Conveying Robot Position Teaching via Optical Deviation Detection
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Solution Overview
Problem
Conventional methods for establishing the relationship between a robot coordinate system and an external coordinate system in assembly and conveying robots, particularly in clean environments like semiconductor manufacturing, require skilled manual operations, are prone to inaccuracies due to environmental factors, and can generate dust and particles when using contact-based methods.
Innovation Solution
A conveying system utilizing a rotary table with a sensor to detect deviations of a disk-shaped object, allowing a robot to autonomously determine and align the object's position without the need for exclusive jigs or contact, using a method that includes acquiring deviation information at multiple positions to teach the robot's operation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If an exclusive jig and touch sensor are mounted on the robot hand to specify the relationship between robot coordinate system and external coordinate system, then the relationship can be grasped, but the teaching operation requires manual skill and time, and dust and particles are generated due to contact with workpieces
Solution Approach 1:
The patent replaces the mechanical contact-based measurement system (jig and touch sensor) with a non-contact optical measurement system using a camera and image processing. The camera captures images of the workpiece and reference marks to calculate position and orientation without physical contact, thereby eliminating dust and particle generation while maintaining measurement precision
Solution Approach 2:
The patent creates a visual copy (image) of the workpiece and reference marks using a camera, then processes this copy through image recognition algorithms to determine spatial relationships. This copying approach allows measurement without direct contact with the actual workpiece, preventing contamination in clean environments
2Object-generated harmful factors
If a visual sensor is used to specify the relationship between robot coordinate system and external coordinate system, then contact with workpieces is avoided, but the measuring accuracy is subject to environmental light conditions
Solution Approach 1:
The patent uses reference marks with specific color properties (high-contrast colors like black and white patterns) that are easily distinguishable by the camera. These color-coded reference marks provide stable visual targets that are less sensitive to variations in environmental lighting conditions, improving measurement accuracy consistency
Solution Approach 2:
The patent employs advanced image processing algorithms that substitute simple optical detection with sophisticated computational methods. These algorithms include contrast enhancement, edge detection, and feature matching techniques that compensate for lighting variations and maintain high measurement precision across different environmental conditions
3Measurement precision
If manual teaching operation is performed using an exclusive jig, then the relationship between coordinate systems can be specified, but skilled operation and time are required
Solution Approach 1:
The patent enables the system to automatically perform the teaching operation by having the robot autonomously move to predetermined positions, capture images with the camera, and process the images to calculate coordinate transformations. This self-service approach eliminates the need for skilled manual operation and significantly reduces teaching time while maintaining accuracy
Solution Approach 2:
The patent pre-sets the positions and configurations of reference marks and predetermined measurement points before the teaching operation begins. This preliminary preparation allows the automatic teaching process to proceed efficiently without requiring real-time manual intervention or complex calculations during execution
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
Enables precise and stable teaching of the robot's operation without operator intervention, preventing particle generation in clean environments and eliminating the need for skilled manual handling.
Implementation Method 1
a sensor portion configured to acquire an information of a deviation of a disk-shaped conveyance object placed on the rotary table with respect to a reference position of the rotary table
Data Source
AI summary
In this system, regarding an conveyance object placed on a rotary table, based on positions temporarily set previously as a taking position of the disk-shaped conveyance object in a storing container and a reference position of the rotary table, information of the taking position of the conveyance object in the storing container and of the reference position of the rotary table is acquired based on information of the deviation of the conveyance object placed on the rotary table with respect to the reference position of the rotary table acquired by a sensor portion so as to teach a conveying operation of the conveyance object from the storing container to the rotary table by the robot based on the acquired position information.