Workpiece Placement System Using 3D Shape Sensing

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Solution Overview

Problem

Existing workpiece placement systems struggle to accurately place workpieces in containment areas or on jigs when workpiece shape data is unknown or when the position or shape of the containment area or jig is unknown, leading to potential misplacement and a lack of flexibility in choosing the workpiece placement posture.

Innovation Solution

A workpiece placement system that includes a robot, a three-dimensional sensor for measuring the containment area or jig, a processor for determining the optimal placement position and posture based on the three-dimensional shape, and a robot controller for precise placement, along with user-selectable workpiece postures and placeable areas, ensuring accurate and flexible placement.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Manufacturing precision

If workpiece shape data is unknown or containment area shape is unknown, then the system cannot determine appropriate placement position and posture, but acquiring complete shape data increases measurement complexity and time

Engineering Contradiction:

Improveworkpiece placement precisionVSAvoidshape measurement complexity

Core Design Contradiction:

Manufacturing precisionVSDifficulty of detecting and measuring

Solution Approach 1:

The system performs partial measurement by only measuring the workpiece and containment area shapes that are necessary for placement determination, rather than complete exhaustive measurement. The sensor captures shape data selectively focusing on relevant geometric features needed for positioning and posturing decisions.

Inventive Principle:

Principle #16Partial or excessive action

Solution Approach 2:

The patent replaces traditional mechanical measurement methods with optical sensing. A sensor (likely camera-based) captures images to obtain workpiece and containment area shapes, substituting physical contact measurement with non-contact optical detection, thereby reducing measurement complexity and time.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

2Productivity

If the system uses fixed taught positions for placement, then placement speed is fast, but the system cannot adapt when workpiece shape data is unknown or containment area changes

Engineering Contradiction:

Improveplacement speedVSAvoidplacement adaptability

Core Design Contradiction:

ProductivityVSAdaptability or versatility

Solution Approach 1:

The system transitions from static fixed positions to dynamic adaptive positioning. The robot controller dynamically calculates placement positions and postures based on real-time shape data of workpieces and containment areas, allowing the system to adapt to varying geometries while maintaining efficient automated operation.

Inventive Principle:

Principle #15Dynamics

Solution Approach 2:

The system changes the parameters used for placement determination from pre-programmed fixed coordinates to calculated positions based on measured shape parameters. By using shape data from sensors to determine placement parameters, the system adapts to different workpiece and containment area geometries.

Inventive Principle:

Principle #35Parameter changes

3Ease of operation

If the robot places workpieces based on pre-taught positions, then the operation is simple and fast, but placement accuracy deteriorates when workpieces are displaced or containment area geometry is unknown

Engineering Contradiction:

Improveoperation simplicityVSAvoidplacement accuracy

Core Design Contradiction:

Ease of operationVSManufacturing precision

Solution Approach 1:

The system performs self-measurement and self-correction. The sensor automatically measures the actual shapes of workpieces and containment areas, and the robot controller automatically recalculates placement positions and postures based on measured data, eliminating the need for manual re-teaching when geometries change or workpieces are displaced.

Inventive Principle:

Principle #25Self-service

Solution Approach 2:

The system implements a feedback loop where shape measurement data from sensors is fed back to the robot controller, which then adjusts placement positions and postures accordingly. This closed-loop approach maintains placement accuracy by continuously adapting to actual workpiece and containment area geometries.

Inventive Principle:

Principle #23Feedback

Data Source

PatentUS10722992B2Workpiece placement system for placing workpiece in containment area or on jig

Publication Date: 2020.07.28 FANUC LTD

AI summary

A workpiece placement system includes a robot for placing a workpiece in a containment area or on a jig; a sensor for measuring a three-dimensional shape of the containment area or jig; a processor for performing a process to determine a workpiece placement position and a workpiece placement posture based on the three-dimensional shape; and a robot controller for controlling the robot based on the workpiece placement position and the workpiece placement posture. The processor obtains a workpiece shape of the workpiece to be placed; retrieves workpiece placement postures chosen by a user; calculates a vacant area of the containment area or jig based on the three-dimensional shape; calculates workpiece placeable areas that satisfy the workpiece shape and the workpiece placement posture in the vacant area; and determines the workpiece placement position and the workpiece placement posture suitable for placement of the workpiece in the workpiece placeable areas.