Adaptive Bin Picking With Dual Vision and Robot Path Planning
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Solution Overview
Problem
Manual handling of parts with varying locations and orientations in bins leads to inefficiencies, fatigue, and ergonomic stressors in manufacturing processes, particularly when dealing with heavy parts that require repetitive motions and quality checks.
Innovation Solution
A system and method utilizing a robot with a first vision system to identify and orient parts within a bin, a second vision system to determine the destination's location and orientation, and a controller for adaptive trajectory planning, along with an end effector to automatically move parts between the bin and destination, allowing for efficient and ergonomic part handling.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If manual handling is used to move parts from bins to destinations, then flexibility in handling various part types with random locations and orientations is maintained, but worker fatigue, ergonomic stressors, and operational delays increase
Solution Approach 1:
The patent replaces the manual mechanical handling system with an automated robotic system equipped with vision guidance and adaptive trajectory planning. The robot autonomously identifies parts with random orientations using vision systems, calculates optimal pickup locations and orientations, executes precise pickup and placement operations, and eliminates ergonomic stressors while maintaining high operational efficiency
Solution Approach 2:
The robotic system performs self-guided operations by using vision systems to automatically detect part locations and orientations, computing optimal pickup strategies without human intervention, and autonomously navigating to destinations. The system serves itself by making real-time decisions about part manipulation based on sensor feedback and pre-programmed logic
2Productivity
If automated robotic systems are implemented to move parts automatically, then productivity and efficiency increase, but system complexity and initial implementation costs increase
Solution Approach 1:
The robotic system is designed with universal capabilities to handle multiple part types with varying geometries, materials, and orientations using the same hardware platform. The vision system and control algorithms are configured to recognize and adapt to different part characteristics, eliminating the need for dedicated systems for each part type and reducing overall system complexity
Solution Approach 2:
The system dynamically adjusts operational parameters such as gripper force, pickup location, and trajectory based on real-time vision data about part mass, geometry, and orientation. This adaptability allows a single robotic system to efficiently handle diverse part types without requiring complex mechanical reconfigurations
3Manufacturing precision
If vision systems and adaptive trajectory planning are used to identify parts and plan robot paths, then picking accuracy and placement precision improve, but computational requirements and processing time increase
Solution Approach 1:
The system performs preliminary vision-based part identification and characterization before the robot approaches the bin. The vision system captures images, identifies part locations and orientations, and pre-calculates optimal pickup strategies in advance, allowing the robot to execute precise operations without real-time computational delays during the actual picking motion
Data Source
AI summary
A system and method for automatically moving one or more parts between a bin at a source location and a destination using a robot is provided. The system includes a first vision system to identify a part within the bin and to determine the pick location and pick orientation of the part. A second vision system determines the location and orientation of a destination inside or outside of the bin, which may or may not be in a fixed location. A controller plans the best path for the robot to follow in moving the part between the pick location and the destination. An end effector is attached to the robot for picking the part from the bin, holding the part as the robot moves it, and placing the part at the destination. The system may also check the part for quality by one or both of the vision systems.