Robot Position Control Using Dual Vision Alignment Feedback
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Solution Overview
Problem
Robot apparatuses face challenges in precisely controlling the position of a member after it has been conveyed, leading to potential task failures due to inaccuracies in positioning and orientation adjustments.
Innovation Solution
A controller system that utilizes two vision sensors and an arithmetic processing unit to generate movement commands for a robot, enabling precise alignment of a second member with respect to a first member by calculating movement directions and amounts based on images captured by both sensors, allowing for approaching and position adjustment controls.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a robot conveys a member to a target position, then the member can be delivered to the destination, but the position and orientation of the member may deviate from the target, resulting in misalignment
Solution Approach 1:
The patent employs vision sensors to capture images of the member before and after conveyance, detects its actual position and orientation, and feeds this information back to the controller. The controller then calculates correction values and adjusts the robot's position to eliminate misalignment, ensuring accurate placement despite initial deviations
Solution Approach 2:
The system performs preliminary detection of the member's position and orientation using vision sensors before the robot executes the conveyance task. This preliminary information is used to pre-calculate the required conveyance parameters, allowing the robot to compensate for potential misalignments in advance and achieve accurate positioning
2Measurement precision
If a single vision sensor is used to detect member position, then the system structure remains simple, but the measurement accuracy and reliability are insufficient
Solution Approach 1:
The patent divides the vision detection function into two separate vision sensors positioned at different locations. Each sensor captures images from its specific viewpoint, and the controller processes these separate image sets to calculate the member's position and orientation more accurately by combining information from both perspectives
Solution Approach 2:
The system transitions from single-point detection to multi-point detection by placing vision sensors at different spatial positions. This dimensional expansion allows the system to capture the member's position and orientation from multiple angles, improving measurement accuracy through triangulation and perspective comparison
3Manufacturing precision
If the robot adjusts position frequently to maintain alignment, then positioning accuracy improves, but the operation time increases
Solution Approach 1:
The system performs preliminary detection of the member's position and orientation before conveyance, calculates the required adjustments in advance, and executes the corrected position in a single conveyance operation. This eliminates the need for frequent intermediate adjustments, maintaining high positioning accuracy while reducing overall operation time
Data Source
AI summary
A controller of the robot apparatus performs approaching control for making a second workpiece approach a first workpiece and position adjustment control for adjusting a position of the second workpiece with respect to a position of the first workpiece. The approaching control includes control for calculating a movement direction and a movement amount of a position of the robot based on an image captured by a first camera, and making the second workpiece approach the first workpiece. The position adjustment control includes control for calculating a movement direction and a movement amount of a position of the robot based on an image captured by the first camera and an image captured by the second camera, and precisely adjusting a position of the first workpiece with respect to the second workpiece.