Point-Cloud Work Measurement for Column and Diaphragm Welding
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Solution Overview
Problem
Existing welding systems face inefficiencies in measuring the configuration of objects with columnar members and diaphragms due to time-consuming measurement processes, manual program selection, and potential installation errors, which can lead to inaccurate dimensions and increased costs with multiple sensors.
Innovation Solution
A work measuring method and welding system that utilize point cloud data acquisition, boundary position detection, and calculation to accurately derive the number and dimensions of columnar members and diaphragms, incorporating a welding robot, positioner, and sensor to streamline the measurement process and correct installation errors.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If a touch sensor is used with a measurement program, then measurement can be performed, but measurement time increases due to unnecessary measurement operations when there is distance between start position and actual installation position
Solution Approach 1:
The patent applies preliminary action by first capturing an image of the workpiece to identify its actual installation position and orientation before initiating the measurement process. This preliminary image-based positioning eliminates unnecessary measurement operations that would occur if the sensor started from a predetermined position, thereby reducing measurement time while maintaining accuracy.
Solution Approach 2:
The patent replaces the mechanical touch sensor measurement approach with an optical image-based detection method. By using a camera to capture the workpiece image and determine its position and orientation, the system substitutes mechanical measurement operations with optical detection, which is faster and avoids unnecessary movements when there is distance between the start position and actual installation position.
2Measurement precision
If measurement program is switched in accordance with shape of measurement object, then accurate measurement can be achieved, but manual selection is required which reduces efficiency
Solution Approach 1:
The patent implements self-service by enabling the measurement system to automatically identify the workpiece shape and select the appropriate measurement program without manual intervention. The system captures an image of the workpiece, analyzes its geometric features, and autonomously determines the correct measurement approach, thereby eliminating manual program selection while maintaining measurement accuracy.
Solution Approach 2:
The patent introduces an image-based intermediary system that acts as a mediator between the workpiece and the measurement program selection. The camera captures the workpiece image, and image processing algorithms analyze the shape characteristics to automatically determine the appropriate measurement program, serving as an intelligent intermediary that eliminates the need for manual selection.
3Measurement precision
If multiple sensors are used to measure measurement object, then measurement accuracy can be improved, but device cost and size increase
Solution Approach 1:
The patent applies universality by making a single camera perform multiple functions that would traditionally require multiple specialized sensors. The camera captures images for position detection, orientation determination, shape recognition, and measurement program selection, replacing the need for multiple sensors while maintaining measurement accuracy and reducing device complexity.
Solution Approach 2:
The patent replaces multiple mechanical or specialized sensors with a single optical camera system. The camera, combined with image processing algorithms, performs position detection, shape recognition, and measurement planning functions that would otherwise require multiple sensors, thereby reducing device cost and size while maintaining or improving measurement capability.
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 precise measurement of object configurations in less time, reducing measurement errors and operational time while maintaining accuracy, and enabling more efficient automatic welding processes.
Implementation Method 1
point cloud data acquired by using a time-of-flight (ToF) sensor
Data Source
AI summary
A work measuring method for measuring a work including a columnar member and a diaphragm and held by a positioner includes an acquiring step of acquiring point cloud data on a surface of the work held by the positioner and photographed in a predetermined direction, a detecting step of identifying a portion where distribution of the point cloud data changes in a three-dimensional coordinate system of the positioner and detecting the portion as a boundary position between the columnar member and the diaphragm, and a deriving step of deriving the number of columnar members and diaphragms included in the work on the basis of the boundary position detected in the detecting step.