Encoder Synchronization for Conveyor Tracking Precision
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Solution Overview
Problem
Existing conveyer tracking systems face challenges in accurately tracking workpieces due to time lags between imaging command issuance and actual imaging, especially at higher conveying speeds, which can lead to deviations in tracking precision.
Innovation Solution
An image processing apparatus and system where the visual sensor synchronizes its encoder counter values with the robot control device, ensuring that the timing of actual imaging is aligned with the intended imaging timing, even with delays, by receiving and transmitting pulse signals from the encoder to maintain accurate positional information.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the conveying speed of the conveyer is enhanced to improve productivity, then productivity increases, but tracking precision deteriorates due to time lag between imaging command and actual imaging
Solution Approach 1:
The system uses encoder pulses as feedback to continuously track the conveyer position. The visual sensor counts encoder pulses to determine the conveyer's travel distance, and this position information is fed back to correct the workpiece position coordinates. This feedback mechanism allows the system to maintain tracking precision even at high conveying speeds by continuously updating the position reference based on actual conveyer movement.
Solution Approach 2:
The system performs preliminary positioning by capturing the encoder pulse count at the moment imaging is triggered. This preliminary position information is stored and used as a reference point. Subsequently, the system counts the number of encoder pulses that elapse during the time lag period to calculate the workpiece's displacement, thereby compensating for the delay before the robot performs the picking action.
2Measurement precision
If a pulse coder is attached to the conveyer to detect travel distance, then positioning accuracy improves, but device complexity increases
Solution Approach 1:
The encoder attached to the conveyer serves multiple functions: it provides travel distance measurement for positioning accuracy, generates timing signals for synchronization, and supplies position feedback for continuous tracking correction. By making the encoder multi-functional, the system achieves high positioning accuracy without adding separate dedicated components for each function, thereby limiting the increase in device complexity.
Solution Approach 2:
The encoder acts as an intermediary device that mediates between the conveyer's mechanical movement and the visual sensor's measurement system. Instead of directly measuring the workpiece position or the conveyer speed separately, the encoder provides a unified pulse signal that serves as a common reference for both positioning and timing, simplifying the overall system architecture while maintaining high measurement precision.
Data Source
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AI summary
This image processing apparatus comprises: an interface (14) for receiving a signal indicating the travel of a conveying device (10) in a conveying route; an interface (NW) for communicating with a control device (200) for controlling a movement mechanism (300) for handling a workpiece, the movement mechanism (300) being disposed downstream of an imaging area of an imaging part in the conveying route; a means for synchronously maintaining the travel in the conveying route between the control device (200) and a means (100) for acquiring positional information about a region that corresponds to a pre-registered workpiece in an image, by measuring an image obtained by imaging performed by an imaging part (100); a means (100) for initiating imaging by the imaging part in response to an imaging command; and a means for transmitting, to the control device, positional information and the travel at the time imaging is performed involving the image used to acquire the position information.