Robotic Arm Camera System with Integrated Illumination
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Solution Overview
Problem
Robotic arm systems in manufacturing often require specialized programming and intervention by robotics specialists for machine vision tasks, and they struggle with lighting variations that can lead to errors, especially when operating in environments with variable illumination.
Innovation Solution
A robotic arm camera system integrated at the end effector wrist module with a built-in light source and data connection, allowing for image correction based on the arm's pose, enabling end-users to teach the system to recognize objects under varying illumination conditions without specialist intervention.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a camera system is mounted to a robotic arm, then the system can observe the working space from multiple positions, but lighting variations cause machine vision errors
Solution Approach 1:
The patent combines the camera system with an integrated light source at the robotic arm end effector. This merging ensures that the camera and its illumination source move together as a single unit, maintaining consistent lighting conditions on the workpiece regardless of the arm's position. The light source is specifically positioned to illuminate the field of view while the camera captures images, eliminating lighting variations that would otherwise occur with arm movement.
Solution Approach 2:
The system incorporates feedback mechanisms where the camera captures images of the workpiece under the integrated light source, and the system processes these images to verify proper illumination and positioning. The feedback loop allows the system to detect and correct any lighting-related vision errors, ensuring reliable machine vision accuracy even as the robotic arm moves to different positions in the working space.
2Measurement precision
If a robotic specialist programs the machine vision system, then the system can perform precise object recognition, but the system complexity and programming time increase
Solution Approach 1:
The patent implements self-service capabilities where the robotic arm system automatically performs calibration and object recognition without requiring extensive programming by specialists. The integrated camera and light source system includes automated calibration routines that the system performs itself, and pre-configured object recognition algorithms that work out-of-the-box. This allows operators to simply load workpieces and the system handles the vision and recognition tasks autonomously.
Solution Approach 2:
The system utilizes parameter changes to simplify programming by automatically adjusting vision system parameters based on detected workpiece characteristics. The camera and light source parameters (such as exposure time, gain, and illumination intensity) are dynamically modified based on the workpiece material, color, and position, allowing the system to adapt to different objects without requiring manual reprogramming for each parameter adjustment.
3Area of stationary object
If the camera optics are positioned to view the end effector direction, then the system can monitor the work area, but the optics interfere with the robotic arm movement
Solution Approach 1:
The patent employs a nested configuration where the camera optics are positioned within recesses or cavities in the end effector structure. The optics are nested into the end effector body, allowing them to protrude only as much as necessary to capture the required field of view. This nesting approach protects the delicate optics from damage while maintaining adequate viewing angles, and allows the robotic arm to move freely without the optics interfering with the arm's range of motion or colliding with surrounding components.
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 automated object model calibration and recognition, allowing the robotic arm system to assist operators in tasks with improved image quality and reduced errors, even in environments with ambient lighting, by compensating for lighting variations and allowing end-users to configure the system independently.
Implementation Method 1
The camera can include an illumination source for providing light to a field of view
Implementation Method 2
The camera body can include an image sensor and optics extending sideways in the body
Data Source
AI summary
A robotic arm mounted camera system allows an end-user to begin using the camera for object recognition without involving a robotics specialist. Automated object model calibration is performed under conditions of variable robotic arm pose dependent feature recognition of an object. The user can then teach the system to perform tasks on the object using the calibrated model. The camera's body can have parallel top and bottom sides and adapted to be fastened to a robotic arm end and to an end effector with its image sensor and optics extending sideways in the body, and it can include an illumination source for lighting a field of view.