Vision-Guided Robot Assembly with In-Motion Part Detection
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Solution Overview
Problem
Conventional robot assembly systems are inflexible and costly due to reliance on precision tooling and part locating hardware, and the process of capturing and processing vision images for robotic guidance is time-consuming, limiting manufacturing efficiency.
Innovation Solution
A method and system that uses cameras to guide the movement of a robotic arm by capturing images while in motion, allowing for real-time determination of part position deviations and readiness for actions, thereby optimizing the manufacturing process and minimizing cycle time.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If precision tooling and part locating hardware are used to guide the robotic arm, then manufacturing precision is improved, but device complexity and cost increase
Solution Approach 1:
The patent replaces mechanical precision tooling and part locating hardware with a vision-based guidance system using cameras and image processing. The robotic arm is guided by capturing images of parts and calculating positions through software algorithms rather than physical fixtures, thereby reducing mechanical complexity while maintaining positioning accuracy.
Solution Approach 2:
The patent creates a digital copy of the part position and orientation through camera imaging and image processing. Instead of using physical locators to define part positions, the system captures optical information and processes it to determine precise part locations, replacing physical reference structures with their digital counterparts.
2Productivity
If vision images are captured and processed before robotic arm reaches target position, then productivity is improved, but measurement precision may deteriorate
Solution Approach 1:
The patent implements preliminary action by capturing vision images of parts before the robotic arm reaches the target position. The system processes these images in advance to calculate part positions and orientations, so that when the robotic arm arrives, the guidance information is already prepared. This overlapping of vision processing with robotic movement reduces idle time and accelerates the assembly cycle.
3Manufacturing precision
If rigid part locating hardware is used, then manufacturing precision is improved, but adaptability deteriorates
Solution Approach 1:
The patent implements universality by creating a vision-based guidance system that can adapt to different part types and assembly configurations through software programming rather than physical reconfiguration. The same camera and processing system can guide the robotic arm for various assembly tasks by simply changing the image processing algorithms and target identification parameters, eliminating the need for dedicated fixtures for each part type.
Data Source
AI summary
A method includes the following steps: actuating a robotic arm to perform an action at a start position; moving the robotic arm from the start position toward a first position; determining from a vision process method if a first part from the first position will be ready to be subjected to a first action by the robotic arm once the robotic arm reaches the first position; commencing the execution of the visual processing method for determining the position deviation of the second part from the second position and the readiness of the second part to be subjected to a second action by the robotic arm once the robotic arm reaches the second position; and performing a first action on the first part using the robotic arm with the position deviation of the first part from the first position predetermined by the vision process method.