Image-Based Control System for High-Speed Precision Positioning
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Solution Overview
Problem
Existing positioning techniques in manufacturing sites face challenges in achieving higher speed and accuracy, as they often require trade-offs between speed and accuracy, with prior methods either sacrificing speed for accuracy or struggling to maintain high precision at increased velocities.
Innovation Solution
A control system that employs image processing to specify the position of characteristic parts on an object, utilizing a two-stage control operation: a first stage for accelerating to a high speed and decelerating to an intermediate target position, followed by a second stage for precise positioning using non-stop alignment, where the system continuously adjusts speed and direction based on real-time image data to ensure accurate placement.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If image processing is used for positioning, then positioning accuracy is improved, but positioning speed deteriorates due to repetitive positioning requirements
Solution Approach 1:
The positioning process is divided into two distinct phases: a first control operation for coarse positioning that prioritizes speed, and a second control operation for fine positioning that prioritizes accuracy. This segmentation allows each phase to be optimized independently, resolving the contradiction between speed and accuracy by applying different control strategies at different stages of the positioning process.
Solution Approach 2:
The control system dynamically switches between two control modes based on the positioning stage. The first control operation uses a different control instruction generation method than the second control operation, allowing the system to adapt its behavior to the current positioning requirements. This dynamic approach enables the system to achieve both high speed during initial positioning and high accuracy during final positioning.
2Productivity
If moving speed is increased to meet demand for higher speed, then productivity is improved, but positioning accuracy deteriorates
Solution Approach 1:
The positioning process is divided into two distinct phases: a first control operation for coarse positioning that prioritizes speed, and a second control operation for fine positioning that prioritizes accuracy. This segmentation allows each phase to be optimized independently, resolving the contradiction between speed and accuracy by applying different control strategies at different stages of the positioning process.
Solution Approach 2:
The first control operation performs preliminary positioning at high speed to bring the object close to the target position, preparing the system for the subsequent fine positioning phase. This preliminary action allows the system to cover most of the distance quickly, reserving the slower, more accurate second control operation only for the final approach, thereby maximizing overall positioning speed while maintaining accuracy.
3Measurement precision
If repetitive positioning is performed to maintain accuracy, then positioning precision is improved, but time consumption increases
Solution Approach 1:
The positioning process is divided into two distinct phases: a first control operation for coarse positioning that prioritizes speed, and a second control operation for fine positioning that prioritizes accuracy. This segmentation allows each phase to be optimized independently, resolving the contradiction between speed and accuracy by applying different control strategies at different stages of the positioning process.
Solution Approach 2:
The second control operation continuously acquires image data during movement and generates control instructions in real-time, maintaining continuous useful action throughout the fine positioning process. This continuous feedback and adjustment eliminates the need for stopping and repetitive positioning cycles, reducing time consumption while maintaining high positioning precision through ongoing correction.
Data Source
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AI summary
It is requested to realize positioning using image processing at higher speed and higher accuracy. A control system (1) executes a first control operation, and then executes a second control operation. In the first control operation, the image processing section (100) obtains the image data and specifies a position of a characteristic part (12, 14). The control section (200) determines a control instruction for accelerating an object (2) to a predetermined first speed based on the specified position of the characteristic part (12, 14) and then decelerating the object (2) to a predetermined second speed lower than the first speed, to move the object (2) to an intermediate target position away from the final target position by a predetermined margin distance. In the second control operation, the image processing section (100) obtains the image data during movement of the moving mechanism (300) and specifies the position of the characteristic part (12, 14), and the control section (200) determines a control instruction for positioning the object (2) to the final target position based on the specified position of the characteristic part (12, 14). The margin distance is determined such that the object (2) does not pass the final target position when the speed of the moving mechanism (300) is decreased from the second speed at an allowable maximum acceleration.