Workpiece Posture Alignment Using Reference Image Lines
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Solution Overview
Problem
Existing workpiece installation methods, such as those described in JP2011180B, face challenges with accuracy and efficiency when dealing with workpieces having uneven surfaces or large sizes, leading to potential attachment errors due to discrepancies between estimated and actual postures, particularly when multiple workpieces require machining.
Innovation Solution
A method and system that involves using a reference workpiece to adjust the posture of subsequent workpieces by capturing images with a camera, setting workpiece reference lines, and generating a measurement combined image to align the workpiece's posture accurately with the reference lines, ensuring precise alignment and reducing the need for repeated measurements with a contact probe.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If a measurement contact probe is used to obtain precise position and posture of workpieces, then measurement precision is improved, but productivity deteriorates due to repeated measurements and corrections being necessary for multiple workpieces
Solution Approach 1:
The patent uses a reference workpiece to create a template for posture adjustment. By measuring the reference workpiece once with high precision using a contact probe, the same measurement results are applied to multiple subsequent workpieces through visual recognition and image processing, eliminating the need to repeatedly measure each workpiece individually.
Solution Approach 2:
The reference workpiece is measured and its posture is determined in advance before processing subsequent workpieces. This preliminary measurement creates a reference dataset that guides the positioning of all following workpieces, reducing the overall measurement time while maintaining precision.
2Productivity
If visual recognition is used to estimate workpiece posture, then productivity is improved, but measurement precision deteriorates due to errors on uneven surfaces and large workpieces
Solution Approach 1:
The patent introduces a reference workpiece as an intermediary between the measurement system and subsequent workpieces. The reference workpiece serves as a mediator that captures the precise measurement data, which then guides the positioning of other workpieces through visual recognition, combining the accuracy of contact measurement with the efficiency of visual methods.
Solution Approach 2:
The patent merges the advantages of contact probe measurement (high precision) with visual recognition methods (high speed). By combining these two approaches through the reference workpiece concept, the system achieves both accurate posture determination and efficient processing of multiple workpieces.
3Productivity
If a reference workpiece measurement approach is used, then productivity is improved by reducing repeated measurements, but device complexity increases due to additional camera configuration and image processing requirements
Solution Approach 1:
The camera system is configured to perform multiple functions: capturing images of the reference workpiece, recognizing visual markers on subsequent workpieces, and calculating positions based on these images. This multi-functionality reduces the need for separate measurement devices while maintaining productivity gains.
Data Source
AI summary
A workpiece installation method includes obtaining a reference image that shows a reference workpiece whose posture has been adjusted, setting workpiece reference lines on a boundary of a first image area occupied by the reference workpiece in the reference image, obtaining a measurement image that shows a workpiece, generating, using a processor, a measurement combined image in which workpiece reference lines are superimposed on the measurement image and which shows the workpiece reference lines pass through positions respectively identical to workpiece reference line positions, and adjusting a posture of the workpiece such that a boundary of a second image area occupied by the workpiece in the measurement combined image is shown to be substantially parallel to or substantially coincident with the workpiece reference lines.