Centering Device for Plate Workpieces Using Camera Feedback
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Solution Overview
Problem
Existing centering devices for plate-shaped workpieces face challenges in increasing speed and operational rate, and are not adaptable for conveying multiple workpieces, often requiring multiple implements or robots that increase complexity and cost.
Innovation Solution
A centering device comprising a table with a conveyor mechanism, camera, table movement mechanisms, and a computation unit that adjusts the conveyor and table movements based on camera-acquired position information to accurately position plate-shaped workpieces, allowing for increased speed and operational efficiency without the need for multiple implements or robots.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If implements are used to grasp and convey blanks, then the blanks can be positioned, but numerous implements must be prepared for different shapes, increasing manufacturing cost and storage space
Solution Approach 1:
The patent employs a single robot arm equipped with a gripper that can handle various blank shapes through adaptive control. The robot system is designed to perform multiple functions by adjusting its motion paths and gripper positions based on the specific blank geometry, eliminating the need for multiple dedicated implements for different shapes.
Solution Approach 2:
The system changes operational parameters such as robot motion speed, gripper force, and trajectory based on the detected blank shape and position. By dynamically adjusting these parameters, the single robot can adapt to different blank configurations without requiring physical reconfiguration or multiple specialized tools.
2Productivity
If implements are moved more quickly to increase conveying speed, then productivity increases, but scratches become more prominent on the blanks
Solution Approach 1:
The patent replaces the mechanical grasp-and-convey method with a robotic system that uses controlled motion and positioning. The robot arm moves the blank through programmed trajectories with precise speed control, reducing mechanical impact and scratching while maintaining high conveying speed. The system substitutes rigid mechanical handling with flexible, programmable motion control.
Solution Approach 2:
The robot system dynamically adjusts its motion characteristics based on the blank properties and position. The conveying speed and acceleration are continuously optimized to prevent scratches while maintaining high productivity. The system transitions smoothly between different motion states, avoiding sudden impacts that could damage the blank surface.
3Manufacturing precision
If implements are replaced for each different blank shape, then positioning accuracy is maintained, but the molding press machine is stopped during replacement, decreasing the rate of operation
Solution Approach 1:
The robot system performs self-adjustment for different blank shapes through automated recognition and adaptive path planning. Instead of requiring manual implementation changes, the system automatically adapts its control parameters and motion trajectories based on the detected blank characteristics, maintaining positioning accuracy without interrupting the molding press machine operation.
4Device complexity
If a single robot is used to transport and position blanks, then implementation complexity is reduced, but the process takes too much time and is too slow for the cycle time
Solution Approach 1:
The robot system performs preliminary positioning and preparation actions while the molding press machine is completing its cycle. The robot can simultaneously handle multiple tasks such as blank retrieval, positioning, and preparation for the next operation, optimizing the use of cycle time and maintaining high productivity with a single robot.
5Productivity
If two robots are used to increase speed, then the process is fast enough for cycle time, but interference between robots becomes a problem, control becomes complicated, and more space is needed
Solution Approach 1:
The patent divides the work space and tasks into distinct zones that can be efficiently managed by a single robot. The robot alternates between different operational zones (retrieval zone, positioning zone, transfer zone) in a systematic sequence, achieving high speed without the interference problems that would arise from multiple robots operating in overlapping spaces.
Data Source
AI summary
A centering device for a plate-shaped workpiece comprises: a table (21) having a conveyor mechanism (23) for conveying a plate-shaped workpiece (10) in the horizontal direction; a camera (56) for taking an image of the plate-shaped workpiece (10) placed on the table (21); a table movement mechanism (28) for moving the table (21) horizontally in the direction orthogonal to the conveyance direction; a table rotation mechanism (60) for rotating the table (21) about a vertical axis; a computation unit (58) for comparing target central position information and information acquired by the camera (56) and computing the movement amount of the conveyor mechanism (23), the movement amount of the table movement mechanism (28), and the movement amount of the table rotation mechanism (60); and a control unit (59) for controlling the conveyor mechanism (23), the table movement mechanism (28), and the table rotation mechanism (60) on the basis of the movement amounts calculated by the computation unit (58).