Normal Vector Estimation for Molded Product Take-Out Collision Avoidance
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Solution Overview
Problem
The existing methods for taking out molded products from molding machines are prone to collisions between the take-out head and the die due to variable mounting states, requiring high operator proficiency to avoid damage, and there is a need to automate the recognition of the mounting state of the die and attachment.
Innovation Solution
A method and system that estimate normal vectors to the attachment and die using imaging devices capable of capturing depth or coordinate data, allowing for the determination of the mounting state and posture of the attachment to prevent collisions by defining vectors perpendicular to mating surfaces and imaginary planes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If manual teaching programming is used to program the path and posture of the take-out head, then the operator can control the operation, but the take-out head may collide with the die due to variable mounting states requiring high operator proficiency
Solution Approach 1:
The patent replaces manual mechanical teaching programming with an automated optical measurement system. A 3D imaging device captures images of the die and take-out head, and a processor automatically calculates normal vectors and determines mounting states, eliminating the need for manual path programming and reducing operator involvement while improving reliability
Solution Approach 2:
The patent creates a digital copy of the physical mounting state by capturing 3D images of the die and take-out head. This digital representation allows the system to analyze and determine the actual mounting state without physical contact or manual measurement, enabling automated collision avoidance
2Loss of time
If the operator assumes constant mounting state for teaching programming, then the programming process is simplified, but collisions occur when the mounting state varies
Solution Approach 1:
The patent performs preliminary measurement of the actual mounting state before the take-out operation begins. By capturing images and calculating normal vectors in advance, the system prepares accurate posture information that accounts for the actual mounting variations, preventing collisions without requiring time-consuming manual adjustments
Solution Approach 2:
The patent implements a feedback mechanism where the actual mounting state is measured and used to adjust the teaching program. The system continuously monitors the relationship between the take-out head and die, and automatically corrects posture based on measured deviations from the ideal mounting state
3Productivity
If the take-out head approaches the die without posture control, then the operation is simple, but the take-out head may contact or damage the die when tilted
Solution Approach 1:
The patent replaces mechanical trial-and-error approach with automated optical measurement and calculation. The system uses 3D imaging to detect the actual mounting state and automatically calculates the correct posture, enabling fast operation without manual intervention while preventing die damage through accurate posture control
Data Source
AI summary
A method of estimating a normal vector to an attachment mounted to an approach frame of an apparatus for taking out a molded product and a normal vector to a die mounted to a molding machine is provided. A normal vector to a take-out head is estimated through computation using a coordinate/depth determination section and a normal vector computation section on the basis of depth data or coordinate data on three mounting members. Three or more extending portions are specified from the image, the extending portions being each a part of a fixed die or a movable die or a part of a surrounding component and extending in a direction that coincides with the open direction for the dies. A normal vector to the die is estimated through computation on the basis of the depth data or coordinate data on the specified extending portions.