Cassette Transfer Robot Vision for Warped Workpiece Unloading
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Solution Overview
Problem
The complexity of unloading workpieces from cassettes is increased due to varying cassette configurations and potential dimensional errors, as well as workpiece warps or bends, requiring operators to manually set the robot hand position, which is cumbersome and error-prone.
Innovation Solution
A transfer apparatus with a transfer robot equipped with an imaging unit that captures multiple images of the cassette, allowing the controller to determine the robot hand's position automatically, eliminating the need for manual recognition of cassette configurations and workpiece bends.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If the transfer robot uses manual positioning based on operator recognition of cassette configuration, then the robot can unload workpieces from cassettes, but the operator's work becomes complex and time-consuming due to varying cassette configurations and workpiece warps
Solution Approach 1:
The system performs self-positioning by automatically imaging the cassette and workpiece to determine the robot hand insertion position, eliminating the need for operator intervention in position setting. The transfer robot autonomously adapts to different cassette configurations and workpiece warps through automated imaging and position determination.
Solution Approach 2:
The manual mechanical positioning process is replaced with an automated optical measurement system. The imaging unit captures images of the cassette and workpiece, and the controller automatically processes these images to determine the robot hand position, substituting operator recognition and manual adjustment with automated vision-based positioning.
2Reliability
If the operator manually sets the robot hand position based on advance information, then workpiece unloading is possible, but errors occur due to dimensional variations in cassettes from different manufacturers and production lots
Solution Approach 1:
The system uses real-time feedback from the imaging unit to determine the actual position of the workpiece and cassette features. By imaging the cassette and workpiece before unloading, the system obtains actual position information that accounts for dimensional variations and workpiece warps, enabling accurate robot hand positioning despite cassette configuration variations.
Solution Approach 2:
The system dynamically adjusts the robot hand position parameters based on actual imaging results rather than using fixed predetermined values. The controller calculates the insertion position by processing images that capture the actual state of the cassette and workpiece, allowing the system to adapt to dimensional variations in cassettes from different manufacturers and production lots.
3Measurement precision
If the robot hand position is determined manually for each workpiece warp, then accurate unloading is achieved, but the work process becomes complex and requires frequent adjustments
Solution Approach 1:
The system automatically determines the robot hand insertion position by imaging the workpiece and calculating the appropriate position based on the captured images. This self-positioning capability eliminates the need for operators to manually adjust the robot hand position for each workpiece warp, maintaining measurement precision while simplifying the operation.
Solution Approach 2:
Manual position adjustment is replaced with automated vision-based positioning. The imaging unit captures the workpiece state, and the controller automatically processes these images to determine the robot hand insertion position, substituting the complex manual adjustment process with automated optical measurement and calculation.
Data Source
AI summary
With reference to a plurality of images formed by an imaging unit, the position of a robot hand to be inserted into a cassette at the time of unloading a workpiece from the cassette is determined. Hence, it is not necessary for an operator to recognize in advance configuration details of the cassette and a warp or bending of the workpiece accommodated in the cassette. Accordingly, the operator's work at the time of unloading the workpiece from the cassette is simplified.