Camera-Guided Assembly Synchronization for Mixed Human-Robot Work
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Solution Overview
Problem
The assembly of custom products requires experienced operators, leading to increased assembly time and risk of errors, as well as a dependency on skilled labor, which can result in fatigue and mistakes due to the complexity and variety of products.
Innovation Solution
An assembly system that includes a controller and a robotic manipulation tool, which monitors and synchronizes operator and machine performed steps using a camera to provide real-time feedback and instructions, allowing less experienced operators to achieve comparable quality and efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If experienced operators perform manual assembly steps, then assembly quality and precision are improved, but assembly time increases and operator fatigue leads to errors
Solution Approach 1:
The assembly process is divided into operator performed steps and machine performed steps. The robotic manipulation tool handles specific assembly operations while the operator performs other steps, allowing parallel execution and reducing total assembly time while maintaining quality through specialized machine operations.
Solution Approach 2:
The camera monitors the work space to detect completion of operator performed steps. This feedback is sent to the controller, which then triggers or coordinates machine performed steps accordingly, ensuring synchronized operations and preventing errors from premature or delayed machine actions.
2Manufacturing precision
If experienced operators perform manual assembly steps, then assembly quality is improved, but dependency on skilled labor increases causing operational risk
Solution Approach 1:
The system uses camera-based monitoring and automated detection to identify when operator performed steps are complete, eliminating the need for operator self-reporting or manual verification. This reduces dependency on operator experience and attention while maintaining quality control.
Solution Approach 2:
The patent replaces reliance on human operator judgment and experience with an automated vision system and controller that objectively detect step completion and coordinate machine operations, transferring the intelligence from human operators to the automated system.
3Adaptability or versatility
If new operators are deployed, then operational flexibility increases, but assembly time increases and error rate increases
Solution Approach 1:
The camera-based monitoring system provides real-time feedback on assembly progress, allowing new operators to receive immediate guidance and correction. The system detects when steps are complete and can trigger instructional feedback, reducing errors and improving efficiency without requiring extensive operator experience.
4Adaptability or versatility
If the variety of products to be assembled increases, then market adaptability improves, but the complexity of assembly steps increases making it difficult for operators to perform without mistakes
Solution Approach 1:
The robotic manipulation tool and controller are designed to handle multiple product types and assembly variations through programmable instructions. The same hardware system can adapt to different products by receiving updated assembly sequences and parameters, eliminating the need for specialized equipment for each product variant.
Solution Approach 2:
The patent replaces complex human cognitive processing required to manage product variety with an automated controller that stores and executes assembly sequences. The vision system and controller handle the complexity of detecting step completion and coordinating operations, freeing operators from needing to remember complex procedures for different products.
Data Source
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AI summary
Method of performing an assembling of an object, comprising assembling one or more object parts to a semi-manufactured object such as to manufacture the object, wherein the method is performed by an operator using an assembly system, the assembly system including a controller and a robotic manipulation tool, the method comprising a plurality of assembling steps including one or more machine performed steps to be performed by the a robotic manipulation tool and one or more operator performed steps to be performed by the operator, the method including the steps of monitoring, by the assembly system using a camera, a work space wherein the or each operator performed step is being performed and identifying, by the controller, at least one of the operator performed steps as an assembling step that precedes at least one of the machine performed steps, and controlling the robotic manipulation tool such as to synchronize performing of the at least one machine performed step dependent on a state of completion of the identified operator performed step.