Robot Arm Control Using 3D Sensing for Container Opening Alignment

Solution Overview

Problem

Conventional robot systems require manual and skill-dependent touch-up operations to identify the position, orientation, and size of container openings, leading to variability and inefficiency when containers are replaced.

Innovation Solution

A robot system equipped with a three-dimensional sensor that captures two-dimensional image data and three-dimensional point cloud data to automatically identify the position, orientation, and size of container openings, using markers for accurate feature extraction and correction of robot arm movements to avoid interference.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Measurement precision

If manual touch-up operation is used to identify container opening, then the robot can be taught the position and orientation of the container opening, but the operation is troublesome and time-consuming every time the container is replaced

Engineering Contradiction:

Improveposition coordinate values of container openingVSAvoidtime for touch-up operation

Core Design Contradiction:

Measurement precisionVSLoss of time

Solution Approach 1:

The patent replaces the manual mechanical touch-up operation with an optical measurement system. A sensor captures images of the container opening, and image processing automatically extracts position and orientation data, eliminating the need for manual mechanical contact and measurement.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The system enables self-service by allowing the robot to automatically identify and adapt to different containers through image processing. The container itself provides visual features that the system uses for automatic positioning, eliminating the need for external manual teaching.

Inventive Principle:

Principle #25Self-service

2Measurement precision

If manual touch-up operation is used to identify container opening, then the robot can be taught the position and orientation of the container opening, but the quality varies depending on the skill of the worker

Engineering Contradiction:

Improveposition coordinate values of container openingVSAvoidquality consistency

Core Design Contradiction:

Measurement precisionVSReliability

Solution Approach 1:

The patent replaces manual mechanical touch-up operation with an optical measurement system. A sensor captures images of the container opening, and image processing automatically extracts position and orientation data, eliminating the need for manual mechanical contact and measurement.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The system enables self-service by allowing the robot to automatically identify and adapt to different containers through image processing. The container itself provides visual features that the system uses for automatic positioning, eliminating the need for external manual teaching.

Inventive Principle:

Principle #25Self-service

3Extent of automation

If automated sensor-based identification is used to identify container opening, then manual operations are eliminated and consistency is improved, but additional equipment is required

Engineering Contradiction:

Improveautomated container opening identificationVSAvoidsensor and image processing system

Core Design Contradiction:

Extent of automationVSDevice complexity

Solution Approach 1:

The patent replaces manual mechanical touch-up operation with an optical measurement system. A sensor captures images of the container opening, and image processing automatically extracts position and orientation data, eliminating the need for manual mechanical contact and measurement.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The system enables self-service by allowing the robot to automatically identify and adapt to different containers through image processing. The container itself provides visual features that the system uses for automatic positioning, eliminating the need for external manual teaching.

Inventive Principle:

Principle #25Self-service

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

Enables precise and automated identification of container openings, reducing manual errors and variability, and ensuring consistent operation across different containers without the need for touch-up operations.

Implementation Method 1

a three-dimensional sensor that obtains two-dimensional image data including the container and three-dimensional point cloud data including the container

Methodology Applied

Scientific EffectImage capture and three-dimensional sensing:

Data Source

PatentUS20240308081A1Robot system and control apparatus

Publication Date: 2024.09.19 FANUC LTD

AI summary

A robot system according to one aspect of the present disclosure includes a robot arm mechanism to which a hand for gripping a workpiece stored in a container with an opening at a top of the container is attached, a sensor configured to obtain two-dimensional image data including the container and three-dimensional point cloud data including the container, and a control apparatus configured to identify a position, direction, and size of the opening of the container based on the image data and the point cloud data and control the robot arm mechanism so as not to interfere with the container. It is possible to identify the position, orientation, and size of the opening of the container without performing a touch-up operation on the container.