AR Headset Virtual Robot Display for Blind-Side Manufacturing
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Solution Overview
Problem
In manufacturing processes, especially when dealing with large objects like aircraft components, human operators cannot visually monitor robotic devices operating on the opposite side, leading to slowed processes and safety hazards due to the lack of visibility of the robotic device's actions, such as drilling, which can be dangerous and may violate health and safety regulations.
Innovation Solution
The implementation of an augmented reality system using AR headsets to display the real-time position and orientation of robotic devices, with imaging devices tracking fiducial markers on both the robotic device and the AR headset, allowing human operators to see the robotic device's actions through virtual images, thereby enhancing visibility and coordination.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If a human operator is positioned on the opposite side of a large object to perform manual operations, then the operator can work on both sides of the object, but the operator cannot see the robotic device's actions in real-time, creating safety hazards and slowing down the manufacturing process
Solution Approach 1:
The patent creates a virtual copy of the robotic device that is displayed to the human operator through an augmented reality headset. This virtual representation shows the robotic device's position, orientation, and actions in real-time, allowing the operator to see what the robotic device is doing without being exposed to actual physical risks. The virtual model is updated based on tracking data from imaging devices that monitor the robotic device's actual movements.
Solution Approach 2:
The patent introduces an augmented reality headset as an intermediary between the human operator and the robotic device. Instead of the operator directly observing the robotic device through line-of-sight, the AR headset acts as a mediator that captures visual information about the robotic device's position and actions, processes it, and presents it to the operator in a safe and accessible manner.
2Productivity
If the human operator waits for the drill bit to pierce through the object to see where the robotic device is drilling, then no additional visualization equipment is needed, but the manufacturing process slows down significantly
Solution Approach 1:
The patent implements a feedback system where imaging devices continuously track the robotic device's position and orientation, and this information is immediately fed back to the human operator through the augmented reality headset. This real-time feedback allows the operator to see the robotic device's actions as they happen, enabling timely interventions and maintaining high manufacturing speeds without sacrificing safety or visibility.
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
This solution improves manufacturing efficiency and safety by enabling real-time visualization of robotic operations, reducing the risk of accidents and allowing for safer and faster fabrication processes.
Implementation Method 1
the first imaging device includes at least one camera, and a processor that uses photogrammetry to track the coordinate data for the first marker
Implementation Method 2
the first fiducial marker and the second fiducial marker each include a plurality of references points having a Light Emitting Diode (LED)
Data Source
AI summary
Systems and methods for virtually displaying a robotic device to a human operator. An exemplary system includes an augmented reality headset for use by the human operator. The system includes a first imaging device having a field of view of a first side of an object, and tracks coordinate data for a first marker on the robotic device positioned on the first side. The system includes a second imaging device having a field of view of a second side of the object, and tracks coordinate data for a second marker on the augmented reality headset positioned on the second side. The system includes a controller that generates a virtual image of the robotic device in a coordinate system based on the coordinate data for the first and second markers, and provides the virtual image of the robotic device to the augmented reality headset for display to the human operator.