System and method for automated movement of a robotic arm
A positioning system is provided for insertions and placements with increased accuracy and precision for the placement and insertion of components into elements. The system may utilize one or more sensors to provide individual images or data for each individual insertion of components into elements. The system may use known information to compare the individual images or data to provide increased accuracy and precision for insertion of components into elements.
1. A system, comprising:
a robotic arm;
a gripper coupled to an end of the robotic arm;
a first sensor coupled to the robotic arm, wherein the first sensor is arranged to obtain a first image, the first image including the gripper and a target location in an engine element for the gripper to insert or place an engine component;
a second sensor coupled to the robotic arm and configured to obtain a second image;
a third sensor unattached to the robotic arm in a workspace and configured to obtain a third image; and
a controller coupled to the robotic arm and the gripper, wherein the controller controls motion of the robotic arm and operation of the gripper, wherein the controller is configured to:
control the second sensor to obtain the second image, the second image showing the engine element and the target location within the engine element;
analyze the second image to determine coordinates of the target location and/or the engine element relative to the robotic arm;
control the robotic arm and the gripper to grip the engine component;
control the third sensor to obtain the third image, the third image showing the engine component and the gripper;
analyze the third image to determine coordinates of the engine component relative to the gripper;
control the robotic arm to position the gripper in a vicinity of the target location;
create a preliminary control path for insertion of the engine component at the target location based upon the analysis of the second image and the third image;
control the first sensor to obtain the first image, the first image showing the gripper, the engine element and reference marks on the gripper, and analyze the first image to determine coordinates of the gripper and the component relative to the target location;
update the preliminary control path to form a final control path based upon the analysis of the first image; and
controls to the robotic arm to insert the engine component to the engine element at the target location according to the final control path.
2. The system of claim 1 , wherein the controller is configured to move the gripper and first sensor from a first location to a second location prior to obtaining the first image, wherein the first location is not in the vicinity of the target location and the second location is in the vicinity of the target location.
3. The system of claim 1 , wherein the target location is a slot of the engine element, and wherein the gripper is configured to insert the component into the slot of the engine element.
4. The system of claim 3 , wherein the controller is further configured to obtain distance information from the second sensor and analyze the second image and the distance information to obtain slot orientation information and z-axis information, the slot orientation information and the z-axis information describing an orientation and a position of the slot in the engine element as disposed in a carrier relative to the robotic arm.
5. The system of claim 4 , wherein the controller is configured to analyze the third image to obtain component orientation information, the component orientation information describing an orientation of the engine component relative to the gripper.
6. The system of claim 4 , wherein the second sensor comprises a camera and a laser device, wherein: the camera and the laser device are coupled to the robotic arm and the controller, and the camera and the laser device are configured to obtain the z-axis information.
7. The system of claim 5 , wherein the third sensor comprises a camera, wherein: the camera is positioned above the robotic arm within the workspace, the camera is coupled to the controller, and the camera obtains the component orientation information.
8. The system of claim 1 , wherein the gripper comprises two pinching members configured to hold the engine component.
9. A method, the method comprising:
arranging a gripper coupled to an end of a robotic arm;
arranging a first sensor coupled to the robotic arm to obtain a first image, wherein the first image includes the gripper and a target location for the gripper;
arranging a second sensor coupled to the robotic arm to obtain a second image;
arranging a third sensor unattached to the robotic arm in a workspace to obtain a third image;
by a controller:
controlling the second sensor to obtain the second image, the second image showing an engine element and a target location within the engine element;
analyzing the second image to determine the coordinates of the target location and/or engine element relative to the robotic arm;
controlling the robotic arm and the gripper to grip an engine component;
controlling the third sensor to obtain the third image, the third image showing the engine component and the gripper;
analyzing the third image to determine coordinates of the engine component relative to the gripper;
controlling the robotic arm to position the gripper in a vicinity of the target location;
creating a preliminary control path for insertion of the engine component at the target location based upon the analysis of the second image and the third image;
controlling the first sensor to obtain the first image, the first image showing the gripper, the engine element and reference marks on the gripper, and analyzing the first image to determine coordinates of the gripper and the component relative to the target location;
updating the preliminary control path to form a final control path based upon the analysis of the first image; and
controlling the robotic arm to insert the engine component to the engine element at the target location according to the final control path.
10. The method of claim 9 , wherein the controller is configured to move the gripper and the first sensor from a first location to a second location prior to obtaining the first image, wherein the first location is not in the vicinity of the target location and the second location is in the vicinity of the target location.
11. The method of claim 9 , wherein the gripper is configured to grip the engine component.
12. The method of claim 11 , wherein the target location is a slot of the engine element, and wherein the gripper is configured to insert the engine component into the slot of the engine element.
13. The method of claim 12 , further comprising obtaining a distance information from the second sensor and analyzing the second image and the distance information to obtain slot orientation information and z-axis information, the slot orientation information and the z-axis information describing an orientation and a position of the slot in the engine element as disposed in a carrier relative to the robotic arm.
14. The method of claim 13 , further comprising analyzing the third image to obtain component orientation information, the component orientation information describing an orientation of the component relative to the gripper.
15. The method of claim 13 , wherein the second sensor comprises a camera and a laser device, wherein the camera and the laser device are coupled to the robotic arm and the controller, and the camera and the laser device are configured to obtain the z-axis information.
16. The method of claim 14 , wherein the third sensor comprises a camera, wherein: the camera is positioned above the robotic arm within a workspace, the camera is coupled to the controller, and the camera obtains the component orientation information.