Time Synchronized Camera for Part Tracking
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Solution Overview
Problem
Automated systems using web-based part transfer systems face challenges in precisely determining part locations due to web slippage, as existing photo sensor solutions are costly, time-consuming to install, and not suitable for all applications.
Innovation Solution
An Ethernet-based machine vision system synchronizes cameras and motion controllers using a master clock, allowing cameras to capture images at predetermined trigger times to calculate and transmit position differences, enabling adjustments to system operating characteristics.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If photo sensors are used to track part location throughout the region, then part location tracking precision is improved, but system cost increases due to the large number of photo sensors needed
Solution Approach 1:
The patent uses a camera to capture optical images of parts, creating a visual copy of the part location. This single camera can track multiple parts throughout the entire region simultaneously, replacing the need for numerous photo sensors. The image data is then processed to determine precise part locations, achieving high measurement precision with a single sensing device.
Solution Approach 2:
The patent transitions from one-dimensional photo sensor detection (point-based) to two-dimensional camera imaging (area-based). This dimensional change allows a single camera to monitor the entire region and track multiple parts simultaneously, dramatically reducing the number of sensors needed while maintaining or improving location tracking precision.
2Measurement precision
If photo sensors are positioned very close to the part path to sense part location, then measurement precision is improved, but installation complexity and time increase
Solution Approach 1:
The camera is positioned at a distance from the part path, utilizing the air space above the conveyor as an additional dimension for sensing. This eliminates the need to install sensors in close proximity to moving parts, significantly simplifying installation while maintaining measurement precision through optical imaging.
3Loss of information
If photo sensors are used to detect part presence, then part location feedback is obtained, but adaptability decreases when process modifications require changing part locations
Solution Approach 1:
The camera provides universal monitoring capability across the entire region, capturing images that contain information about all parts regardless of their specific locations. When process modifications require changing part locations, the same camera continues to function without repositioning, as it captures the whole area. The system adapts to new location requirements through software processing rather than physical reconfiguration.
4Loss of information
If photo sensors are used to locate parts, then position feedback is provided, but ease of operation decreases for difficult to locate products
Solution Approach 1:
The camera creates a complete visual copy of the entire region, capturing images of all parts simultaneously. This allows the system to locate any part regardless of its difficulty to detect, as long as it appears in the image. The part location is determined by analyzing the captured image data, making the detection process independent of part characteristics that might challenge photo sensors.
Data Source
AI summary
A method for use in a part tracking system including a camera and a motion controller, the method comprising the steps of time synchronizing the motion controller and the camera at a trigger time when it is anticipated that a part is within the field of view of the camera, causing the camera to obtain an image, using the obtained image to determine an actual location of the part at the trigger time, comparing the actual location and the anticipated location of the part to identify a position difference and at the motion controller, using the position difference at the trigger time to adjust at least one operating characteristic of the automated system.