Vision Sensor Imaging for Workpiece Detection
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing imaging systems for detecting workpieces in robot systems face challenges due to varying environmental light conditions, which can lead to reduced image contrast and halation, making it difficult to accurately detect the workpiece's features and position.
Innovation Solution
An imaging device that uses a vision sensor to capture multiple images of a workpiece from different positions, with an image processing unit converting these images into composite images, allowing for accurate detection and inspection by compensating for environmental light changes and halation effects.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If a vision sensor captures an image of a workpiece under environmental light, then the workpiece can be detected, but the image contrast reduces and halation occurs due to light intensity and direction changes
Solution Approach 1:
The system performs preliminary actions by capturing multiple images from different positions before final detection. The imaging device takes a plurality of first images at different relative positions, then converts them to second images assuming a standard detection position. This preliminary multi-position capture allows the system to later select or composite the best image quality, preventing the harmful effect of single-position light variation.
Solution Approach 2:
The system changes the parameter of imaging position by capturing images from multiple different relative positions between the vision sensor and workpiece. By varying this spatial parameter, the system can find positions where environmental light does not cause halation or contrast reduction, thus resolving the contradiction between detection accuracy and image quality.
2Reliability
If multiple images are captured from different positions to compensate for light variations, then image quality improves, but the complexity of the imaging system increases
Solution Approach 1:
The system replaces complex mechanical light control mechanisms with a computational approach. Instead of using movable mirrors, shutters, or complex illumination systems to control light, the patent uses image processing algorithms to convert multiple captured images into second images assuming a standard detection position. This substitution of mechanical complexity with computational simplicity resolves the contradiction between reliability and device complexity.
Solution Approach 2:
The image processing device performs multiple functions: it captures images, converts them to standard positions, composites them, and detects workpiece features. By making the imaging system multi-functional through software processing rather than requiring separate dedicated hardware for each function, the system achieves high reliability without proportionally increasing physical complexity.
3Loss of information
If the camera is positioned to capture workpiece features, then detection is possible, but environmental light causes brightness changes and feature loss
Solution Approach 1:
The system applies local quality by treating each captured image locally and converting it to what it would look like from the detection position. The image processing device converts each first image to a second image assuming the vision sensor is at the detection position, preserving local features while removing the harmful effect of position-dependent lighting. This allows feature visibility to be maintained regardless of where the actual capture position was.
Data Source
AI summary
An imaging device includes a camera, a robot that moves the camera, and a controller that processes an image. A detection surface defined on a workpiece and a set position serving as an imaginary position of the robot for detecting the workpiece are determined in advance. The camera captures a plurality of first images at a plurality of positions. The controller includes an image conversion unit converting the plurality of the first images into a plurality of second images when captured at the set position. The controller includes a composition unit generating a composite image into which the plurality of the second images are composited, and a composite image processing unit performing at least one of detection and inspection of the workpiece on the detection surface on the basis of the composite image.