Vision-Guided Robot Assembly for Jigless Component Welding
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Solution Overview
Problem
Existing component assembly methods in the industrial field rely on exclusive jigs, which fail to actively respond to molding tolerance, leading to welding defects and require costly jig re-manufacturing for new models, resulting in inefficient and costly assembly processes.
Innovation Solution
A robot system utilizing a virtual vision coordinate system recognized through a camera, which includes hanger robots and welding robots, automatically performs component restriction, location correction, assembly, and welding, eliminating the need for complex jigs by aligning robot and vision coordinate systems for precise control and assembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If exclusive jigs are used to fix components during assembly, then component positioning is stable, but the system cannot actively respond to molding tolerance variations and requires costly re-manufacturing for new models
Solution Approach 1:
The patent replaces the mechanical exclusive jig system with a vision-based coordinate recognition system. The camera captures images of components, and the vision controller calculates actual position coordinates to determine molding tolerance variations, enabling adaptive response without physical jigs.
Solution Approach 2:
The patent creates a virtual copy of the component positions through image capture and coordinate calculation. By recognizing the actual positions of components through the vision system, the system can detect and respond to molding tolerance variations without physical contact or fixed mechanical constraints.
2Manufacturing precision
If exclusive jigs are manufactured for each component model, then assembly precision is maintained, but manufacturing cost and facility investment increase continuously
Solution Approach 1:
The patent implements a universal vision-based assembly system that can handle multiple component models without requiring model-specific jigs. The same camera and control system are used across different models, eliminating the need for continuous jig re-manufacturing while maintaining assembly precision through adaptive coordinate recognition.
Solution Approach 2:
The patent replaces the mechanical jig manufacturing approach with a software-based vision recognition system. Instead of physically manufacturing new jigs for each model, the system uses image processing and coordinate calculation to adapt to different component specifications, significantly reducing manufacturing costs.
3Ease of operation
If operators manually fix components on fixed jigs, then assembly process is simple, but productivity is low and welding defects occur due to inability to respond to tolerance variations
Solution Approach 1:
The patent enables the assembly system to automatically detect and compensate for position variations through the vision system. The robot controller receives actual position coordinates from the vision controller and automatically adjusts the welding path, eliminating the need for manual intervention while improving both productivity and defect prevention.
Solution Approach 2:
The patent implements a feedback loop where the vision system continuously monitors component positions, calculates actual coordinates, and provides this information to the robot controller. The robot controller then adjusts the welding operations based on this feedback, enabling automatic response to tolerance variations and improving both productivity and quality.
4Device complexity
If robot welding is performed along a set route without coordinate correction, then welding process is simple, but welding defects occur due to molding tolerance and position variations
Solution Approach 1:
The patent implements a feedback mechanism where the vision system provides actual position coordinates to the robot controller, which then corrects the welding path in real-time. This feedback loop maintains welding quality by compensating for position variations without significantly increasing operational complexity.
Solution Approach 2:
The patent dynamically changes the welding path parameters based on actual component positions detected by the vision system. The robot controller calculates corrected coordinates and adjusts welding parameters accordingly, maintaining welding quality while adapting to molding tolerance variations through parameter modification rather than complex mechanical adjustments.
Data Source
AI summary
Disclosed are a robot system for assembling components and a control method thereof. The control method compares location coordinates of a robot in a vision coordinate system with location coordinates in a robot coordinate system and calculates a first correction value, calculates a second correction value from a difference between location coordinates of a correction tool and a component, and calculates a third correction value from location coordinates of components located at predetermined spaced locations and spacing coordinates, thereby precisely assembling components and performing inspection of the assembling.