Torque-Guided Fastening Position Tracking With External Camera Markers
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Solution Overview
Problem
Existing methods for managing the tightening of fastening parts in compact fluid control devices, such as those in semiconductor manufacturing, face challenges in accurately detecting the tightening position and torque due to the integration of sensors and cameras, which complicates the tool's operability and increases manufacturing costs.
Innovation Solution
A work management system utilizing a tool with a torque sensor and first and second markers for image processing, combined with first and second cameras, calculates the engagement position of the bit with fastening parts by analyzing image data and torque-related data, allowing for accurate management of position and torque information.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If a case containing various sensors, CPUs, and the like is mounted on a tool to detect tightening position, then the tightening position detection function is improved, but the operability of the tool is remarkably lowered and the case becomes an obstacle
Solution Approach 1:
The patent extracts the detection function from a physical case mounted on the tool and relocates it to an external imaging device. The tool is reduced to essential components (grip and bit) while position detection is achieved by capturing images of markers with an external camera system, eliminating the obstacle case that impaired operability.
Solution Approach 2:
The patent introduces markers as intermediary objects attached to the bit and grip. These markers serve as mediators between the tool and the imaging device, enabling position detection without requiring sensors or a case on the tool itself. The markers reflect light and can be detected by the external imaging device, solving the contradiction between detection capability and tool operability.
2Measurement precision
If multiple sensors are mounted on a tool to detect tightening position, then the detection function is improved, but the manufacturing cost of the tool increases
Solution Approach 1:
The patent extracts the expensive sensor assembly from the tool and replaces it with inexpensive markers and an external imaging device. The tool manufacturing cost is reduced while maintaining detection capability through the use of simple reflective markers that can be detected by the external camera system.
Solution Approach 2:
The patent uses optical copying principles where the imaging device captures images of the markers to determine tool position. Instead of using expensive physical sensors on the tool, the system creates an optical copy of the marker positions and processes these images to extract position information, significantly reducing manufacturing costs.
3Measurement precision
If an imaging device is used to capture the tightening work, then the position detection capability is improved, but the grip of the operator's hand and the tool enters the imaging area during imaging, concealing the working position and the tightening position
Solution Approach 1:
The patent employs multiple imaging devices positioned at different spatial locations to capture images from multiple dimensions. By using both a first imaging device and a second imaging device at different positions, the system can capture the marker positions from various angles, ensuring that the grip and tool body do not obstruct the view of the working position in at least one of the captured images.
Data Source
AI summary
A work management apparatus, method, and system enable to accurately manage position, tightening torque and other information for all fastening parts, for tightening work using a tool with a torque sensor. The system includes: a driver provided with a torque sensor; and first and second cameras that capture images of a product from different viewpoints. The torque sensor starts measurement of the tightening torque when a detected tightening torque exceeds a set threshold value, stops measurement of the tightening torque when the measurement data satisfies a predetermined condition, and outputs torque related data that includes measurement time. The system further includes: a PC that calculates coordinates of an engagement position of a bit from a plurality of image data captured by the first and the second cameras corresponding to the measurement time included in the torque related data; and a marker mounting device provided with a marker and removably mounted to the bit.