Molded Product Take-Out Teaching With Single-Camera Lateral Alignment
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Solution Overview
Problem
Conventional teaching methods for taking out molded products require multiple imaging devices and rely on operator skill to adjust the take-out head in the lateral direction, posing risks and increasing operation time due to the need for visual alignment, which is difficult and often results in contact between the die and the head.
Innovation Solution
A teaching method using a single imaging device positioned to capture images from above or obliquely above the die, with the imaging range center aligned with the attachment mounting portion's center, allowing for lateral adjustment by aligning with reference symmetric structures like tie bars, eliminating the need for direct downward imaging and reducing reliance on operator skill.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If a single imaging device is used to capture images from above or obliquely above the die, then the device complexity is reduced and operation time is shortened, but the measurement precision for lateral positioning becomes insufficient due to the difficulty of visual alignment in the depth direction
Solution Approach 1:
The patent transforms the lateral positioning problem from a direct visual alignment task in three-dimensional space to a two-dimensional image plane alignment task. By projecting the three-dimensional spatial relationship onto a two-dimensional display, the operator can accurately determine lateral position using only vertical and horizontal coordinates visible on the screen, eliminating the need for depth judgment.
Solution Approach 2:
The patent introduces an intermediary computational process that calculates the lateral position based on image coordinates and predetermined geometric relationships. This intermediary calculation layer translates the captured image data into accurate lateral positioning information, bridging the gap between simple top-down imaging and precise lateral measurement.
2Ease of operation
If the operator climbs on top of the molding apparatus to make alignment in the lateral direction through visual observation, then the lateral positioning can be performed, but the safety risk increases due to the fall hazard and the operation time is extended
Solution Approach 1:
The patent replaces the mechanical approach of physically climbing and manually aligning the take-out head with an automated image-processing and calculation system. The lateral positioning is achieved through computational methods based on image coordinates and geometric relationships, eliminating the need for operator intervention in hazardous positions.
Solution Approach 2:
The system performs self-positioning by automatically calculating the lateral position of the take-out head based on image data from the top-down camera. The apparatus determines its own alignment status without requiring external visual inspection or manual adjustment, improving both safety and efficiency.
3Measurement precision
If multiple imaging devices are used to capture images from multiple angles, then the measurement precision for lateral positioning is improved, but the device complexity and operation time increase
Solution Approach 1:
The patent extracts only the essential information needed for lateral positioning from the image data. By using a single top-down camera and calculating lateral position based on the vertical projection of the take-out head center onto the die surface, the system obtains sufficient positioning information without requiring multiple cameras or complex multi-angle imaging.
Data Source
AI summary
An image display device displays an image such that a pair of reference symmetric structure portions, e.g. a pair of guide pins, are included in a captured image displayed on a display section, the pair of reference symmetric structure portions being located symmetrically with respect to a second virtual plane which extends in the opening direction and the vertical direction and includes a virtual center line of the molding apparatus which extends in the opening direction. A teaching execution section is used to determine the lateral position of an approach frame in the take-out operation by changing the position of the approach frame such that the center of an imaging range is located at a middle position between the pair of reference symmetric structure portions included in the captured image.