Monocular Workpiece Detection With Height-Based Secondary Matching
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Solution Overview
Problem
Existing workpiece detection devices using monocular cameras struggle to accurately measure the position of workpieces due to inaccuracies in height measurement, leading to potential process failures and stops in workpiece holding robots.
Innovation Solution
A workpiece detection device and method that includes trapezoid correction, pattern matching with multiple models of varying sizes and angles, actual load height calculation, and secondary detection to enhance accuracy, utilizing a monocular camera to photograph workpieces and re-detect position and angle based on selected models.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If a monocular camera is used to photograph the workpiece, then the device complexity is reduced, but the measurement precision of workpiece height and position deteriorates
Solution Approach 1:
The patent introduces a scale as an intermediary object placed behind the workpiece. The scale provides reference markings that, when photographed together with the workpiece by the monocular camera, enable calculation of the workpiece height and position through image processing. This mediator allows the simple monocular camera to achieve precise measurements that would otherwise require complex multi-camera systems.
2Measurement precision
If pattern matching with multiple models of varying sizes and angles is performed, then the detection accuracy is improved, but the processing time increases
Solution Approach 1:
The patent pre-generates multiple models of the workpiece with varying sizes and angles before the actual detection process. These pre-prepared models are stored and ready for rapid comparison with the photographed image. By performing the computationally intensive model generation in advance rather than in real-time, the system achieves high detection accuracy through comprehensive pattern matching while minimizing the time lost during actual workpiece detection.
Data Source
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AI summary
A pattern matching unit (302) carries out a pattern matching between a photographed image obtained by photographing a workpiece with a monocular camera and a first plurality of models having a plurality of sizes and a plurality of angles, and selects a model having a size and an angle with the highest degree of matching. A primary detection unit (304) detects a position and an angle of an uppermost workpiece from among loaded workpieces based on the selected model. An actual load height calculation unit (305) calculates an actual load height of the uppermost workpiece based on a hand height detected by a workpiece holding robot (10). A secondary detection unit (306) re-detects the position and the angle of the uppermost workpiece based on a model having a size and an angle with the highest degree of matching selected by carrying out a pattern matching between the photographed image and a second plurality of models selected or newly created based on the actual load height.