Mirror-Based Workpiece Alignment for Precise Relative Positioning
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Solution Overview
Problem
Existing robot control systems face challenges in accurately aligning objects with fixed receiving objects during assembly, as precise relative alignment between the object and the receiving object is difficult to achieve.
Innovation Solution
An alignment device comprising a holding device, a moving device, a mirror member, an image sensor, and a control device that calculates the position of a second workpiece relative to a first workpiece based on captured images and performs feedback control to align the second workpiece with the first workpiece, using a mirror to reflect the second workpiece and capture its image simultaneously with the first workpiece.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a robot control system uses a single camera to image an object from multiple directions with a reflecting mirror, then the system can capture multi-directional views, but it becomes difficult to achieve accurate relative alignment between the object and a fixed receiving object during assembly
Solution Approach 1:
The patent introduces a mirror member arranged in a second direction (Y-axis) perpendicular to the first direction (Z-axis), enabling the image sensor to capture both the first workpiece and the mirror image of the second workpiece simultaneously. This dimensional arrangement allows multi-directional imaging while maintaining alignment precision by providing separate visual references for each workpiece in orthogonal directions.
Solution Approach 2:
The mirror member acts as an intermediary that reflects the second workpiece into the image sensor's field of view. This intermediary element enables the system to indirectly observe the second workpiece's position and orientation without requiring the sensor to physically move or change viewing angles, thus maintaining measurement precision while achieving multi-directional capability.
2Ease of operation
If the second workpiece is arranged away from the first workpiece to allow movement and assembly, then the assembly process becomes flexible, but accurate relative alignment between the two workpieces becomes difficult to achieve
Solution Approach 1:
The control device calculates the position and orientation of the second workpiece relative to the first workpiece based on images captured by the image sensor, and performs feedback control of the moving device to align the second workpiece with the first workpiece. This closed-loop feedback mechanism maintains manufacturing precision while allowing assembly flexibility.
Solution Approach 2:
The patent replaces mechanical alignment methods with an optical measurement and control system. The image sensor captures visual information, the control device processes this data to calculate relative positions, and the moving device executes alignment based on this information, substituting mechanical trial-and-error alignment with precision optical measurement and controlled movement.
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
This configuration enables accurate alignment of the second workpiece with respect to the first workpiece, improving the precision of relative alignment between the two objects.
Implementation Method 1
a mirror member capable of reflecting the second workpiece, the mirror member being arranged adjacent to the first workpiece in a second direction intersecting the first direction
Data Source
AI summary
An alignment device includes a holding device capable of holding the second workpiece, a moving device that moves the holding device toward the first workpiece, a mirror member capable of reflecting the second workpiece, the mirror member being arranged adjacent to the first workpiece, an image sensor arranged to be able to simultaneously and continuously capture the first workpiece and a mirror image of the second workpiece reflected on the mirror member, and a control device that performs feedback control of the moving device based on the calculated position of the second workpiece with respect to the first workpiece based on the first workpiece and the mirror image of the second workpiece, which are captured by the image sensor, to align the second workpiece with the first workpiece.