Free resources to learn about industrial and collaborative robots
April 6, 2022
Robots serve as sophisticated playback machines, meticulously executing tasks in strict accordance with their programmed instructions. These instructions, imparted by human operators, are faithfully replicated by the robot. While this method proves effective when handling consistently positioned parts, any deviation, such as environmental changes leading to displacement, necessitates re-teaching the robot—a task fraught with challenges.
To mitigate this issue, vision systems emerge as indispensable tools. Before initiating a movement, the robot’s camera captures an image, enabling it to assess whether the target part has shifted. Armed with this visual feedback, the robot can dynamically adjust its movements, ensuring precise alignment with the target. The integration of a vision sensor into the robot’s arsenal not only enhances accuracy but also streamlines operations, reduces downtime, and minimizes errors, thereby optimizing the production cycle.
These systems can be categorized into three main types based on the mounting configuration of the vision sensors and the nature of the workpieces being measured or manipulated:
Here you see the 3 types:
Let us understand the difference between these systems:
In this category, vision sensors are directly mounted on the robot’s end effector or tooling. These sensors provide real-time feedback to the robot about the position, orientation, size, and other relevant characteristics of the workpieces it is tasked with handling. By measuring the workpieces, the robot can adapt its movements and actions accordingly, ensuring accurate manipulation and assembly processes. Applications include pick-and-place operations, assembly tasks, and quality inspection where the workpieces are located in various positions within the robot’s workspace.
Unlike the previous category, here the vision sensors are installed at fixed locations within the robotic workspace, typically above or adjacent to the work area. These sensors capture images or data of the workpieces as they move through the production line or are presented to the robot for processing. The robot receives information from these sensors to plan its actions and make decisions regarding the handling or processing of the workpieces. This setup is beneficial for applications where the workpieces follow a predictable trajectory or are presented at specific locations within the manufacturing environment.
This category involves vision sensors that are fixedly mounted in the workspace but are focused on the workpieces held by the robot during manipulation or processing. The sensors provide feedback to the robot about the condition, orientation, and other relevant attributes of the workpieces it is currently handling. By continuously monitoring the workpieces, the robot can ensure precise control and adjust its movements as necessary to maintain accuracy throughout the operation. This setup is common in tasks such as welding, machining, and material handling, where the robot interacts closely with the workpieces throughout the manufacturing process.
Selecting the most suitable robot vision system from the three categories mentioned depends on several factors, including the specific requirements of the application, the characteristics of the workpieces, the complexity of the tasks involved, and the operational environment. Here’s a guideline to help determine which category is the most appropriate:
1.Application Requirements:
Consider the specific tasks that the robot will perform and the level of precision and flexibility required. If the application involves tasks where the workpieces are presented at different locations or orientations within the workspace, a robot-mounted vision sensor or a fixed-mounted vision sensor measuring workpieces to be operated by the robot may be more suitable, as they provide real-time feedback for adaptive control. Conversely, if the workpieces follow a predictable trajectory or are held consistently by the robot, a fixed-mounted vision sensor measuring workpieces held by the robot may suffice.
2.Workpiece Characteristics
Analyze the size, shape, surface characteristics, and variability of the workpieces. If the workpieces vary significantly in these attributes or if precise manipulation is required, a robot-mounted vision sensor or a fixed-mounted vision sensor measuring workpieces to be operated by the robot may be necessary to ensure accurate handling and processing. On the other hand, if the workpieces are relatively uniform and predictable in their characteristics, a fixed-mounted vision sensor measuring workpieces held by the robot may be sufficient for monitoring and control.
3.Operational Environment
Evaluate the environmental conditions in which the robot will operate, including lighting, temperature, humidity, and presence of contaminants. Some vision sensors may perform better under certain environmental conditions than others. For example, if the application involves harsh or variable lighting conditions, a robot-mounted vision sensor with integrated lighting and advanced image processing capabilities may be preferred for consistent performance.
4.Cost and Complexity
Consider the budget constraints and the complexity of integrating and maintaining the vision system. Robot-mounted vision sensors typically offer higher flexibility and adaptability but may be more complex to install and calibrate compared to fixed-mounted sensors. Additionally, consider the long-term costs associated with maintenance, upgrades, and support services.
5.Future Scalability and Expansion
Anticipate future requirements and scalability of the system. Choose a vision system that can accommodate potential changes in the production process, such as introducing new workpieces or modifying tasks. A modular and flexible system may offer easier scalability and expansion capabilities.
By carefully assessing these factors and understanding the specific needs of the application, you can select the most suitable robot vision system from the three categories to optimize performance, efficiency, and reliability in industrial automation. Consulting with experts in robotics and machine vision can also provide valuable insights and recommendations tailored to your specific requirements.
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