Vision-Based Tool Tip Localization for Precise Robotic Assembly
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Solution Overview
Problem
Existing robotic systems face challenges in accurately localizing tool tips, which can lead to misalignment and potential damage during assembly processes due to the limitations of manual teach-point methods, such as the '3 point teach' approach, which is laborious and time-consuming.
Innovation Solution
A vision-based tool localization system using cameras and sensors to capture images from multiple vantage points, combining user input, 2D and 3D overlays, and space carving to accurately determine the tool contact area and center point, enabling precise robotic arm control without manual intervention.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If manual teach-point methods (e.g., '3 point teach') are used for tool localization, then the system is simple to operate, but the localization accuracy is limited by user ability and the process is laborious and time-consuming
Solution Approach 1:
The patent replaces manual mechanical positioning with an automated vision-based system. Cameras capture images of the tool from multiple vantage points, and image processing algorithms automatically determine tool contact areas and center points, eliminating the need for manual teach-point methods while achieving sub-millimeter accuracy
Solution Approach 2:
The patent creates visual copies (images) of the tool from multiple perspectives and uses these copies to determine tool localization. By processing multiple image copies and identifying consistent contact areas across views, the system achieves accurate tool positioning without physical manual measurement
2Productivity
If manual teach-point methods are used, then the device complexity is low, but the productivity is reduced due to laborious operation
Solution Approach 1:
The patent segments the tool localization problem into multiple independent image captures from different vantage points. Each image is processed separately to identify tool contact areas, and the results are combined to determine the final tool center point, enabling parallel processing and improved efficiency
Solution Approach 2:
The patent introduces image processing algorithms as intermediaries between the physical tool and the robotic system. These algorithms automatically extract tool contact areas from images and calculate tool center points, serving as a mediator that translates visual information into actionable positioning data without manual intervention
3Reliability
If manual teach-point methods are used, then the system requires minimal equipment, but the reliability is compromised due to potential damage from misalignment
Solution Approach 1:
The patent transitions from 2D manual positioning to 3D vision-based localization by capturing images from multiple vantage points. This dimensional approach allows the system to accurately determine tool contact areas and center points in three-dimensional space, ensuring precise alignment and preventing assembly damage
Solution Approach 2:
The patent implements a feedback mechanism where the vision system continuously captures images, processes them to determine tool contact areas, and uses this information to accurately position the tool. This closed-loop feedback ensures reliable localization by constantly verifying and adjusting tool position based on visual feedback
Data Source
AI summary
A method for vision-based tool localization (VTL) in a robotic assembly system including one or more calibrated cameras, the method comprising capturing a plurality of images of the tool contact area from a plurality of different vantage points, determining an estimated position of the tool contact area based on an image, and refining the estimated position based on another image from another vantage point. The method further comprises providing the refined position to the robotic assembly system to enable accurate control of the tool by the robotic assembly system.