Position Control System with Dual Detection Processing
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Solution Overview
Problem
In factory automation, position detection failures in production lines lead to productivity degradation due to manual intervention, as operators must visually set position coordinates, causing production line stops and extended downtime.
Innovation Solution
A position control system that includes a control portion, an acquisition portion, a first detection portion, and a second detection portion, which use image data to detect object positions using different processing methods, allowing for automatic position correction and reduced manual input.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a single detection processing method is used for position detection, then the detection speed is fast, but the detection reliability deteriorates when the object is out of position
Solution Approach 1:
The detection system is segmented into multiple detection processing methods with different robustness levels. The first detection processing method is used under normal conditions for fast detection, while the second detection processing method is activated when the first method fails to detect the object. This segmentation allows the system to maintain high reliability by switching methods based on detection success, while avoiding the complexity of continuously running all detection methods.
Solution Approach 2:
The system dynamically switches between different detection processing methods based on the detection results. When the first detection processing method successfully detects the object position, the system continues using this method. When detection fails, the system dynamically transitions to the second detection processing method with higher robustness. This dynamic adaptation ensures reliable position detection across varying conditions without permanently increasing system complexity.
2Productivity
If manual position coordinate input is required when detection fails, then the position can be corrected, but the production line stops and productivity deteriorates
Solution Approach 1:
The system prepares multiple detection processing methods in advance, with the second method designed specifically to handle cases where the first method fails. By having the second detection method ready beforehand with higher robustness, the system can automatically recover from detection failures without requiring manual intervention. This preliminary preparation of alternative detection methods ensures continuous production and maintains productivity while improving detection reliability.
3Reliability
If the second detection processing method with higher robustness is always used, then the position detection reliability is improved, but the detection speed and processing efficiency deteriorate
Solution Approach 1:
The detection system is segmented into two processing methods with different characteristics: the first method prioritizes speed for normal conditions, while the second method prioritizes robustness for failure conditions. By segmenting the detection approaches and selecting based on need, the system achieves high reliability only when necessary, maintaining fast detection speed during normal operation.
Solution Approach 2:
Instead of always applying the more robust but slower second detection method, the system applies detection methods partially based on the situation. The first faster method is used for the majority of normal detection cases, while the second more robust method is applied only partially when detection failures occur. This selective application maintains overall detection speed while improving reliability at critical moments.
Data Source
AI summary
A position control system 1 acquires image data obtained by imaging a workpiece, detects a position of the workpiece on the basis of the image data by first detection processing, outputs a control command for controlling the position of the workpiece in a case in which the position of the workpiece has been detected, detects the position of the workpiece on the basis of the image data in accordance with second detection processing that is more robust than first detection processing in a case in which the position of the workpiece has not been detected, and outputs a control command for controlling the position of the workpiece on the basis of a result of the detection in the second detection processing.