Workpiece Alignment Search Range Using Position Sensor Prediction
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Solution Overview
Problem
Existing alignment systems face issues with degraded prediction accuracy in determining the search range for workpiece positioning, leading to increased search time and processing load due to repeated searches when marks are not detected accurately.
Innovation Solution
An alignment system that uses an image processor to detect identification targets within a predetermined search range based on position information from position sensors, allowing precise and fast positioning by limiting the search range to only the necessary portion of the captured image.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the search range is increased to avoid failure in detecting marks, then the reliability of mark detection is improved, but the search time and processing load increase
Solution Approach 1:
The system performs preliminary prediction of the workpiece position using movement amount prediction based on past driving amounts before the actual mark detection. This preliminary action establishes an expected position range that guides the subsequent search process, allowing the system to focus detection efforts on the most probable location and avoid exhaustive full-range searches.
Solution Approach 2:
The search range is dynamically adjusted based on the predicted movement amount and prediction accuracy. Instead of using a fixed search range, the system adapts the search area size according to the workpiece's movement characteristics, expanding the search range when prediction accuracy is low and reducing it when prediction is highly accurate, thereby optimizing both reliability and efficiency.
2Reliability
If the search range is increased to ensure mark detection, then the reliability is improved, but the processing load increases
Solution Approach 1:
The system performs preliminary prediction of the workpiece position using movement amount prediction based on past driving amounts before the actual mark detection. This preliminary action establishes an expected position range that guides the subsequent search process, allowing the system to focus detection efforts on the most probable location and avoid exhaustive full-range searches.
Solution Approach 2:
The search range is dynamically adjusted based on the predicted movement amount and prediction accuracy. Instead of using a fixed search range, the system adapts the search area size according to the workpiece's movement characteristics, expanding the search range when prediction accuracy is low and reducing it when prediction is highly accurate, thereby optimizing both reliability and efficiency.
3Measurement precision
If the prediction accuracy is improved by calculating speed based on past driving amounts, then the positioning precision is improved, but the prediction accuracy may be degraded due to calculation errors
Solution Approach 1:
The system incorporates feedback mechanisms where the actual detected mark positions are compared with predicted positions, and this information is used to refine future predictions. The feedback loop allows the system to correct accumulated errors in movement amount prediction and adapt to actual workpiece behavior, improving both accuracy and reliability over time.
Solution Approach 2:
The system performs preliminary prediction of the workpiece position using movement amount prediction based on past driving amounts before the actual mark detection. This preliminary action establishes an expected position range that guides the subsequent search process, allowing the system to focus detection efforts on the most probable location and avoid exhaustive full-range searches.
Data Source
AI summary
An alignment system includes an image processor to detect an identification target included in a workpiece from a captured image of the workpiece, and an operation controller to control a driver to move the workpiece based on actual coordinates of the identification target detected by the image processor. The image processor determines within the captured image a search range partially covering the captured image and having a predetermined size based on position information generated based on an output from a position sensor in the driver, and detects the identification target from a portion of the captured image corresponding to the search range.