Imaging Unit Posture Adjustment via Workpiece Tilt Detection
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
In factory automation, adjusting the posture of imaging units, such as cameras, used in visual sensors to ensure proper alignment with the conveying path is challenging due to the lack of precise methods for determining the correct installation posture, leading to difficulties in capturing images of workpieces within the visual field.
Innovation Solution
An image processing device and program that receive captured images from the imaging unit, acquire the position and tilt angle of the workpiece, and output assist information to help adjust the posture of the imaging unit, ensuring the imaging visual field is parallel to the conveying path surface, thereby facilitating accurate image capture.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If manual adjustment by trial and error is used, then the imaging unit can be adjusted, but the adjustment time and complexity increase significantly
Solution Approach 1:
The system captures images through the imaging unit, detects the position and orientation of workpieces in the captured images, calculates tilt angles based on detected features, and provides feedback information to guide adjustment. This closed-loop feedback mechanism replaces trial-and-error manual adjustment with informed, precise adjustments, significantly reducing adjustment time while improving accuracy.
Solution Approach 2:
The patent replaces manual mechanical adjustment with an automated image processing and calculation system. Instead of relying on operators to physically adjust the imaging unit based on visual inspection, the system uses image capture, digital processing, mathematical calculation of tilt angles, and automated feedback to guide precise mechanical positioning, reducing both time and human effort.
2Measurement precision
If tilt information is displayed for camera adjustment, then parallelism can be assessed, but the installation posture cannot be uniquely determined when the camera is not fixed on a copy board
Solution Approach 1:
The system uses the same imaging unit for both capturing workpiece images and acquiring reference information for posture determination. By detecting features from workpieces or reference objects in the field of view, the system derives both tilt angle and position information universally, eliminating the need for specialized copy boards or fixed installations while maintaining measurement precision.
Solution Approach 2:
The patent introduces image processing and feature detection as intermediaries between the imaging unit and the workpiece. Instead of directly measuring physical parallelism requiring fixed installations, the system uses captured images as intermediaries to indirectly determine tilt angles and position, enabling flexible installation while maintaining measurement accuracy through computational analysis.
Data Source
AI summary
An image processing device includes: an image receiving part configured to receive an image of a target workpiece on a surface of a conveying path captured by means of the imaging unit; a position acquiring part configured to acquire a position of the target workpiece in the captured image; a tilt acquiring part configured to acquire, by using the position of the target workpiece in the captured image acquired by means of the position acquiring part, a tilt angle of an imaging plane of the imaging unit relative to the surface of conveying path; and an outputting part configured to output assistant information used for assisting in the adjustment of the posture of the imaging unit by using the acquired tilt angle.