Robot Program Generator for Vision-Based Teaching Point Correction
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Solution Overview
Problem
Existing robot systems struggle to accurately process workpieces due to manufacturing errors and shape errors, requiring extensive manual adjustments and potentially leading to tool interference, which increases man-hours and reduces processing precision.
Innovation Solution
A method and device for generating a processing robot program that uses a vision sensor to detect and correct the position and orientation of a tool relative to a workpiece by comparing a three-dimensional model with actual images, allowing for automatic adjustment of teaching points and avoiding tool interference.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If manual fine adjustment of robot position and orientation is performed to determine imaging position, then imaging accuracy is improved, but teaching operation time increases
Solution Approach 1:
The invention uses a three-dimensional model as a virtual copy of the workpiece to generate teaching points automatically. Instead of manually adjusting the robot to capture images and teach positions, the system creates a digital replica of the workpiece geometry and uses it to compute the robot's movement path and tool positions, eliminating time-consuming manual teaching while maintaining accuracy
Solution Approach 2:
The invention replaces the manual mechanical adjustment process with an automated computational system. The control device calculates teaching points by processing the three-dimensional model data and comparing it with actual workpiece images, substituting the mechanical jog operation with an automated image processing and coordinate calculation system
2Productivity
If robot tool position and orientation are not corrected for workpiece shape errors, then processing speed is maintained, but tool interference with workpiece occurs
Solution Approach 1:
The system captures actual images of the workpiece and compares them with the three-dimensional model to detect shape deviations. Based on this feedback, the control device automatically corrects the teaching points to compensate for manufacturing errors, allowing the robot to adapt to actual workpiece geometry without manual intervention while maintaining processing speed
Solution Approach 2:
The invention performs preliminary detection and correction of teaching points based on the three-dimensional model before actual processing begins. By pre-calculating the corrected positions and orientations that account for workpiece shape errors, the system prevents tool interference from occurring during the actual processing operation
3Measurement precision
If vision sensor is used to detect workpiece position and orientation, then positional error compensation is improved, but manufacturing error and shape error cannot be accommodated
Solution Approach 1:
The invention transitions from two-dimensional image-based detection to three-dimensional model-based detection. By using a three-dimensional model that captures the full geometry of the workpiece including shape variations, the system can accommodate manufacturing errors and shape errors in addition to positional errors, providing comprehensive error compensation
Data Source
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AI summary
A processing robot program generating device used in a robot system having a vision sensor, capable of accommodating an error in the shape of a workpiece and reducing man-hours required for a teaching operation. Image detection models are generated in a graphic image of a workpiece viewed from a virtual camera. A processing program including data of teaching points for processing segments of a processing line of the workpiece is generated. A detection program for actually imaging the workpiece is generated, and the position and orientation of each segment corresponding to each detection model generated are detected. A command line, for calculating an amount of change between the detection model and the actually captured image of the workpiece, is added to the processing program. Then, a correction program is inserted into the processing program, the correction program being capable of correcting the teaching point for processing each segment.