Vision-Based Calibration for Automatic Pick-and-Place Systems
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Solution Overview
Problem
Conventional automatic insertion machines require a manual teach-and-learn procedure that is imprecise, unstable, and time-consuming, increasing production costs due to operator dependence.
Innovation Solution
An automatic pick-and-place system with a feeding device, visual pattern, and processing unit, where a visual module captures an image of the visual pattern to calculate the coordinate value of electronic components, enabling precise and rapid calibration of the manipulator for accurate component placement.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If manual teach-and-learn procedure is used for calibration, then the system can be set up and operated, but the calibration precision is imprecise and unstable due to operator dependence
Solution Approach 1:
The patent replaces the manual mechanical teach-and-learn procedure with an automated vision-based system. The vision module captures images of the visual pattern on the fixed part, and the processing unit automatically calculates coordinate values to determine the position of electronic components, eliminating operator-dependent mechanical positioning methods.
Solution Approach 2:
The patent introduces a visual pattern as an intermediary element between the fixed part and the vision module. This visual pattern includes reference features that serve as mediators to establish the coordinate system, enabling automatic and precise calibration without direct manual intervention.
2Productivity
If manual teach-and-learn procedure is used, then the system can be calibrated, but the process is time-consuming and increases production cost
Solution Approach 1:
The patent replaces time-consuming manual teaching operations with automated image capture and processing. The vision module automatically captures images of the visual pattern, and the processing unit computes coordinate values, significantly reducing calibration time and increasing productivity.
Solution Approach 2:
The patent implements preliminary action by pre-configuring the visual pattern with reference features on the fixed part before calibration. This pre-prepared visual pattern enables the vision module to immediately capture and process images for automatic calibration, eliminating the need for time-consuming manual setup during calibration.
3Manufacturing precision
If manual teach-and-learn procedure is used, then the robot can be trained to pick and place, but the precision is greatly influenced by operator's experience and technical competence
Solution Approach 1:
The patent replaces operator skill-dependent manual teaching with an automated vision-based positioning system. The vision module captures images of the visual pattern, and the processing unit automatically calculates precise coordinate values, eliminating the influence of operator experience and technical competence on placement precision.
Solution Approach 2:
The patent implements self-service by enabling the system to automatically calibrate and determine component positions without requiring skilled operators. The vision module and processing unit work autonomously to capture images, calculate coordinates, and guide the manipulator, making the system independent of operator expertise.
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
The system achieves precise and stable calibration, reducing production time and costs by eliminating operator-dependent inaccuracies, thereby enhancing the efficiency and yield of the production process.
Implementation Method 1
The visual module captures an image of the visual pattern on the fixed part and transmits the image to the processing unit
Data Source
AI summary
An automatic pick-and-place system is provided, including a feeding device, a visual pattern formed on a fixed part of the feeding device, a manipulator, and a processing unit. An electronic component can be held between the fixed part and a gripping part of the feeding device. A visual module on the manipulator captures an image of the visual pattern, and the processing unit calculates the coordinate value of the electronic component. Thus, the manipulator can move to the target position and pick up the electronic element according to the coordinate value.