Workpiece Transport Height Calibration for Accurate Robot Loading
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Solution Overview
Problem
Existing workpiece transport systems face accuracy issues in detecting the actual loading height of workpieces due to mechanical factors such as sensor adjustment or frame deflection, leading to reduced detection and position accuracy of the workpiece holding robot.
Innovation Solution
A workpiece transport system and method that include a mounting pedestal and a workpiece holding robot equipped with a surface detection sensor. The system detects a height error of the workpiece holding portion based on specific height measurements and theoretical values, allowing for accurate detection of the actual loading height of the workpiece.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If a sensor is attached to the workpiece holding portion to detect actual loading height, then detection accuracy is improved, but mechanical factors such as sensor adjustment or frame deflection cause errors between theoretical and actual heights
Solution Approach 1:
The patent introduces a calibration board as an intermediary object with known height markings. Instead of directly trusting the sensor reading on the workpiece holding portion, the system uses the calibration board to mediate the measurement process. The camera captures the calibration board's known height, and this intermediate reference is used to calculate and correct the height error of the workpiece holding portion, thereby resolving the inconsistency caused by mechanical factors.
Solution Approach 2:
The patent replaces the direct mechanical sensor measurement with an optical measurement system. Instead of relying on the mechanical sensor attached to the workpiece holding portion (which is subject to mechanical errors), the system uses a camera to optically capture the calibration board and calculate heights. This substitution eliminates the direct dependence on mechanical sensor accuracy and frame stability.
2Ease of operation
If the workpiece holding robot uses mechanical theoretical values for height, then the system is simple to operate, but errors accumulate due to mechanical factors
Solution Approach 1:
The patent implements preliminary calibration by placing the calibration board in the work area before actual workpiece measurement. This preliminary action establishes a reference frame and calculates height errors in advance. The calibration board with known height markings is captured by the camera, and the system pre-calculates the height error of the workpiece holding portion based on this reference, ensuring accurate measurements for subsequent workpiece detection.
Data Source
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AI summary
A height error of a workpiece holding portion is detected based on a height from a mounting pedestal side floor surface, on which a mounting pedestal is mounted, to a connection point between the workpiece holding portion and an arm unit at a point in time at which contact with a detection target is detected by a surface detection sensor, a height from the mounting pedestal side floor surface to a surface of the detection target, and a theoretical value of a height of the workpiece holding portion, and an actual loading height of a workpiece mounted on the mounting pedestal is detected in consideration of the height error of the workpiece holding portion.