Real-Time Marking via Machine Vision and Pin Engraving
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Solution Overview
Problem
Existing marking devices face challenges in accurately positioning objects on a conveyor system for precise marking, particularly when objects of different shapes and sizes are processed in a single sequence, leading to erroneous markings and increased costs due to the need for separate marking instructions for each component.
Innovation Solution
A digital camera coupled marking device system that utilizes a master controller with image recognition and machine vision algorithms to analyze the visual state and design parameters of objects in real-time, comparing them to a database of known shapes and patterns to determine the correct marking location and pattern, and sends marking commands to a pin or laser marker for precise engraving.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If separate marking instructions are used for each component type, then marking precision is maintained, but device complexity and processing time increase
Solution Approach 1:
The marking system is designed to handle multiple component types through a single unified process. The conveyor system transports various components through a common marking zone where the marking device can adaptively mark different component types without requiring separate marking systems or manual reconfiguration, thus reducing device complexity while maintaining versatility
Solution Approach 2:
The system employs cameras to capture images of components on the conveyor belt, processes these images to identify component types and orientations, and uses this feedback information to dynamically adjust marking parameters and positioning. This closed-loop feedback mechanism enables the system to maintain high marking precision across different component types without requiring complex pre-programming for each component variant
2Manufacturing precision
If manual positioning is used for each component, then marking accuracy is achieved, but productivity decreases
Solution Approach 1:
The system enables components to be automatically positioned and marked without manual intervention. The conveyor belt automatically transports components through the marking zone, and the image processing system automatically determines the correct marking position based on component orientation and type, eliminating the need for manual positioning while maintaining marking accuracy
Solution Approach 2:
The system replaces manual mechanical positioning with an automated vision-based positioning system. Cameras capture component positions and orientations, image processing algorithms calculate the appropriate marking locations, and the marking device automatically adjusts its positioning based on this digital information, substituting manual mechanical operations with automated optical-mechanical integration
3Manufacturing precision
If real-time image analysis is implemented, then marking precision is improved, but processing time increases
Solution Approach 1:
The system performs image capture and preliminary analysis while components are being transported on the conveyor belt, before they reach the marking position. By initiating the image analysis process early in the component's journey through the system, the processing is completed in advance, allowing the marking device to receive positioning information ready for immediate execution without adding delay to the overall process
Data Source
AI summary
Disclosed are a method and/or a system for real-time analysis and marking of a target surface using a digital camera coupled marking device. In one embodiment, a master controller receives a real-time digital camera signal from the digital camera of a marking device communicatively coupled to the master controller. The master controller analyzes the digital camera signal using an image recognition algorithm, a machine vision algorithm, and a database and archives a visual state and an object design parameter of an object. The master controller compares the visual state of an object with a library of known visual states in the database to extract an associated marking pattern and a desired marking location of the object. The master controller generates and sends a marking command to a pin marker of the marking device. The pin marker engraves the marking pattern onto the object in real time.