Robot Path Programming Using a Dummy Tool and 3D Tracking
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Solution Overview
Problem
Current industrial robot programming methods are complex, time-consuming, and costly, particularly for small to average production volumes, and lack the precision required for advanced manufacturing processes, especially when dealing with complex paths and reflective surfaces like metal and welding operations.
Innovation Solution
An industrial robot programming system that uses a dummy device mimicking real tools, equipped with sensors and a processor to collect and store data on the device's position and orientation during simulated operations, allowing for the creation of optimized trajectories that can be programmed into industrial robots, enhancing accuracy and safety while reducing resource consumption.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If offline programming is used to generate flexible robot programs for complex robot paths, then adaptability is improved, but device complexity and cost increase
Solution Approach 1:
The patent uses a dummy device that copies the physical characteristics and geometry of the real tool, allowing the robot to learn trajectories through visual imitation rather than complex programming. The dummy device is equipped with visual markers that enable the camera system to track and replicate its movements, replacing traditional OLP software complexity with a simpler visual copying mechanism.
Solution Approach 2:
The dummy device acts as an intermediary between the human operator and the robot. Instead of directly programming the robot with complex paths, the operator manipulates the dummy device which serves as a mediator, and the system automatically translates its movements into robot commands through visual tracking, simplifying the programming interface.
2Measurement precision
If traditional tracking methods are used to achieve positioning accuracy, then measurement precision is improved, but manufacturing precision is insufficient for advanced manufacturing systems
Solution Approach 1:
The patent transitions from traditional single-camera or laser tracking to a multi-camera stereoscopic vision system that captures three-dimensional spatial information. By adding the dimension of visual depth perception through multiple camera angles, the system achieves superior positioning accuracy (≤ 0.2 mm) that traditional tracking methods cannot provide, particularly for complex three-dimensional and non-linear paths.
3Ease of operation
If manual online programming is used to program robot paths, then ease of operation is improved, but productivity is reduced due to time-consuming programming
Solution Approach 1:
The system performs preliminary action by having the operator manipulate the dummy device to demonstrate the desired trajectory beforehand. This preliminary demonstration with the dummy device captures all necessary path information, which is then automatically transferred to the robot. This eliminates the need for time-consuming step-by-step robot programming while maintaining operational simplicity, as the operator only needs to perform the task once with the dummy device.
4Measurement precision
If high resolution acquisition systems are used to track dummy device position, then measurement precision is improved, but cost increases significantly
Solution Approach 1:
Instead of using expensive high-resolution industrial tracking systems, the patent employs a cost-effective copying approach using standard cameras and visual markers. The dummy device is equipped with visual markers that can be tracked by ordinary cameras, achieving sufficient precision through image processing algorithms rather than relying on expensive specialized sensors. This replicates the functionality of high-end tracking systems using more affordable components.
Data Source
Figure 1A
Figure 1B~1C
Figure 1D~2
AI summary
The present invention belongs to the field of industrial robots, in particular of automatic programming of industrial robots by means of an industrial programming system. The present invention also relates to a method of industrial robot programming by means of the aforementioned industrial programming system. The present invention is also related to a computer program which carries out the method for the industrial programming.