Camera-Based Jig Inspection for Sensorless Clamp State Detection
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Solution Overview
Problem
Conventional image-based jig inspection systems for vehicle body factories face challenges with increased sensor and wiring costs, space constraints, equipment interference, and cable damage due to the large number of sensors and complex wiring required for accurate state monitoring of clamping units in jigs.
Innovation Solution
An image-based jig inspection system utilizing a camera module and vision system to determine the state of clamping units through image analysis, eliminating the need for physical sensors and cables by using a camera to photograph and process images, identifying vehicle types by color, and calculating matching rates to determine forward and backward moving states of clamping units.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If the number of sensors is increased to accurately detect the state of each clamping unit, then the measurement precision is improved, but the device complexity and installation space requirements increase
Solution Approach 1:
The patent uses image copying by capturing visual images of the jig and clamping units, then processes these image copies to extract state information. This replaces the need for physical sensors by working with optical copies of the scene, thereby reducing device complexity while maintaining measurement precision
Solution Approach 2:
The patent substitutes the mechanical sensor system with an optical imaging system. Instead of using physical sensors that require cables and connectors, the system uses a camera to capture images and processes them computationally to determine clamping unit states, eliminating the mechanical sensor network
2Measurement precision
If the number of sensors and cables is increased to monitor all clamping units, then the measurement precision is improved, but the area of installation space increases
Solution Approach 1:
The patent merges multiple sensing functions into a single imaging device. Instead of having separate sensors for each clamping unit, one camera captures images that contain information about all clamping units simultaneously, and image processing extracts the state of each unit from the combined image data, thereby reducing installation space
3Measurement precision
If the number of sensors and cables is increased to accurately monitor clamping units, then the measurement precision is improved, but equipment interference increases
Solution Approach 1:
The patent extracts the sensing function from the physical sensor-cable system and relocates it to an optical imaging system. By taking out the cables and connectors from the jig structure, the system eliminates the harmful factors associated with cable damage from welding spatter and connector failures, while maintaining state detection accuracy through image analysis
4Loss of information
If cables and connectors are used to connect sensors to the control system, then the state information can be transmitted, but the reliability decreases due to cable damage and contact failure
Solution Approach 1:
The patent substitutes the cable-based information transmission system with an optical imaging system. State information is transmitted through image data captured by the camera and processed computationally, eliminating cables and connectors that are susceptible to damage from welding spatter and contact failure, thereby improving operational reliability while maintaining information transmission capability
Data Source
AI summary
An image-based jig inspection system for inspecting a state of a sensorless jig managed in a vehicle body factory includes: a jig configured to fix a vehicle body component mounted by a plurality of clamping units; a camera module configured to photograph an inspection image of the jig; a vision system configured to compare the inspection image with a predetermined image analysis reference to determine a forward moving state or a backward moving state of a respective one of the clamping units; a welding robot configured to weld the component; and a main controller configured to control the welding robot according to a predetermined process based on the state information of the respective one of the clamping units.