Robotic 2D-to-3D Coordinate Mapping for Precise Workpiece Inspection
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Solution Overview
Problem
Modern manufacturing and repair processes require precise and accurate object inspection and manipulation, but current manual methods are labor-intensive, slow, and limited by human capabilities, leading to a need for automated systems that can accurately inspect and manipulate workpieces with high precision.
Innovation Solution
A robotic system comprising a first sensor, a second sensor, at least one robotic manipulator, and a control system that uses 2D image data from the second sensor to map 3D coordinates based on a projection matrix, generating tool paths and control signals for the manipulator to perform tasks like fluorescent penetrant inspection with precision and efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If manual inspection and manipulation methods are used, then human inspectors can detect and manipulate surface defects, but the process becomes labor intensive and slow
Solution Approach 1:
The patent replaces manual mechanical inspection processes with an automated robotic system that uses sensors (optical, tactile, force) to detect surface defects. The robotic manipulator automatically applies penetrant, performs inspection, and manipulates defects based on sensor feedback, eliminating the need for human inspectors to manually examine workpieces.
Solution Approach 2:
The robotic system performs self-guided inspection and manipulation by using its own sensors to detect defects and automatically determine manipulation strategies. The system independently processes workpieces through the complete FPI workflow without human intervention, making the system self-sufficient in performing inspection tasks.
2Productivity
If automated robotic systems are implemented, then productivity increases, but system complexity increases
Solution Approach 1:
The robotic manipulator is designed to perform multiple functions within a single system: it applies penetrant, manipulates workpieces, and works in coordination with sensors for defect detection. This multi-functionality reduces the need for separate specialized equipment, thereby managing system complexity while maintaining high productivity.
Solution Approach 2:
The control system acts as an intermediary that coordinates between sensors, robotic manipulators, and processing functions. It integrates data from multiple sensor types and translates this into coordinated robotic actions, simplifying the overall system architecture by providing a centralized control layer that manages complexity.
3Manufacturing precision
If precise 3D mapping and tool path generation are used, then manipulation precision improves, but computational requirements increase
Solution Approach 1:
The system performs preliminary 3D mapping and tool path generation before actual manipulation occurs. By pre-calculating optimal tool paths based on detected defect locations and workpiece geometry, the system reduces real-time computational requirements during manipulation while maintaining high precision through预先 prepared accurate pathways.
Solution Approach 2:
The manipulation process is segmented into distinct phases: defect detection, 3D mapping, tool path generation, and execution. Each phase processes specific data independently, allowing computational tasks to be distributed and optimized separately, reducing overall computational burden while maintaining precision in each segment.
Data Source
AI summary
A system includes a first sensor having a fixed location relative to a workspace, a second sensor, at least one robotic manipulator coupled to a manipulation tool, and a control system in communication with the at least one robotic manipulator. The control system is configured to determine a location of a workpiece in the workspace based on first sensor data from the first sensor and a three-dimensional (3D) model corresponding to the workpiece. The control system is configured to map a set of 2D coordinates from a second 2D image from the second sensor to a set of 3D coordinates based on the location, and to generate one or more control signals for the at least one robotic manipulator based on the set of 3D coordinates.