Visual Probe Insertion Calibration for Axial Alignment Accuracy

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Solution Overview

Problem

Existing metallurgical technology probe insertion methods lack axial positioning and initial pose calibration, leading to increased failure rates and reduced quality due to angular deviations and deformation issues, especially when using robots or mechanical mechanisms.

Innovation Solution

A visual measurement-based insertion calibration method and system that uses a vision sensor to adjust the cylindrical rod's position and orientation relative to the metallurgical technology probe, ensuring accurate alignment and compensating for deformation, employing a standard probe for pre-calibration and real-time contour measurement.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Measurement precision

If a mechanical centering device is used for insertion, then point positioning is achieved, but axial positioning function is lacking leading to angular deviation

Engineering Contradiction:

Improvepoint positioning accuracyVSAvoidaxial positioning accuracy

Core Design Contradiction:

Measurement precisionVSManufacturing precision

Solution Approach 1:

The patent replaces mechanical centering devices with a vision-based measurement system. A camera captures images of the probe and cylindrical rod, and a computer calculates their relative position and orientation, eliminating the need for mechanical axial positioning structures.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The patent introduces a vision sensor as an intermediary between the mechanical insertion system and the control system. The vision sensor captures visual information about the probe and rod, which is then processed by a computer to determine precise positioning without direct mechanical contact.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Manufacturing precision

If mechanical positioning structures are added for axial positioning, then axial positioning is achieved, but strong action forces are generated reducing smooth insertion

Engineering Contradiction:

Improveaxial positioning accuracyVSAvoidinsertion force

Core Design Contradiction:

Manufacturing precisionVSForce

Solution Approach 1:

The patent replaces mechanical positioning structures with a vision-based measurement and calculation system. The computer calculates the relative position and orientation from captured images, eliminating the need for mechanical structures that generate strong action forces during insertion.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The system uses the existing visual information from the camera to automatically calculate positioning, eliminating the need for additional mechanical positioning structures that would generate harmful forces during the insertion process.

Inventive Principle:

Principle #25Self-service

3Measurement precision

If visual hole searching is used to adjust robot pose, then initial pose calibration is improved, but deformation of the elongated shaft cannot be compensated

Engineering Contradiction:

Improveinitial pose calibration accuracyVSAvoidinsertion reliability under deformation

Core Design Contradiction:

Measurement precisionVSReliability

Solution Approach 1:

The patent performs continuous measurement of the relative position and orientation between the probe and cylindrical rod during the insertion process, not just initial calibration. This allows real-time detection and compensation of deformation, maintaining insertion reliability throughout the entire process.

Inventive Principle:

Principle #20Continuity of useful action

Solution Approach 2:

The system uses vision measurement to continuously monitor the relative position and orientation, providing feedback that allows for real-time compensation of deformation. The computer calculates adjustments based on the measured deviations, ensuring successful insertion even when deformation occurs.

Inventive Principle:

Principle #23Feedback

4Reliability

If force sensors and visual sensors are used together, then complex control algorithms are required, reducing insertion speed and success rate

Engineering Contradiction:

Improveinsertion reliabilityVSAvoidinsertion speed

Core Design Contradiction:

ReliabilityVSProductivity

Solution Approach 1:

The patent extracts and removes the force sensor from the system, relying solely on vision-based measurement. This simplifies the control algorithm by eliminating the need to process force feedback data, thereby increasing insertion speed while maintaining reliability through accurate visual positioning.

Inventive Principle:

Principle #2Taking out (Extraction)

Data Source

PatentUS11813707B2Metallurgical technology probe insertion calibration method employing visual measurement and insertion system thereof

Publication Date: 2023.11.14 BAOSHAN IRON & STEEL CO LTD

AI summary

A metallurgical technology probe insertion calibration method employing visual measurement and an insertion system thereof are provided. A vision sensor (5), a cylindrical rod (1), and a metallurgical technology probe (2) are used to construct an agreed region (6). In the agreed region (6), the vision sensor (5) acquires relative positions and orientations of the cylindrical rod (1) and the metallurgical technology probe (2), and an acquired position and orientation result is used to control a driving device (3) to insert the cylindrical rod (1) into the metallurgical technology probe (2). To improve the accuracy and reliability of the insertion, a standard probe (7) and a fixing device (4) are used together to perform effective calibration on an initial position, orientation, and axis in the insertion.