3D Time-of-Flight Sensor for Hinged Part Detection
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Solution Overview
Problem
Traditional single-point and 2-D imaging sensors are inefficient for determining the presence or absence of hinged parts in 3-D space, requiring multiple sensors, complex installations, and significant setup time, and fail to provide clear visualization of robot and vehicle positions relative to each other in 3-D space, leading to potential collisions and production downtime.
Innovation Solution
The use of 2.5-D hybrid sensors that project and detect near-infrared patterns to create 3-D graphics of user-defined detection regions, allowing for real-time visualization and automatic coloring of pass or fail conditions, enabling precise detection of hinged parts within defined 3-D spaces without requiring extensive setup or training.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If traditional single-point sensors or 2-D imaging sensors are used to detect hinged parts, then presence/absence detection can be achieved, but the system complexity increases and setup time extends significantly
Solution Approach 1:
The patent transitions from traditional 2-D imaging sensors to 3-D time-of-flight sensors that capture depth information. This dimensional upgrade allows the system to detect hinged parts in three-dimensional space, providing accurate presence/absence detection while reducing the number of sensors needed and simplifying system configuration.
Solution Approach 2:
The 3-D time-of-flight sensor serves multiple functions simultaneously: it detects presence/absence, determines spatial position, identifies orientation, and monitors movement of hinged parts. This multi-functionality replaces what would traditionally require multiple specialized sensors, reducing overall system complexity.
2Area of stationary object
If multiple sensors are deployed to monitor multiple hinged parts in 3-D space, then detection coverage improves, but installation and maintenance complexity increases
Solution Approach 1:
The patent merges multiple detection functions into a single 3-D time-of-flight sensor system. Instead of deploying multiple 2-D sensors or single-point sensors throughout the workspace, one 3-D sensor captures the entire volume, reducing installation complexity and maintenance requirements while maintaining comprehensive detection coverage.
Solution Approach 2:
By adding the depth dimension with 3-D time-of-flight sensing, the system achieves comprehensive volumetric detection coverage with a single sensor rather than requiring multiple 2-D sensors positioned throughout the space. This dimensional expansion eliminates the need for complex multi-sensor installations.
3Measurement precision
If 2-D image processing algorithms are used to infer hinged part positions, then presence detection is possible, but the system becomes sensitive to ambient light and shadows
Solution Approach 1:
The patent replaces optical 2-D image processing with 3-D time-of-flight measurement technology. Instead of analyzing 2-D images that are susceptible to lighting conditions, the system uses active 3-D sensing that measures the time for light to travel to and from objects, providing accurate depth information independent of ambient light and shadow conditions.
4Productivity
If traditional sensors are used without 3-D visualization, then basic detection functions are maintained, but it becomes difficult to visualize robot and vehicle positions relative to each other in 3-D space
Solution Approach 1:
The patent creates a real-time 3-D digital copy or representation of the physical workspace, including the vehicle body, hinged parts, and robot positions. This virtual 3-D model provides intuitive visualization of spatial relationships while the actual production operations continue uninterrupted, preserving productivity while eliminating information loss about 3-D positioning.
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 solution provides accurate and intuitive detection of hinged parts in 3-D space, reducing setup time and collisions by offering real-time visualization and automatic indication of pass or fail conditions, and is insensitive to ambient lighting, allowing for efficient operation in automation tasks.
Implementation Method 1
The sensor has a set of radiation sensing elements which detect reflected, projected radiation to obtain 3-D sensor data
Implementation Method 2
The use of 2.5-D hybrid sensors that project and detect near-infrared patterns to create 3-D graphics
Data Source
Figure 1~3A
Figure 3B
Figure 4A~4C
AI summary
A method and system for determining the presence or absence of a part of an assembly within at least one user-defined, 3-D detection region within a work cell are provided. The system includes a 3-D or depth sensor having a field of view at the work cell. The sensor has a set of radiation sensing elements which detect reflected, projected radiation to obtain 3-D sensor data. A processor processes the sensor data from the sensor to obtain a 3-D graphic of the at least one detection region. A display displays the 3-D graphic from a viewpoint to determine the presence or absence of the part within the detection region.