Machine Vision Feedback for Robotic Fastener Verification
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Solution Overview
Problem
Current robotic manufacturing systems lack adaptability to changing environments and mistakes, such as incorrectly sized or configured fasteners, requiring human intervention for recognition and correction.
Innovation Solution
An automated machine vision system and method that uses a camera system and controller to determine if objects within a work field have predetermined features, such as thread pitch, by capturing image data, applying filters, and determining the presence of specific features, enabling automated quality control and robotic installation systems to ensure correct object configuration and positioning.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If robotic systems are used for repetitive manufacturing tasks, then productivity is improved, but adaptability to changing environments and mistakes deteriorates
Solution Approach 1:
The system captures images of the work area, processes the images to detect objects and their features, and uses this feedback information to determine whether to proceed with installation. The robotic system receives real-time visual feedback about the environment and adjusts its actions accordingly, enabling adaptive automation while maintaining high productivity
Solution Approach 2:
The patent replaces manual visual inspection and decision-making with an automated machine vision system that captures images, processes them through algorithms, and makes installation decisions. This substitution of mechanical/optical systems for human senses and cognition enables both high productivity and adaptability to environmental variations
2Productivity
If automated robotic installation is implemented, then productivity is improved, but ability to recognize and correct mistakes deteriorates
Solution Approach 1:
The system performs preliminary detection and verification of objects and their features before the robotic installation action is executed. By capturing images, processing them to identify objects and their characteristics, and determining whether installation should proceed, the system prevents mistakes before they occur, ensuring both speed and reliability
Solution Approach 2:
The machine vision system provides real-time feedback about the presence and characteristics of objects in the work area. This feedback loop enables the robotic system to recognize incorrect objects or conditions and correct mistakes by adjusting its installation actions or skipping problematic locations, maintaining high reliability while preserving automated speed
3Measurement precision
If machine vision system with image processing is used, then measurement precision is improved, but device complexity increases
Solution Approach 1:
The image processing function is segmented into distinct modules: image capture by the camera system, image processing to extract features, and decision-making based on processed data. This segmentation allows each component to be optimized independently while working together to achieve high measurement precision without requiring the entire system to be overly complex
Solution Approach 2:
The patent introduces an image processing system as an intermediary between the camera and the robotic installation system. This intermediary processes visual information, extracts relevant features, and translates them into actionable data for the robotic system, enabling high measurement precision while managing overall system complexity through functional decomposition
Data Source
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AI summary
Machine vision methods and systems determine if an object within a work field has one or more predetermined features. Methods comprise capturing image data of the work field, applying a filter to the image data, in which the filter comprises an aspect corresponding to a specific feature, and based at least in part on the applying, determining if the object has the specific feature. Systems comprise a camera system configured to capture image data of the work field, and a controller communicatively coupled to the camera system and comprising non-transitory computer readable media having computer-readable instructions that, when executed, cause the controller to apply a filter to the image data, and based at least in part on applying the filter, determine if the object has the specific feature. Robotic installation methods and systems that utilize machine vision methods and systems also are disclosed.(Fig.1)