Robot Picking with 2D-3D Vision for Hidden Stacked Workpieces
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Solution Overview
Problem
Existing robotic systems fail to efficiently retrieve stacked workpieces from a conveyor due to hidden pieces being undetected, leading to missed items and requiring costly installations like arc conveyors or multiple imaging systems.
Innovation Solution
A robot system incorporating a fixed camera for initial positioning, a 3D vision sensor for detailed imaging, and a control unit to determine hidden workpieces, allowing for efficient detection and retrieval of stacked items without additional costly mechanisms.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a single fixed camera is used for imaging, then the system cost is reduced, but hidden workpieces cannot be detected
Solution Approach 1:
The patent transitions from 2D imaging with a fixed camera to 3D imaging by mounting the camera on the robot arm, enabling depth perception and detection of hidden workpieces through multi-dimensional spatial information
Solution Approach 2:
The camera is mounted on the movable robot arm rather than being fixed, allowing the imaging position to dynamically change and capture hidden workpieces that would be obscured from fixed positions
2Measurement precision
If arc conveyor or return mechanism is installed to expose hidden workpieces, then detection capability is improved, but system cost increases
Solution Approach 1:
The patent replaces mechanical systems like arc conveyors and return mechanisms with a robotic arm-mounted camera system that uses dynamic positioning and 3D imaging to detect hidden workpieces without additional mechanical infrastructure
Solution Approach 2:
The robot arm serves multiple functions: both manipulating visible workpieces and positioning the camera to detect hidden workpieces, eliminating the need for separate detection mechanisms
3Measurement precision
If multiple imaging systems are used to detect hidden workpieces, then detection capability is improved, but device complexity increases
Solution Approach 1:
A single camera mounted on the robot arm performs multiple imaging tasks by leveraging the robot's multi-degree-of-freedom movement capability, avoiding the need for multiple fixed cameras or imaging systems
Data Source
AI summary
Provided is a robot system that that can efficiently take out stacked workpieces being conveyed at low cost. A robot system includes: a position acquiring unit that acquires positions of workpieces on a basis of the workpieces captured by a first imaging unit; a three-dimensional information acquiring unit that acquires three-dimensional information of the workpieces of which positions are acquired, on a basis of the workpieces captured by a second imaging unit; a determination unit that determines whether another workpiece is hidden by an exposed workpiece among the workplaces, on a basis of the three-dimensional information of the workpieces; a take-out unit that takes out the exposed workpiece; a detection unit that, in a case in which it is determined that the other workpiece is hidden by the exposed workpiece, detects the other workpiece by causing the second imaging unit to image the other workpiece after the other workpiece is exposed; and a transmission unit, that transmits a detection result by the detection unit to outside of the detection unit for use in a take-out operation by a robot.