Component Feeder Vision Layout for Fixture-Free Part Picking
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Solution Overview
Problem
Existing component feeding systems in automated industrial settings face challenges with overhead cameras, requiring complex calibration, extra hardware, and increased cycle time due to perspective distortions and the need for fixtures, which are inflexible and costly, especially when handling randomly oriented components for human-to-robot transfer.
Innovation Solution
A component feeder with a stationary picking surface and a vision system that includes load sensors to automatically trigger an image scanner or camera, eliminating the need for overhead installations and allowing for automatic generation of vision jobs, reducing programming effort and cycle time by detecting component presence and orientation directly on the surface.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If an overhead camera is used to locate components on the picking surface, then component localization can be achieved, but the system requires complex calibration and produces perspective distortions that affect measurement precision
Solution Approach 1:
The patent inverts the conventional overhead camera arrangement by placing the camera underneath the transparent picking surface, looking upward at the components. This eliminates perspective distortions and calibration complexity while maintaining accurate component localization, as the camera is now in a fixed position relative to the picking surface with no angular distortion.
Solution Approach 2:
The patent transitions from a three-dimensional overhead viewing angle to a two-dimensional planar view by placing the camera in the same plane as the picking surface (underneath it). This dimensional change eliminates the perspective effects that occur with overhead cameras, providing accurate top-down component positioning without calibration requirements.
2Reliability
If fixtures are used to hold components for robot picking, then component positioning is ensured, but the system becomes inflexible and requires extra hardware
Solution Approach 1:
The patent removes the fixtures entirely from the system, extracting the component positioning function from mechanical constraints to optical detection. The vision system locates components directly on the transparent picking surface without requiring physical fixtures, thereby eliminating hardware complexity while maintaining positioning reliability and improving adaptability to different component types.
Solution Approach 2:
The patent replaces the mechanical fixture system with an optical vision system. Instead of using physical fixtures to hold and position components, the system uses a camera underneath the transparent picking surface to detect component locations, substituting mechanical positioning with optical measurement and eliminating the need for fixtures.
3Productivity
If the robot arm moves to pick components, then component transfer is achieved, but the robot arm blocks the camera view or casts shadows
Solution Approach 1:
The patent inverts the camera position from above to below the picking surface. This eliminates the problem of the robot arm blocking the camera view or casting shadows, as the camera is now positioned in a location where the robot arm cannot interfere with the line of sight to the components on the picking surface.
Solution Approach 2:
The patent changes the camera's spatial dimension from an overhead position to an underneath position relative to the picking surface. This dimensional relocation places the camera in a zone free from robot arm interference, eliminating view obstruction and shadowing issues while maintaining continuous monitoring capability.
4Illumination intensity
If overhead lighting is used to illuminate the picking surface, then component visibility is improved, but the system requires extra hardware and increases device complexity
Solution Approach 1:
The patent removes the overhead lighting system entirely, extracting the illumination function from a separate hardware component to the ambient environment. By placing the camera underneath the transparent picking surface, the system utilizes light passing through the transparent material from above, eliminating the need for dedicated overhead lighting hardware while maintaining component visibility.
Solution Approach 2:
The transparent picking surface acts as an intermediary that transmits light from the ambient environment above to the camera below. This eliminates the need for direct overhead lighting by using the transparent surface as a light conduit, allowing ambient light to illuminate components for the underneath camera without requiring additional lighting hardware.
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 reduces integration effort and cycle time by automatically triggering image capture and processing, providing accurate component localization without the need for external cameras or fixtures, enhancing flexibility and reducing hardware costs while maintaining efficient human-to-robot transfer.
Implementation Method 1
a load sensor to detect when a component has been placed on the picking surface
Implementation Method 2
the vision system is configured to automatically trigger the image scanner to scan the component on the picking surface when the load sensor detects that the component has been placed on the picking surface
Data Source
Figure 1~3
Figure 4~5
AI summary
The present invention relates to a component feeder (1) comprising a stationary picking surface (2) for receiving components (14) to be picked, a vision system including an image unit arranged to take images of components distributed on the picking surface and a load device (5) including one or more load sensors adapted to detect the presence of a component on the picking surface and the vision system is configured to automatically trigger the image unit to take an image upon detecting the presence of the component on the picking surface.