Linear Moving Mechanism Positioning Error Detection With Vision Sensors
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Solution Overview
Problem
Current methods for detecting positioning errors in linear moving mechanisms are laborious, costly, and unsuitable for dynamic real-time detection, particularly in industrial automation and intelligent applications, with high assembly errors and complex disassembly requirements.
Innovation Solution
A method using a visual sensor rigidly fixed on a moving element of the linear moving mechanism, capturing images of a calibration object at different positions, and employing coordinate system conversion matrices to analyze positioning errors through a data processing system, allowing for dynamic and static error measurement with high universality and ease of assembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If traditional level/digital level measuring method or three-coordinate instrument is used, then manufacturing precision of static machining state can be detected, but productivity is low and labor consumption is high
Solution Approach 1:
The patent replaces traditional mechanical measurement instruments (level/digital level measuring method, flat micrometer, three-coordinate instrument) with an optical measurement system using visual sensors (cameras). This substitution enables non-contact, dynamic real-time detection during the moving process, significantly improving productivity while maintaining measurement precision.
Solution Approach 2:
The patent transitions from static measurement to dynamic measurement by fixing the visual sensor on the moving element and capturing images during the moving process. This allows real-time detection of positioning errors throughout the motion range, enabling repeated real-time detection-adjustment processes for assembly errors.
2Speed
If optical measurement methods (laser interferometer, laser tracking interferometer) are used, then dynamic measurement capability is improved, but device complexity and cost increase significantly
Solution Approach 1:
The patent uses ordinary visual sensors (cameras) instead of expensive laser interferometers or laser tracking interferometers. The camera system is significantly cheaper and simpler to assemble and operate, while still providing the necessary dynamic measurement capability for detecting positioning errors during motion.
Solution Approach 2:
The patent uses visual sensors to capture optical images of the calibration object at different positions, creating a visual record that can be processed to extract positioning error information. This copying approach through imaging simplifies the measurement system compared to direct laser interference measurement.
3Difficulty of detecting and measuring
If coordinate instrument is used for ground placement measurement, then measurement capability is provided, but adaptability to actual use scenes (ground or air) is limited
Solution Approach 1:
The patent creates a universal measurement system by fixing the visual sensor directly on the moving element of the linear moving mechanism. This configuration allows the system to measure positioning errors regardless of whether the mechanism is placed on the ground or in the air, and adapts to different sizes and structures of moving mechanisms through simple parameter calibration.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The method provides quick, accurate, and cost-effective detection of positioning errors with simplified assembly and disassembly, suitable for various application scenarios, including dynamic and static scenes, and reduces assembly errors through real-time adjustment processes.
Implementation Method 1
shooting the calibration object at different moving position point Pi on the linear moving mechanism by the vision sensor
Data Source
AI summary
A method and a system for detecting positioning error of a linear moving mechanism are provided, which includes a linear moving mechanism, a moving element, a visual sensor, a calibration object and a data processing system. The vision sensor is fixed on the moving element on the linear moving mechanism and is driven by the moving element to move on the linear moving mechanism. The calibration object is arranged in front of sight line of the visual sensor and used for calibrating posture of the visual sensor. The vision sensor shoots the calibration object at different moving positions on the linear moving mechanism, and the data processing system obtains shooting result, and calculates the coordinate system conversion matrix from the linear moving mechanism coordinate system at moving position point to the preset linear moving mechanism coordinate system, thereby analyzing the positioning error of the linear moving mechanism.