Challenge: Robot is closing compressor connectors with rubber caps or kapsoluts. Position of compressor on transport pallet and connector bending tolerances are very wide. Consequently connector tip can be anywhere within the 20 mm diameter sphere. As a result robot's tool is often colliding with the connector. Prior to closing operation robot needs to know position and orientation of the connector in the form of "closing vector" within 1 mm precision. Manufacturing line pace is 5s.
Solution: We designed custom imaging module to acquire spatial image of the part. LabVIEW application uses 3D analysis algorithm then extracts connector's position. Spatial "Closing vector" in real world units within robot's coordinate system is calculated via calibration data of the module and robot. Featured vision solution virtually dismissed the stalls in the manufacturing due to collisions, significantly reduced maintenance cost, saved the customer valuable production hours and enabled swift return of investment.