Stereo Imaging Control for Precision-Safe Workpiece Positioning
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Solution Overview
Problem
The measurement precision of vision sensors in machine control devices is low, leading to potential collisions between tools and workpieces, and existing technologies lack mechanisms to ensure safe operation by determining and improving measurement precision.
Innovation Solution
A machine control device that uses a stereo camera method to control the position and orientation of an imaging device, capturing multiple images at different positions to calculate and adjust the measurement distance and precision, ensuring the imaging device captures images at positions that meet predetermined precision requirements, thereby enhancing safety and precision.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If vision sensor is used for workpiece positioning without considering measurement precision, then positioning operation can be performed, but collision between tool and workpiece may occur causing damage
Solution Approach 1:
The system performs preliminary measurement precision evaluation before positioning operations by capturing images at multiple imaging positions and calculating measurement precision for each position. This preliminary assessment allows the system to determine safe operating parameters in advance, preventing collisions before they occur.
Solution Approach 2:
The system continuously evaluates measurement precision based on images captured at different imaging positions and provides feedback to adjust imaging parameters. This feedback mechanism ensures that positioning operations only proceed when measurement precision meets safety requirements, preventing tool-workpiece collisions.
2Measurement precision
If measurement distance is increased to improve measurement precision, then positioning accuracy improves, but imaging device must move closer to workpiece increasing complexity
Solution Approach 1:
Instead of adjusting only the measurement distance (one dimension), the system utilizes multiple imaging positions with different orientations and distances. By capturing images from multiple angles and positions, the system achieves high measurement precision without requiring the imaging device to move extremely close to the workpiece, thereby reducing mechanical complexity.
Solution Approach 2:
The system dynamically changes multiple parameters including imaging position, orientation, and distance to optimize measurement precision. By adjusting these parameters based on calculated precision requirements, the system achieves accurate positioning without fixing the imaging device at a single complex position.
3Measurement precision
If multiple images are captured at different imaging positions to improve measurement precision, then positioning accuracy improves, but imaging time and processing complexity increase
Solution Approach 1:
The system captures images at multiple imaging positions, but only processes the minimum necessary number of images required to achieve the predetermined measurement precision. By selectively using partial image data rather than processing all captured images, the system reduces processing time while maintaining measurement accuracy.
Solution Approach 2:
The system pre-calculates the measurement precision that can be achieved at each imaging position before full processing. This preliminary assessment allows the system to stop image capture and processing once the predetermined precision is achieved, avoiding unnecessary time consumption from capturing and processing excessive images.
4Device complexity
If imaging device position is fixed, then device complexity is reduced, but measurement precision cannot be optimized for different workpiece positions
Solution Approach 1:
The system implements dynamic imaging position selection where the imaging device can move to optimized positions based on workpiece characteristics and measurement requirements. This dynamic capability allows the system to maintain simple overall device structure while achieving high measurement precision when needed by selectively activating movement to specific imaging positions.
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
The solution improves measurement precision and ensures safe operation by determining and adjusting the imaging device's position to meet specified precision standards, reducing the risk of tool-workpiece collisions and enhancing the reliability of vision sensors in machine control systems.
Implementation Method 1
a measurement distance restoring unit (for example, a measurement distance restoring unit 14) that restores a measurement distance of the object as positional information of the object based on at least two images among the two or more images, distance information between at least two imaging positions corresponding to the at least two images among the two or more imaging positions, and a parameter of the imaging device by using a stereo camera method
Data Source
AI summary
A machine control device includes: an imaging control unit that controls the imaging device to capture two images at two different imaging positions; an imaging position information acquiring unit that acquires positional information of the two imaging positions; a measurement distance restoring unit that restores a measurement distance of the object based on two images, distance information between two imaging positions, and a parameter of the imaging device by using a stereo camera method; and a predetermined precision position calculating unit that calculates distance information between the two imaging positions at which the measurement precision of the object satisfies a predetermined precision based on the two images, the measurement distance of the object, and the parameter of the imaging device, in which the machine control device controls the position and orientation of the imaging device based on the distance information between the two imaging positions, and changes two imaging positions.