Robot Program Simulation With Virtual-Real Layout Correction
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Solution Overview
Problem
Applying a robot program from a virtual space to a real site often results in placement errors, requiring time-consuming and labor-intensive checks and calibrations to match the layouts of the virtual and real spaces, necessitating point-by-point corrections or three-point touchups.
Innovation Solution
A robot system with a simulation device that displays virtual models alongside real equipment, allowing for automatic correction of robot program placement and simulation-based checks, including a virtual model display unit, robot program teaching unit, real space virtual model display unit, and virtual model placement correction unit to align virtual and real equipment positions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a robot program is created in a virtual space and applied to a real site, then the programming efficiency is improved, but placement errors occur due to layout differences between virtual and real spaces
Solution Approach 1:
The patent creates virtual models that are exact copies of real equipment, allowing the robot program to be developed in the virtual space. These virtual models replicate the geometric information and layout of the actual equipment, enabling program creation without direct intervention at the real site while maintaining placement accuracy through subsequent correction processes.
Solution Approach 2:
The patent replaces manual point-by-point teaching and mechanical calibration processes with automated computer-based correction. The correction unit automatically adjusts placement positions by calculating differences between virtual and real space layouts, substituting time-consuming manual operations with computational algorithms.
2Manufacturing precision
If manual checking and calibration is performed to correct placement errors, then the placement accuracy is improved, but the time and labor required increase significantly
Solution Approach 1:
The correction unit operates autonomously to correct placement errors without requiring manual intervention. The system automatically acquires geometric information from both virtual and real spaces, calculates placement deviations, and adjusts the virtual model positions accordingly, enabling self-correction of layout mismatches.
Solution Approach 2:
The patent introduces a correction unit as an intermediary between the virtual model creation process and the final robot program application. This intermediary automatically reconciles differences between virtual and real spaces by calculating and applying placement corrections, eliminating the need for time-consuming manual calibration.
3Manufacturing precision
If point-by-point checking of teaching points is performed, then the placement accuracy is improved, but the complexity and effort of the process increase
Solution Approach 1:
The patent extracts the essential geometric information from both virtual and real spaces, separating it from the complex process of point-by-point checking. By acquiring only the necessary geometric data and using it to calculate overall placement deviations, the system simplifies the correction process while maintaining accuracy.
Solution Approach 2:
The patent replaces the complex manual process of checking each teaching point with an automated computational system. The correction unit uses geometric information to automatically calculate and apply placement corrections, substituting intricate manual procedures with straightforward algorithmic processing.
Data Source
AI summary
The invention provides a robot system that enables easy, efficient, and precise checking through simulation. The invention includes a virtual model display unit configured to place virtual models in a virtual space on a screen and display the virtual models simultaneously with real equipment; a robot program teaching unit configured to perform teaching of a robot program in the virtual space; a real space virtual model display unit configured to display the virtual models and teaching points of the robot program in a real space, based on a positional relationship in the virtual space; and a virtual model placement position correcting unit configured to correct placement positions of the virtual models to match the real equipment in the real space.