Tool Position Deviation Imaging for Precise Workpiece Alignment
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Solution Overview
Problem
Existing techniques for acquiring the deviation amount of a tool's working position relative to a target position on a workpiece lack the necessary accuracy for precise alignment during operations like spot-welding, leading to potential misalignment and inefficiencies.
Innovation Solution
A system comprising a camera positioned in a predetermined relationship with the tool, which images the target position and calculates the deviation amount between the working and target positions based on image data, allowing for accurate alignment without manual operator intervention.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If a camera is used to image the target position and calculate deviation automatically, then measurement precision and productivity are improved, but device complexity increases
Solution Approach 1:
A camera is introduced as an intermediary device to capture images of the workpiece and tool positions. The camera serves as a mediator between the physical workspace and the control system, providing visual data that is processed to calculate deviation amounts. This intermediary approach enables automatic, high-precision measurement without requiring complex manual measurement mechanisms.
Solution Approach 2:
The patent replaces manual measurement methods with an optical imaging system. Instead of using mechanical measurement tools or operator judgment, the system uses a camera to capture images and automatically calculates deviation amounts through image processing. This substitution of mechanical/manual processes with optical and computational methods improves precision while maintaining manageable system complexity.
2Productivity
If manual measurement of deviation amounts is performed, then device complexity is reduced, but measurement precision and productivity deteriorate
Solution Approach 1:
The system performs self-measurement by automatically capturing images of the workpiece and tool positions, processing the image data, and calculating deviation amounts without operator intervention. The control device autonomously completes the entire measurement and calculation process, eliminating the need for manual measurement operations and significantly improving work efficiency.
Solution Approach 2:
Manual measurement operations are replaced with an automated optical imaging and image processing system. The camera captures images and the control device processes them to determine deviation amounts, substituting human operators and manual measurement tools with an automated computational system that delivers both higher productivity and precision.
3Measurement precision
If the camera is positioned close to the tool for accurate imaging, then measurement precision is improved, but the camera may interfere with the tool operation
Solution Approach 1:
The camera is positioned in the vertical dimension above the workpiece, rather than horizontally alongside the tool. This vertical positioning allows the camera to capture images of the target position and tool from above without interfering with the horizontal movement and operation of the tool. The dimensional separation resolves the conflict between achieving accurate imaging and avoiding interference with tool operations.
Data Source
AI summary
A device capable of acquiring a deviation of a working position of a tool with respect to a target position of a workpiece with higher accuracy in accordance with actual work. A device for acquiring a deviation amount of a working position of a tool with respect to a target position when a work is performed on a workpiece with respect to the target position by the tool, the tool being moved by a movement machine, the device including: a camera arranged in a predetermined positional relationship with respect to the tool and configured to image the target position at a first time point when the tool performs an operation for the work; and a deviation amount acquisition section configured to acquire a deviation amount between the working position and the target position at the first time point, based on a position of the target position in image data imaged by the camera and information indicating a position of the working position in the image data.