Structured Light Camera Positioning for Micron-Scale Part Localization
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Solution Overview
Problem
Current industrial manufacturing processes lack a versatile, low-cost method for precise localization and positioning of mechanical components with micron to submicron accuracy, necessitating costly and specific instrumentation.
Innovation Solution
A multi-wavelength structured light camera system utilizing a wide-angle camera, two spatially separated cameras, and a light projector, combined with machine-learning for keypoint detection, to achieve high-precision localization and positioning by projecting structured light patterns, capturing images, and applying triangulation for accurate 3D positioning.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If extensive instrumentation is used to achieve high precision localization, then measurement precision is improved, but device complexity and cost increase
Solution Approach 1:
The system segments the localization task into multiple stages: first capturing a full image to identify regions of interest, then zooming in on specific regions for detailed measurement. This segmentation allows the system to achieve high precision only where needed rather than across the entire object, reducing overall system complexity while maintaining measurement precision.
Solution Approach 2:
The system transitions from 2D image capture to 3D surface profile estimation by combining images from multiple cameras at different spatial locations. This dimensional transition enables accurate localization in three-dimensional space using relatively simple camera equipment, avoiding the need for complex specialized instrumentation.
2Measurement precision
If tailored instrumentation is used for specific components, then measurement precision is improved, but adaptability decreases
Solution Approach 1:
The system employs a universal multi-camera setup that can handle arbitrary parts and components. By using standard cameras with zoom capabilities and processing multiple regions of interest sequentially, the system achieves high precision positioning for any component type without requiring component-specific instrumentation, thereby maintaining both accuracy and versatility.
Solution Approach 2:
The system dynamically adapts to different components by automatically identifying regions of interest and adjusting zoom levels based on the specific component being measured. This dynamic adjustment allows the same hardware system to achieve high precision for various component types and sizes, providing both accuracy and adaptability.
3Device complexity
If rough estimation systems are used, then device complexity is reduced, but measurement precision deteriorates
Solution Approach 1:
The system segments the measurement process into a coarse positioning stage (full image capture) and a fine measurement stage (zoomed region analysis). This segmentation allows the use of simple wide-angle cameras for initial positioning while achieving high precision through subsequent detailed analysis of specific regions, maintaining system simplicity while improving accuracy.
Solution Approach 2:
The system performs preliminary coarse positioning by capturing full images to identify regions of interest before conducting detailed measurements. This preliminary action enables the simple camera system to first locate the object broadly, then focus resources on achieving high precision for specific critical points, combining simplicity with accuracy.
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
Enables precise localization and positioning of mechanical components with micron to submicron accuracy, applicable to any object, reducing costs and enhancing automation efficiency.
Implementation Method 1
generate a first set of images and a second set of images of the identified region by the first camera and the second camera, respectively based on reflected probe light signals from the identified region
Data Source
AI summary
This disclosure provides a precision-positioning/quality control system capable of measuring the exact position of any given mechanical component/part of any size or shape used during an assembly process. In one aspect, a process for performing high-accuracy localization and positioning of a rigid object is disclosed. This process can begin by receiving a full image of the object. The full image is then processed by a deep-learning module to identify a set of regions of interest on the object. Next, the identified regions in the set of regions of interest are subsequently processed to identify a number of surface points within each identified region and accurately estimate their positions. After sequentially processing all the regions of interest, the process subsequently generates an accurate position estimation for the object based on the combined set of identified high-precision surface points for the set of regions of interest.