Vision-Based Jig Inspection for Sensorless Clamp State Detection
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Solution Overview
Problem
Conventional image-based jig inspection systems for vehicle body factories face challenges with increased sensor and wiring costs, space constraints, equipment interference, and cable damage due to the complexity of sensor installations and wiring in jigs with multiple clamping units, which affects the accuracy and reliability of state monitoring.
Innovation Solution
An image-based jig inspection system utilizing a camera module and vision system to determine the state of clamping units without sensors, using image analysis to identify and compare the state of clamping units based on predetermined reference templates, reducing the need for physical sensors and cables by using a camera to photograph and process images to determine the forward and backward moving states of clamping units.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If the number of sensors is increased to accurately detect the state of each clamping unit, then the measurement precision is improved, but the device complexity and installation space requirements increase
Solution Approach 1:
The patent uses image copying by capturing visual images of clamping units and comparing them with reference images to determine state information. Instead of installing physical sensors at each clamping unit, the system creates optical copies (images) of the clamping units and processes these copies to extract state information, thereby eliminating the need for numerous physical sensors while maintaining detection accuracy
Solution Approach 2:
The patent replaces the mechanical sensor-based detection system with an optical image-based detection system. The conventional approach using physical sensors and cables is substituted with a camera module that captures images and a vision system that processes these images to determine clamping unit states, eliminating mechanical contact and complex wiring
2Measurement precision
If the number of sensors and cables is increased to monitor more clamping units, then the measurement precision is improved, but the area of stationary object increases
Solution Approach 1:
The system uses image copying to represent the physical state of clamping units. Instead of requiring separate sensor inputs for each clamping unit on the PLC card, the system processes optical copies (images) of all clamping units simultaneously, dramatically reducing the number of I/O points required on the PLC card from dozens to just a few
Solution Approach 2:
The patent merges the detection function of multiple individual sensors into a single integrated vision system. The camera module and vision processing system combine to perform what would otherwise require multiple separate sensors, consolidating the detection capability into one system that occupies minimal PLC card space
3Measurement precision
If more cables and connectors are installed to connect sensors to the main control center, then the measurement precision is improved, but the reliability deteriorates due to cable damage and contact failure
Solution Approach 1:
The patent replaces the mechanical cable and connector system with an optical system. The camera module captures images wirelessly or through minimal data connections, eliminating the need for numerous sensor cables that are exposed to welding spatter and physical damage. The optical path is not susceptible to the same environmental damages as electrical cables in welding environments
Solution Approach 2:
By using image copying instead of physical sensor connections, the system eliminates the need for extensive cable wiring. The state information is obtained through optical copies rather than electrical signals transmitted through vulnerable cables and connectors, thereby removing the reliability issues associated with cable damage and contact failure
Data Source
AI summary
An image-based jig inspection system for inspecting a state of a sensorless jig managed in a vehicle body factory includes: a jig configured to fix a vehicle body component mounted by a plurality of clamping units; a camera module configured to photograph an inspection image of the jig; a vision system configured to compare the inspection image with a predetermined image analysis reference to determine a forward moving state or a backward moving state of a respective one of the clamping units; a welding robot configured to weld the component; and a main controller configured to control the welding robot according to a predetermined process based on the state information of the respective one of the clamping units.