Flexible Flat Workpiece Positioning With Vision-Guided Multi-Gripper Transfer
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Solution Overview
Problem
Limp flat workpieces, which are dimensionally unstable and often randomly folded, pose challenges in being efficiently and reliably transferred to a defined position for machining or processing, as existing automated solutions require multiple grippings and are not always precise or crease-free.
Innovation Solution
A positioning device equipped with a camera for image recognition, multiple grippers, and manipulators or a linear drive unit, allowing for single-time transfer of limp flat workpieces from a random state to a flat, spread-out position with high reliability and speed, using machine learning modules to identify grippable edges and orientations for precise handling.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If multiple grippers are used to transfer the workpiece through multiple regripping operations, then the workpiece can be positioned from a random state, but the cycle time increases and productivity decreases
Solution Approach 1:
The system segments the gripping function across multiple grippers (first, second, and third grippers) that can operate simultaneously or sequentially. Each gripper is responsible for a specific portion of the workpiece, enabling parallel handling operations that reduce the total cycle time compared to sequential single-gripper approaches while maintaining reliable positioning control.
Solution Approach 2:
Multiple grippers are merged into a coordinated system that transfers the workpiece in a single operational cycle. The first gripper picks up the workpiece from the provisioning area while the second and third grippers simultaneously prepare to receive it, merging multiple gripping actions into one synchronized transfer operation that eliminates idle time between regripping steps.
2Ease of operation
If manual transfer is used to position flat workpieces, then simplicity is maintained, but automation level and productivity are limited
Solution Approach 1:
The system incorporates image recognition technology that automatically identifies and locates the workpiece edges and features without human intervention. The camera captures images, processes them to determine gripper positioning, and guides the robotic grippers to the correct locations, enabling the system to serve itself in terms of workpiece localization and gripper coordination.
Solution Approach 2:
Manual visual inspection and positioning operations are replaced with an automated vision system. The camera and image processing algorithms substitute for human eyes and hands in detecting workpiece edges, determining orientation, and guiding gripper placement, thereby increasing automation while maintaining operational simplicity through software-based control.
3Extent of automation
If the first gripper grips the workpiece from a random folded state, then automation is achieved, but positioning precision and reliability are reduced due to difficulty in identifying grippable edges
Solution Approach 1:
The system uses a camera to capture images of the workpiece in the provisioning area and processes these images to provide feedback on workpiece location, orientation, and edge positions. This visual feedback loop enables the control system to adjust gripper positions and orientations dynamically, ensuring precise gripping even when the workpiece is in a random folded state, thereby maintaining both automation and positioning precision.
Data Source
AI summary
A positioning device for positioning a limp flat workpiece has a provisioning area for providing the flat workpiece to be positioned and a camera for generating a camera image of the flat workpiece to be positioned. Furthermore, the positioning device comprises a first manipulator having a first gripper, a second gripper and a third gripper. The second gripper and the third gripper are configured to take over at least a portion of the limp flat workpiece from the first gripper. In addition, a method of positioning a limp flat workpiece is presented.