system is equipped with vision systems and adaptive planning capabilities that enable it to autonomously identify items, determine optimal pick locations and orientations, plan trajectories, and execute picking and placing operations without human intervention. This self-service capability improves productivity while maintaining ease of operation through automation.
2Productivity
If mechanical aids like cranes are used to move heavy items, then productivity is improved, but ease of operation deteriorates due to difficulty in using and staff resistance
Solution Approach 1:
The patent replaces complex mechanical aids like cranes with a more user-friendly robotic system. The robot is controlled through software interfaces and vision guidance, making it easier to operate than traditional mechanical aids while maintaining improved productivity for moving heavy items.
Solution Approach 2:
The robotic system is designed with multi-functionality, capable of performing various picking and placing operations for different types of items (heavy, large, or regular items) using the same platform. This universality improves productivity across different tasks while maintaining ease of operation through consistent control interfaces.
3Productivity
If automated systems are introduced to replace manual operations, then productivity and safety are improved, but device complexity increases
Solution Approach 1:
The automated system is segmented into distinct functional modules: vision systems for item identification, adaptive trajectory planning for path optimization, and robotic execution for picking and placing operations. This segmentation manages device complexity by organizing functions into separate, manageable components while maintaining high productivity.
Solution Approach 2:
The system incorporates feedback mechanisms where vision systems continuously monitor item locations and orientations, and adaptive trajectory planning adjusts paths based on real-time conditions. This feedback loop enables the system to handle variability in item placement while managing complexity through intelligent control algorithms.
Data Source
AI summary
A system and method for automatically moving one or more items between a structure at a source location and a destination using a robot is provided. The system includes first and second vision systems to identify an item and to determine the precise location and orientation of the item at the source location and the precise location and orientation of the destination, which may or may not be in a fixed location. A controller plans the best path for the robot to follow in moving the item between the source location and the destination. An end effector on the robot picks the item from the source location, holds it as the robot moves, and places the item at the destination. The system may also check the item for quality by one or both of the vision systems. An example of loading and unloading baskets from a machine is provided.