Workpiece Placement Identification Using Image Overlay Alignment
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Solution Overview
Problem
Existing techniques for identifying the placement of a workpiece in a machining chamber are time-consuming and prone to errors, particularly due to environmental fluctuations and the need for manual or lengthy calculations.
Innovation Solution
A placement identifying apparatus comprising a camera, a UI apparatus, and a controller that captures an image of the workpiece, preliminarily adjusts a reference image to match the workpiece's placement, and allows for fine adjustments by the user to accurately determine the workpiece's position and angle.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If pattern matching process is applied to captured image to calculate workpiece position, then position can be identified, but calculation time becomes very long
Solution Approach 1:
The patent divides the workpiece image into multiple regions of interest (ROIs) and processes each region independently to identify characteristic points. This segmentation reduces the computational burden compared to processing the entire image, thereby decreasing calculation time while maintaining position identification accuracy.
Solution Approach 2:
The patent extracts only the essential characteristic points and regions from the captured image that are necessary for position and angle calculation. By taking out only the relevant features rather than processing the complete image data, the system achieves fast calculation while preserving measurement precision.
2Measurement precision
If image analysis is used to calculate workpiece angle based on characteristic points, then angle can be determined, but errors occur due to external environment fluctuation
Solution Approach 1:
The patent performs preliminary adjustment of the reference image to align with the captured workpiece image before final angle calculation. This preliminary alignment compensates for environmental fluctuations and positioning errors, improving the reliability of subsequent angle measurements.
Solution Approach 2:
The system allows operators to visually verify the overlay of reference and captured images, and to manually adjust the reference image position and angle. This feedback mechanism enables correction of errors caused by environmental fluctuations, ensuring reliable angle calculation even under varying conditions.
3Measurement precision
If touch probe measurement is used to measure workpiece placement, then position can be measured, but measurement period becomes long
Solution Approach 1:
The patent replaces the mechanical touch probe measurement system with an optical image-based measurement system. The camera captures the workpiece image, and computer vision algorithms calculate position and angle, eliminating the time-consuming mechanical probing process while maintaining measurement precision.
Solution Approach 2:
The system creates a digital copy (image) of the workpiece and performs all measurements on this copy rather than physically contacting the workpiece with a probe. This copying approach enables rapid non-contact measurement, significantly reducing the measurement period while preserving accuracy.
Data Source
AI summary
A placement identifying apparatus includes: a camera that captures an image of a target; an UI apparatus; and a controller configured to identify a placement of a measurement target. The controller is configured to: store in advance a reference image representing a shape of a reference target; identify a provisional placement of the measurement target based on a position identifying image which is a captured image of the measurement target; preliminarily adjust a position and an angle of the reference image based on the provisional placement, and generate an overlap image which is an image in which the reference image is overlapped over the position identifying image; receive from a user command of fine adjustment for the position and the angle of the reference image; and identify a true placement of the measurement target based on the reference image after the fine adjustment.