Optical Robot Programming for Safe Bending Machine Handling
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Solution Overview
Problem
Current robot control programming methods for machine tools are time-consuming, pose safety risks to operators, and require them to be in close proximity to the robot, as they typically involve manual tracking or operating consoles.
Innovation Solution
A method and device that use optical sensors and image processing to generate a robot control program by recording the movements of an operator or workpiece, allowing for remote programming by converting the operator's actions into robot movements, eliminating the need for direct robot operation and enabling offline programming across different manufacturers.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If robots are programmed using operating consoles or portable control consoles, then the operator can control the robot movement, but the operator is exposed to safety dangers and can only move the robot at creep speed
Solution Approach 1:
The patent introduces an optical sensor system and image processing computer as intermediaries between the operator and the robot. The operator manipulates a physical object (workpiece) in the real world, and the system automatically translates these manipulations into robot control commands through image capture, processing, and trajectory calculation, eliminating the need for the operator to directly control the robot console
Solution Approach 2:
The system creates a digital copy of the operator's manual manipulations by capturing images of the workpiece and hand movements, processing these images to extract trajectory data, and using this copied movement information to program the robot. This allows the robot to learn from observing the operator's actions rather than receiving direct control commands
2Ease of operation
If robots are programmed by manual tracking with the operator standing next to the robot, then programming can be performed, but safety dangers still arise due to proximity
Solution Approach 1:
The optical sensor system acts as a remote intermediary that captures the operator's manipulations from a distance. The operator works with the workpiece in the real world while the sensor system and computer process the visual information to generate robot commands, allowing the operator to remain outside the robot's dangerous movement zone
Solution Approach 2:
The patent replaces the mechanical proximity-based manual tracking method with an optical field-based system. Instead of the operator physically following and controlling the robot's movements in real-time proximity, the system uses optical sensors to capture and process images, substituting direct mechanical control with automated image processing and trajectory calculation
3Productivity
If traditional robot programming methods are used, then the robot can be controlled, but the programming process is time-consuming
Solution Approach 1:
The system performs preliminary action by having the operator manually manipulate the workpiece to demonstrate the desired trajectory and operations. The optical sensor system captures these preliminary manipulations, and the computer automatically processes the images to generate the complete robot control program, eliminating the need for time-consuming step-by-step programming
Solution Approach 2:
The system rapidly copies the operator's manual manipulations through image capture and processing. By capturing multiple images during the operator's demonstration and automatically extracting trajectory data from these images, the system quickly generates the robot control program without requiring slow, methodical programming steps
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 simplifies and accelerates robot programming, reduces safety risks by allowing operators to program from a safe distance, and enables efficient offline programming of robots without requiring knowledge of robot controllers, facilitating the creation of precise robot control programs.
Implementation Method 1
generating image material of a machining operation of a workpiece on the bending machine by means of at least one optical sensor
Implementation Method 2
extracting at least one part of the workpiece and/or at least one part of a hand of an operator handling the workpiece from the image material by comparing a 3D object of the workpiece known from a bending plan with the image material
Data Source
AI summary
The present disclosure relates to a method for creating a robot control program for operating a machine tool, in particular a bending machine, having the steps of generating image material of a machining operation of a workpiece on the machine tool by means of at least one optical sensor; extracting at least one part of the workpiece and/or at least one part of a hand of an operator handling the workpiece from the image material; generating a trajectory and/or a sequence of movement points of at least one part of the workpiece and/or at least one part of a hand of an operator from the extracted image material; and creating a robot control program by reverse transformation of the trajectory and/or the sequence of movement points.