Optical Boresight Alignment for Robotic Workpiece Positioning
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Solution Overview
Problem
Current methods for accurately aligning robotic workpieces in precision manufacturing are labor-intensive and time-consuming, relying on manual intervention and mechanical feelers or optical sensors to prevent robotic arm contact with the workpiece, which complicates the alignment process.
Innovation Solution
A camera system with an optical boresight, beam splitter, and sensors is used to split and measure collimated input beams, determining translation and angle offsets from the centerline, enabling precise location of a target within six degrees of freedom with high accuracy, independent of distance, using a computing device and diffractive optical elements for alignment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If manual intervention and mechanical feelers are used to align the robotic arm with the workpiece, then the risk of damage to the camera, robotic arm, or workpiece is reduced, but the alignment process becomes labor-intensive and time-consuming
Solution Approach 1:
The patent replaces mechanical feelers and manual alignment operations with an optical measurement system using a camera and laser boresighting. The system uses optical fields instead of mechanical contact to detect workpiece features and calculate alignment parameters, eliminating the need for mechanical protection while enabling fully autonomous operation.
Solution Approach 2:
The system enables the robotic arm to perform self-alignment by automatically detecting workpiece features through the camera system and computing the necessary transformation parameters. The robotic system serves itself by autonomously determining its position and orientation relative to the workpiece without requiring manual intervention or protective mechanical feelers.
2Measurement precision
If the camera is positioned close to the workpiece using mechanical feelers or optical sensors, then accurate feature registration is achieved, but the alignment process becomes labor intensive and time consuming
Solution Approach 1:
The patent replaces mechanical feelers and slow optical sensing with a laser-based boresighting system that rapidly measures workpiece features. The laser system provides precise distance and position measurements without requiring slow mechanical positioning or manual feature identification, achieving both high accuracy and fast alignment.
Solution Approach 2:
The system performs preliminary alignment by using the laser boresight to pre-position the camera in the correct orientation and distance from the workpiece before detailed feature registration. This preliminary positioning is achieved rapidly through optical measurements, reducing the time required for subsequent precise feature matching.
3Measurement precision
If conventional coordinate measurement methods are used to align the robot and workpiece, then the workpiece can be registered to the robot coordinate system, but the process requires semi-autonomous operation and adds considerable time to manufacturing operations
Solution Approach 1:
The patent replaces conventional coordinate measurement machines and manual alignment procedures with an integrated laser-camera system that automatically captures workpiece geometry and computes coordinate transformations. The system uses optical fields to rapidly scan and measure workpiece features, enabling fully autonomous operation without manual intervention in the alignment process.
Solution Approach 2:
The system achieves full automation by enabling the robotic system to independently perform all alignment operations. The camera automatically detects workpiece features, the processing system computes the coordinate transformation parameters, and the robotic arm self-corrects its position and orientation without requiring semi-autonomous operator intervention.
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 approach allows for efficient and accurate alignment of workpieces to within 0.001 inches and 0.02 degrees, reducing labor and time in manufacturing operations by enabling autonomous robotic assembly without the need for high-precision robotic systems.
Implementation Method 1
a first surface including a beam splitter configured to split the collimated input beam into a first sub-beam and a second sub-beam
Implementation Method 2
a second surface including a reflective surface configured to reflect the second sub-beam and direct the second sub-beam to the second sensor
Implementation Method 3
a quarter wave plate proximate a second end of the housing along the boresight centerline... causing the output beam from the laser to be polarized as circularly polarized waves
Implementation Method 4
a collimating optic disposed between the laser source and the quarter wave plate along the boresight centerline
Data Source
AI summary
A method, system and computer program product are provided for position and orientation measurement using a camera system having an optical boresight centerline. Methods may include: receiving at an aperture a collimated input beam; splitting the input beam at a first surface including a beam splitter into a first sub-beam and a second sub-beam; receiving at a first sensor the first sub-beam; receiving at a second sensor the second sub-beam; and determining one or more offsets of the input beam from the centerline based on data received from the first sensor and the second sensor. Methods may include: determining a location and irradiance of the first sub-beam of the input beam received by the first sensor; and determining a location and irradiance of the second sub-beam of the input beam received by the second sensor.