Toolpiece Positioning by Image Matching in Obscured Assembly
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Solution Overview
Problem
Current systems for accurately tracking the location of tools, especially in high-precision applications like assembly of helicopter gearboxes or car production, face challenges in achieving sub-centimeter accuracy and reliability due to signal interference and obscuration of bolts within structures.
Innovation Solution
A tool equipped with an imaging device that captures images of its environment and an image processor comparing these images with pre-stored reference images to determine its location, allowing for automatic adjustment of operating modes and torque settings based on precise positioning.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If satellite positioning systems are used to determine object location, then the system is simple and provides outdoor coverage, but the accuracy is limited to a few metres and fails indoors
Solution Approach 1:
The patent introduces acoustic transmitters and receivers as intermediary devices to enable location determination in environments where satellite signals are blocked. The acoustic signals serve as a mediator that can penetrate indoor environments and provide the necessary measurement data for position calculation.
Solution Approach 2:
The patent replaces electromagnetic satellite-based positioning with acoustic-based positioning. By substituting the electromagnetic wave propagation mechanism with acoustic wave propagation, the system overcomes the limitation of signal blockage in indoor environments.
2Measurement precision
If acoustic transmitters and receivers are used to improve location accuracy to tens of centimetres, then indoor positioning becomes feasible, but the accuracy is still insufficient for sub-centimetre applications
Solution Approach 1:
The patent combines multiple positioning techniques (acoustic time-of-flight measurement with visual image recognition) into a hybrid system. The acoustic system provides coarse positioning while the visual system refines the position to sub-centimetre accuracy, and the systems support each other to overcome individual limitations.
Solution Approach 2:
The patent adds a visual dimension to the acoustic positioning system. By incorporating image capture and processing capabilities, the system transitions from purely acoustic 3D positioning to a multi-sensory system that uses visual features for precise location determination and verification.
3Measurement precision
If multiple cameras are used to achieve visual tracking accuracy, then sub-centimetre precision can be achieved, but the system complexity increases and requires clear line of sight
Solution Approach 1:
The patent makes the imaging device serve multiple functions: it captures visual features for position determination, verifies toolpiece engagement with the workpiece, and provides feedback for process monitoring. This multi-functionality reduces the need for separate specialized sensors and simplifies the overall system.
Solution Approach 2:
The imaging device on the toolpiece carrier performs self-verification of its own position and engagement status. The system uses the captured images to automatically determine whether the toolpiece is correctly positioned on the target feature, eliminating the need for external verification systems.
4Manufacturing precision
If the toolpiece position is tracked with high accuracy to distinguish neighbouring bolts, then assembly precision is improved, but the system fails when bolts are obscured inside structures
Solution Approach 1:
The patent uses preliminary acoustic positioning to bring the toolpiece into the vicinity of the target feature before final visual engagement verification. This two-stage approach ensures the tool is positioned correctly even when the final target feature is initially obscured, as the acoustic system can operate without line-of-sight requirements.
Solution Approach 2:
The system continuously monitors the visual field for the presence of target features and provides feedback on engagement status. If a feature is detected as obscured or missing in the visual feed, the system can alert the operator or adjust the positioning strategy, ensuring assembly precision is maintained.
Data Source
AI summary
A system for determining the location of a toolpiece, wherein: the toolpiece is carried by a tool and the tool comprises an imaging device for capturing images of the environment around the tool; and the system comprises an image processor communicatively coupled to the imaging device for receiving images therefrom and having access to one or more reference images of an expected environment, the image processor being configured to compare an image captured by the imaging device with at least one reference image to identify a match therebetween and to determine in dependence on characteristics of that match the location of the toolpiece.