Camera-Based Component Placement on Curved Surfaces
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing systems for pinpointing the exact location of component placement in assembly processes are limited by their suitability only for flat surfaces, are prone to interference, and are expensive and cumbersome, failing to accurately position components on complex or curved surfaces.
Innovation Solution
A method and system using a camera, computing means, and display to create a computer model of the mounting component, allowing for accurate placement by superimposing a mounting component target image over a live image of the base component, enabling precise alignment on complex surfaces through determination of camera position and viewing direction.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If a laser system is used to trace an outline on a mounting surface, then the operator can see the placement location, but the system only works on flat surfaces and is blocked by objects above the surface
Solution Approach 1:
The patent creates a virtual copy of the mounting component and displays it on a screen rather than using a physical laser projection. This virtual model can be viewed from any angle and is not blocked by physical obstructions, allowing accurate placement guidance on complex curved surfaces where laser systems fail.
Solution Approach 2:
The patent replaces the mechanical laser projection system with a computer-based virtual reality system. Instead of projecting light physically onto the surface, the system uses a camera to capture the surface, creates a computer model, and displays the component overlay on a screen, eliminating the limitations of light blockage and surface flatness requirements.
2Measurement precision
If a laser system is used for component placement guidance, then the outline is visible, but the system is expensive and cumbersome
Solution Approach 1:
The patent uses a standard camera and computer system that can perform multiple functions: capturing the mounting surface, creating 3D models, generating virtual component overlays, and displaying guidance information. This multi-functional approach replaces specialized expensive laser equipment with versatile common technology.
Solution Approach 2:
The system creates a virtual copy of the component and displays it on a standard computer screen rather than using expensive specialized projection equipment. This virtual modeling approach provides the same placement guidance functionality using much more affordable and less complex equipment.
3Adaptability or versatility
If the mounting surface is curved or complex, then the component placement becomes difficult, but flat surface systems cannot accommodate these surfaces
Solution Approach 1:
The patent moves the guidance display from the physical mounting surface plane to a separate screen plane. The camera captures the 3D curved surface, the computer creates a model, and the virtual component overlay is displayed on a 2D screen that the operator views separately, allowing accurate placement guidance on surfaces of any complexity without being constrained by surface geometry.
Solution Approach 2:
The system creates a virtual copy of both the mounting surface and the component, allowing the operator to see the component's position and orientation in relation to the complex curved surface from any viewing angle on the screen, eliminating the limitations of physical projection on irregular surfaces.
Data Source
Figure 1~2
Figure 3~4
Figure 5~6
AI summary
A computer model is formed of a mounting component (18) to be mounted at a target location on a mounting surface (12) of a base component (11). A position and viewing direction of a digital camera (3) is determined relative to the base component (11) and a live image (11') of the base component as viewed by the camera (3) is displayed on a monitor (4). The monitor (4) also displays a mounting component target image (18") generated by a computer (2) of the mounting component (18) mounted at the target location on the mounting surface (12) superimposed over the live image (11') of the base component. A user physically moves the mounting component (18) relative to the base component (11) until a live image of the mounting component as viewed by the camera (3) coincides with the mounting component target image (18").