3D Robot Teaching Correction Using Base Distortion Reproduction
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Solution Overview
Problem
Existing 3D simulation techniques for teaching industrial robots fail to account for distortions in the real-world manufacturing environment, requiring repeated re-teaching on actual manufacturing lines, especially for operations like connector fitting and screwing.
Innovation Solution
A simulation system using a camera attached to an articulated robot captures images of landmarks on a base, analyzes marker distortions, and corrects teaching data in a 3D space to align with real-world conditions, adjusting torque and force applied by the robot to compensate for distortions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If 3D simulation technique is used for teaching industrial robot, then teaching efficiency is improved and preparation time is reduced, but teaching accuracy deteriorates due to base distortion not being reflected
Solution Approach 1:
The system performs preliminary capture of base distortion data using markers and cameras before robot teaching, then reproduces this distortion in the 3D simulation environment. This allows the simulation to pre-account for real-world base distortions, maintaining both high teaching efficiency and improved accuracy by eliminating the need for repeated re-teaching on actual manufacturing lines
Solution Approach 2:
The system changes the simulation parameters by introducing distortion correction factors derived from real base measurements. By adjusting position and posture parameters in the 3D simulation based on captured marker data, the system compensates for base distortions while maintaining simulation efficiency
2Manufacturing precision
If actual manufacturing line is activated for re-teaching, then teaching accuracy is improved, but time consumption and operational complexity increase
Solution Approach 1:
The system creates a distorted copy of the real base by capturing marker positions and reproducing the distortion pattern in the 3D simulation. This virtual copy allows accurate robot teaching to be performed in simulation without needing to repeatedly activate the actual manufacturing line for re-teaching
3Measurement precision
If markers are used for detecting object position, then position detection capability is improved, but system complexity increases
Solution Approach 1:
The marker system serves multiple functions: it detects base distortion, establishes coordinate systems, and enables distortion reproduction. This multi-functional use of simple markers achieves high measurement precision without requiring complex specialized equipment for each function
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
Enables accurate and efficient correction of teaching data to account for manufacturing line distortions, reducing the need for repeated re-teaching and improving operational precision.
Implementation Method 1
a camera (111) attached to an articulated robot (100), and a simulation device (200), wherein the camera (111) transmits an image of a landmark (150) arranged at a base (120) in a manufacturing line (10) in a real world to the simulation device (200)
Implementation Method 2
the simulation device (200) analyzes a plurality of markers evenly arranged on the landmark (150) in the image, estimates distortion of the base (120) based on a shape of each of the plurality of markers and arrangement intervals between the plurality of markers viewed from the camera (111)
Data Source
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AI summary
Teaching data created by three-dimensional (3D) simulation is corrected in accordance with distortion of a base or the like in a manufacturing line in a real space. A simulation system includes a camera (111) attached to an articulated robot (100) and a simulation device. The camera (111) transmits an image of a landmark (150) arranged at a base (120) in a manufacturing line (10) in a real world to the simulation device. The simulation device analyzes a plurality of markers evenly arranged on the landmark (150) in the image, estimates distortion of the base (120) based on a shape of each of the plurality of markers and arrangement intervals between the plurality of markers viewed from the camera (111), reproduces based on a result of estimation, distortion of the base (120) in the manufacturing line (10) reproduced in a 3D space, corrects teaching data in a process for working by the articulated robot on a workpiece (140) on the distorted base (120) in the 3D space, and gives as feedback, a result of correction of the teaching data to a control device for the articulated robot.