Robot Operation Simulation Using Camera-Visible 3D Setting Points
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Solution Overview
Problem
Simulation devices for robot operations face inaccuracies due to the inclusion of workpiece portions not visible from cameras, leading to discrepancies between simulated and actual robot operations, resulting in potential failure in tasks like workpiece transportation.
Innovation Solution
A simulation device utilizing three-dimensional information from two two-dimensional cameras to generate robot and workpiece models, excluding invisible setting points and calculating accurate positions and orientations, thereby improving simulation accuracy by mimicking actual camera visibility and sensor data.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the simulation device calculates three-dimensional information for all portions of the workpiece including those not visible from the camera, then the simulation can be implemented for the entire workpiece, but the simulation accuracy deteriorates because the distance image differs from the actual robot device
Solution Approach 1:
The patent extracts and excludes setting points that are not visible from the camera from the simulation calculations. The exclusion unit removes invisible setting points from the set of all setting points, ensuring that only visible portions of the workpiece are used for simulation. This resolves the contradiction by taking out the problematic invisible portions while maintaining simulation implementation for visible areas.
Solution Approach 2:
The patent changes the parameter set used for simulation by dynamically selecting only visible setting points based on camera visibility. The system determines visibility status for each setting point and adjusts the calculation parameters accordingly, using only those points that are actually observable by the camera, thus aligning simulation parameters with real-world sensing capabilities.
2Productivity
If the simulation device uses all setting points on the workpiece surface, then the simulation can be completed, but the operation program may be incorrect because invisible portions are included
Solution Approach 1:
The exclusion unit extracts and removes invisible setting points from the simulation dataset, ensuring that only visible setting points are used for calculating workpiece position and orientation. This prevents the inclusion of erroneous data from invisible portions while maintaining simulation completion for visible areas.
Solution Approach 2:
The system implements a feedback mechanism where the visibility status of each setting point is determined and used to adjust the simulation calculations. The exclusion unit provides feedback by identifying which setting points should be excluded, and this information is fed back into the simulation process to ensure accurate position and orientation calculations based only on visible data.
3Ease of operation
If the simulation includes invisible workpiece portions, then the simulation runs smoothly, but the robot device may fail to detect the workpiece position in actual operation
Solution Approach 1:
The patent removes invisible setting points from the simulation dataset, ensuring that the simulation only processes workpiece portions that are actually visible to the camera. This extraction of invisible data points resolves the contradiction by eliminating the source of discrepancy between simulation and actual robot operation.
Solution Approach 2:
The system performs preliminary visibility assessment of all setting points before executing the simulation. The exclusion unit pre-identifies and excludes invisible setting points, so that the subsequent simulation execution only uses valid visible data. This preliminary action prevents detection failures by ensuring data consistency between simulation and actual operation from the outset.
Data Source
AI summary
A simulation device simulates a robot device including two two-dimensional cameras. The simulation device includes a setting point arrangement unit which arranges a plurality of setting points on a surface of a workpiece model, and a distance calculation unit which calculates distances from a three-dimensional sensor model to each of the setting points. The simulation device includes a three-dimensional information generating unit which generates three-dimensional information including positions of the setting points and distances from the three-dimensional sensor model to the setting points. The simulation device includes an exclusion unit which excludes the setting point that is not visible from the camera models. The simulation device changes a position and orientation of a robot model on the basis of the three-dimensional information.