Machine Vision Positioning With Stereo Precision Evaluation
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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, as the existing systems do not adequately consider the precision when positioning based on image data from these sensors.
Innovation Solution
A machine control device that uses a stereo camera method to calculate and enhance measurement precision by adjusting the imaging positions and orientation of the vision sensor, determining if the precision meets predetermined standards, and adjusting the inter-viewpoint distance to achieve the required precision.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Speed
If vision sensor is used for positioning without considering measurement precision, then positioning speed is improved, but collision risk increases and safety deteriorates
Solution Approach 1:
The system performs preliminary measurement precision evaluation before positioning operations. The measurement precision evaluation unit assesses the vision sensor's measurement precision in advance, and the control unit uses this evaluation result to determine whether positioning can proceed safely, preventing collisions before they occur.
Solution Approach 2:
The system implements a feedback mechanism where measurement precision information is continuously evaluated and fed back to the control unit. The control unit adjusts positioning operations based on this feedback, modifying control parameters when precision is insufficient to maintain safe operation.
2Measurement precision
If measurement precision is improved by using higher precision sensors, then safety is improved, but device complexity and cost increase
Solution Approach 1:
The invention introduces a measurement precision evaluation unit as an intermediary component that works with the existing vision sensor. This unit calculates and evaluates measurement precision based on image data and sensor parameters without requiring replacement of the vision sensor itself, thus improving measurement capability while maintaining device simplicity.
Solution Approach 2:
The system improves measurement precision by changing control parameters and processing methods rather than hardware. The measurement precision evaluation unit analyzes image data with consideration of the vision sensor's characteristics, and the control unit adjusts positioning parameters based on evaluated precision levels, achieving improved measurement capability through parameter optimization.
3Reliability
If control parameters are adjusted based on measurement precision evaluation, then safety is improved, but processing time increases
Solution Approach 1:
The system applies partial evaluation action by focusing measurement precision assessment on critical areas and parameters. The measurement precision evaluation unit evaluates precision where it matters most for safety, and the control unit adjusts parameters selectively based on these partial evaluations, reducing overall processing time while maintaining safety.
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
This approach ensures safer operation by improving measurement precision, allowing the system to stop or adjust the control process when precision is insufficient, thereby preventing damage and enhancing the reliability of machining operations.
Implementation Method 1
an imaging device (for example, a vision sensor 2) to image the object (W)
Implementation Method 2
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 an imaging device to capture two images at two different imaging positions; an imaging position information acquiring unit that acquires positional information of two imaging positions; a measurement distance restoring unit that restores a measurement distance of an object based on two images, distance information between two imaging positions, and a parameter of the imaging device, by using a stereo camera method; a measurement precision calculating unit that calculates a measurement precision of the measurement distance of the object based on two images, the distance information between two imaging positions, and the parameter of the imaging device; an area specifying unit that specifies a partial area of the object as a specified area; and a measurement precision determining unit that determines whether the measurement precision of the object satisfies a predetermined precision in the specified area.