Virtual Axis Motion Control for Machine Vision Triggering
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Solution Overview
Problem
Machine vision systems face inaccuracies and reliability issues due to the use of encoders for position data, which can lead to inefficiencies and increased points of failure.
Innovation Solution
The system calculates object position using motion data from a motion controller, eliminating the need for a separate encoder by generating a virtual axis and image acquisition trigger signals based on this data, ensuring synchronized motion and image capture.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If an encoder is used to communicate object position to the vision system, then trigger signals can be generated at calculated times for image acquisition, but the system experiences inaccuracies, noise immunity issues, and reliability problems
Solution Approach 1:
The patent removes the encoder component from the system entirely. Instead of using an encoder to communicate object position, the vision system calculates position based on motion data from the motion controller, thereby eliminating the reliability issues associated with encoders while maintaining position measurement accuracy
Solution Approach 2:
The patent introduces a virtual axis as an intermediary concept that links the motion controller's motion data to the vision system's trigger signal generation. This virtual axis allows position calculation without requiring a physical encoder, serving as a software-based mediator that resolves the contradiction between measurement precision and reliability
2Productivity
If an encoder is used to provide position data to the imaging device, then image acquisition can be triggered at calculated times, but the system has increased points of failure and reduced efficiency
Solution Approach 1:
The encoder is extracted and removed from the system. The vision system directly receives motion data from the motion controller and calculates trigger times without the intermediary encoder, reducing device complexity and eliminating points of failure while maintaining or improving productivity
Solution Approach 2:
The patent merges the position data source directly from the motion controller to the vision system, eliminating the separate encoder component. This consolidation reduces the number of components and communication interfaces, thereby reducing device complexity and potential failure points while maintaining efficient image acquisition
Data Source
AI summary
Systems and methods trigger an image acquisition of an object using motion data communicated from a motion controller on a network, the motion controller coupled to a motion drive. Based upon motion data from the motion controller, a virtual axis application is used to plan the movement of a virtual axis for a motion cycle, the virtual axis allowing an acquisition trigger rate to be calculated to follow movement of the object caused by the motion drive. Based on the calculated acquisition trigger rate, an acquisition trigger signal is generated for triggering the image acquisition of the object.