Vision-Based Robot Teaching for Welding Path Calibration
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Solution Overview
Problem
Existing robot teaching systems require skilled operators to generate precise teaching data, which is time-consuming and dependent on operator skills, especially for accurate robot operations like welding.
Innovation Solution
A robot teaching system that uses a camera to photograph an image including a welding target and a marker installed on an industrial robot, allowing the system to set a camera coordinate system, determine an operation path for the robot, and generate a working program that converts the path from the camera coordinate system to the robot's coordinate system.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If a skilled operator manually operates the robot using a teaching pendant to generate teaching data, then the precision of robot operation is improved, but the time required for teaching increases significantly
Solution Approach 1:
The patent replaces the manual mechanical operation method (teaching pendant) with an automated vision-based system. A camera captures images of the workpiece and marker, and image processing automatically determines the robot's position and orientation, eliminating the need for manual operator intervention while maintaining high precision.
Solution Approach 2:
The patent uses a camera to create an optical copy (image) of the physical workspace including the workpiece and marker. This visual information is then processed to determine robot position and orientation, replacing the need for physical manual teaching operations.
2Extent of automation
If multiple reference markers and a robot coordinate system specifying marker are installed to recognize robot position using an AR device, then the automation of robot teaching is improved, but the device complexity increases
Solution Approach 1:
The patent extracts the marker recognition function from the complex multi-marker AR-based system and implements it using a single marker with a camera. This simplifies the system by removing the need for multiple reference markers while maintaining automated position recognition capabilities.
Solution Approach 2:
The single marker in the patent serves multiple functions: it establishes the camera coordinate system, enables position recognition, and facilitates coordinate system conversion. This multi-functional marker replaces the need for multiple specialized markers in traditional AR-based systems.
3Measurement precision
If the marker is installed on the workpiece near the welding target, then the accuracy of welding position detection is improved, but the ease of operation decreases due to installation constraints
Solution Approach 1:
Instead of installing the marker on the workpiece (traditional approach), the patent inverts the approach by installing the marker on the robot itself. This allows the marker to move with the robot, maintaining a constant relative position for accurate detection without constraining workpiece installation.
Data Source
AI summary
A robot teaching system includes: a photographing unit that photographs an image including a welding target and a marker installed on an industrial robot; a camera coordinate system setting unit that sets a camera coordinate system on a basis of the marker included in the image; an operation path setting unit that sets an operation path of the industrial robot on a basis of a welding position of the welding target included in the image in the camera coordinate system; and a program generation unit that generates a working program, while converting the set operation path from the camera coordinate system into a robot coordinate system set in a robot control apparatus on a basis of a position of the marker installed on the industrial robot. The robot teaching system generates a working program allowing appropriate welding at a welding position.