Robotic Feature Mapping via Projection Matrix
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Solution Overview
Problem
Modern manufacturing and repair processes require precise object inspection and manipulation, but current manual methods are labor-intensive, slow, and prone to human errors, necessitating the development of automated systems for robotic inspection and manipulation.
Innovation Solution
A robotic system that creates a projection matrix based on a 3D model of a workpiece and sensor data to map 2D sensor coordinates to 3D coordinates, generating control signals for robotic manipulators to perform tasks such as fluorescent penetrant inspection (FPI) with automated feature identification and tool path generation, optimizing tool positions and motions for efficient and accurate manipulation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If automated robotic systems are implemented for inspection and manipulation, then productivity and accuracy are improved, but device complexity increases
Solution Approach 1:
The system segments the complex task of robotic inspection into distinct functional modules: sensor data acquisition, projection matrix generation, feature detection, coordinate transformation, and tool path generation. Each module handles a specific aspect of the inspection process, making the overall system more manageable and maintainable while achieving high productivity
Solution Approach 2:
The projection matrix serves as an intermediary data structure that bridges sensor coordinates and 3D model coordinates. This intermediary enables seamless coordinate transformation between different reference frames, simplifying the integration between sensing and manipulation subsystems
2Manufacturing precision
If projection matrix mapping is used to transform sensor coordinates to 3D coordinates, then manufacturing precision is improved, but computational requirements increase
Solution Approach 1:
The projection matrix is generated in advance based on the 3D model and sensor configuration, before the actual inspection task begins. This preliminary computation establishes the coordinate transformation relationship, enabling fast real-time mapping during inspection without repeated complex calculations
Solution Approach 2:
The system creates a virtual 3D model with associated projection matrices that replicates the physical workpiece geometry. This digital copy enables coordinate transformations and feature mapping without requiring repeated physical measurements or complex real-time computations on the actual part
3Reliability
If automated feature detection and tool path generation are implemented, then human error is reduced, but system complexity increases
Solution Approach 1:
The system employs feedback mechanisms where sensor data from the robotic manipulator is continuously acquired, compared against the 3D model and feature locations, and used to adjust tool path execution. This closed-loop control ensures accurate feature manipulation while automating the inspection process
Solution Approach 2:
The system performs self-calibration and self-guidance by automatically generating tool paths based on detected feature coordinates. The robotic manipulator uses the projection matrix and feature locations to autonomously navigate to target positions and execute manipulation tasks without continuous human intervention
Data Source
AI summary
A system includes one or more processors configured to create a projection matrix based on a three-dimensional (3D) model of a part and sensor data associated with a workpiece in a workspace of a robotic manipulator. The projection matrix provides a mapping between sensor coordinates associated with the sensor data and 3D coordinates associated with the 3D model. The one or more processors are configured to identify a set of sensor coordinates from the sensor data corresponding to a feature indication associated with the workpiece, and to determine from the set of sensor coordinates a set of 3D coordinates using the projection matrix.