3D Vision System for Robotic Teat Cup Attachment
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Solution Overview
Problem
Existing dairy milking systems face challenges in accurately positioning and maneuvering robotic arms due to the unpredictable movement of dairy livestock, such as cows, and the variability in teat positions, which leads to inefficiencies and inaccuracies in teat cup attachment and milk extraction processes.
Innovation Solution
A vision system incorporating a robotic arm, laser, and processor that uses 3D images and profile signals to detect and compensate for leg and teat movement, avoid the tail, and identify teat positions in real-time, allowing for precise teat cup attachment without hard coding specific movements or positions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If hard coded movements and positions are used for robotic arm operations, then device complexity is reduced, but manufacturing precision and reliability deteriorate due to unpredictable livestock movement and teat position variability
Solution Approach 1:
The system transitions from static hard-coded positions to dynamic real-time positioning. The robotic arm continuously adjusts its movements based on live feedback from the vision system that tracks teat positions and livestock movement, enabling precise attachment despite positional variability
Solution Approach 2:
The vision system provides continuous feedback on teat location and livestock movement. This feedback loop allows the control system to automatically compensate for position changes and maintain high attachment precision without requiring complex hard-coded movement sequences
2Measurement precision
If real-time vision tracking is implemented to compensate for movement, then positioning accuracy is improved, but device complexity and energy consumption increase
Solution Approach 1:
The vision system is divided into specialized components: a laser for generating profile signals, cameras for capturing images, and a processor for analyzing teat positions. This segmentation allows each component to be optimized for its specific function, reducing overall system complexity while maintaining high measurement precision
3Reliability
If multiple scans are performed to verify teat position, then positioning reliability is improved, but operation time increases
Solution Approach 1:
The system performs preliminary scans to establish expected teat positions before the robotic arm arrives. This advance preparation allows for faster final positioning and attachment, reducing the time penalty associated with multiple verification scans while maintaining high reliability
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 vision system enhances the accuracy and speed of robotic arm operations, enabling efficient teat cup attachment and milk extraction by adapting to the dynamic movements of dairy livestock, improving operational efficiency and reducing errors.
Implementation Method 1
The laser is coupled to the robotic arm and is configured to generate a plurality of profile signals, each profile signal comprising information associated with a relative distance between the laser and at least a portion of the dairy livestock
Data Source
AI summary
A leg (205) detection system comprising: a robotic arm (200) comprising a gripping portion (208) for holding a teat cup (203, 210) for attaching to a teat (1102, 1104, 1106, 1108, 203S, 203) of a dairy livestock (200, 202, 203); an imaging system coupled to the robotic arm (200) and configured to capture a first three-dimensional (3D) image (138, 2400, 2500) of a rearview of the dairy livestock (200, 202, 203) in a stall (402), the imaging system comprising a 3D camera (136, 138) or a laser (132), wherein each pixel of the first 3D image (138, 2400, 2500) is associated with a depth value; one or more memory (104) devices configured to store a reference (3D) 3D image (138, 2400, 2500) of the stall (402) without any dairy livestock (200, 202, 203); and a processor (102) communicatively coupled to the imaging system and the one or more memory (104) devices, the processor (102) configured to: access the first 3D image (138, 2400, 2500) and the reference (3D) 3D image (138, 2400, 2500); subtract the first 3D image (138, 2400, 2500) from the reference (3D) 3D image (138, 2400, 2500) to produce a second 3D image (138, 2400, 2500); perform morphological image (138, 2400, 2500) processing on the second 3D image (138, 2400, 2500) to produce a third 3D image (138, 2400, 2500); perform image (138, 2400, 2500) thresholding on the third 3D image (138, 2400, 2500) to produce a fourth 3D image (138, 2400, 2500); cluster (2616, 2618, 2626, 2628) data from the fourth 3D image (138, 2400, 2500); identify, using the clustered data from the fourth 3D image (138, 2400, 2500), one or more legs (205) of the dairy livestock (200, 202, 203); and provide instructions for movements of the robotic arm (200) to avoid the identified one or more legs (205) while attaching the teat cup (203, 210) to the teat (1102, 1104, 1106, 1108, 203S, 203) of the dairy livestock (200, 202, 203).