1. iRVision 3D Area Sensor Based Bin Picking
Parts From End Customer “Ergonomic Solutions”
Feasibility Study Report
February 14, 2014

2. CONDITIONALLY SUITABLE
Summary
Abstract: Tests with FANUC 3D Sensor Area Sensor were performed to study feasibility and performance of detection of 3 different types of parts from the end customer “Ergonomic Solutions”. A simple pointer was used as robot tooling, parts were removed manually.
Results:
Part # 1 and part # 2 are conditionally suitable for Bin Picking with FANUC 3D Sensor Area Sensor.
Part # 3 – not suitable for Bin Picking!
Part 1
Part 2
Part 3
CONDITIONALLY SUITABLE
NOT SUITABLE
18/09/2018

3. Part 1 Part 2 Part 3 Summary - Details 1200 800 800 600 1200 800
CONDITIONALLY SUITABLE
Conditions:
Small but strong magnetic tool to pick parts at any point
Area Sensor Peak Locator, Area Sensor Blob Locator Tool
Simple Bin Picking - separation of parts only, w/o orientation
Average cycle time (Bin Picking): 2-3 sec/part
Bin Picking cell should be shaded from outside light
Challenges:
After Bin Picking: Centering or accurate offset locating by visual detection of a picked part
Total cycle time (customer requirement): 6 sec
Part 2
800
600
CONDITIONALLY SUITABLE
Conditions: - same as for part 1
Challenges: - same as for part 1
Part 3
1200
800
NOT SUITABLE
Reasons (in the order of matter):
Interlocking!
Overlapping in chain (“roof tile” phenomenon)
Shiny  Detection issue
Total cycle time (customer requirement): 6 sec
18/09/2018

4. Part 1 Detection 3DAS height ~ 2.3 m above container
Distance between cameras ~ 600 mm
18/09/2018

5. Part 2 Detection 3DAS height ~ 2.0 m above container
Distance between cameras ~ 600 mm
18/09/2018

6. Part 3 Detection 3DAS height ~ 2.5 m above container
Distance between cameras ~ 600 mm
18/09/2018

7. Addendum
18/09/2018

8. Two General Detection Methods (From “iRVision Bin Picking Operator Manual”)
“3D detection with only 3D map” detects parts only with 3D map without the camera image. If the postures of parts vary greatly then the 2D image […] is not consistent. However this method can execute stable detection independent of the postures. The Area Sensor Peak Locater Tool and the Area Sensor Blob Locator Tool, are provided for “3D Detection with Only 3D Map”. These two tools are useful when the parts postures are completely random. Advantages: Low search time  fast Bin Picking, short time to setup iRVision “3D detection with combination of 2D locator tool and 3D map” detects parts by a combination of a 2D locator tool (such as GPM or CSM tool) and a 3D Command Tool (Area Sensor COG Tool or Area Sensor Plane tool ). In this detection, the 2D locator tool finds the parts (2D image), and the position and the posture of the found parts is measured using the 3D map points within the specified area centered at the origin of the found 2D image. Advantages: High confidence and accuracy, pick position can be offset
18/09/2018

9. Applications With 3D Area Sensor
3D Area Sensor is ideal for:
Bin Picking Applications , Depalletizing Applications
Parts with simple fixed shape, or - if they can be any highest point - any shape (even random shape - food etc.)
Using a high powered magnet or high volume vacuum to pick parts by moving straight down to the highest point on the part
Using a standard powered magnet or vacuum cups to pick parts perpendicular to a flat surface on the part
Find the tilt and rotation of a part using 2D features and flat surface on the part. This solution requires the parts to have a limited number of features and not be steeply tilted. Only good for parts that are stacked relatively flat in the container.
After a part has been taken from the heap / stack
It cannot be loaded into a machine directly because part offset data is often either not available or not accurate enough!
Consider a subsequent positioning or accurate offset locating by visual detection of a picked workpiece!
The most challenging applications include:
Transparent or shiny or light absorbing parts
Parts that interlock together
Parts that cannot be gripped with a magnet or vacuum gripper
Completely random parts without any consistent or highly tilted grip surfaces
Randomly located complex parts that have to be gripped by a mechanical specified position with high accuracy
Very small parts with surface size …
< 1 times XY-Resolution of the 3D map – not possible to detect individually / separated
1…3 times XY-Resolution of the 3D map – only OK if peak detection sufficient for picking (with magnet / vacuum)
4…5 times XY-Resolution of the 3D map – OK for peak detection or rough(!) tilt measurement (W and P angles)
Very big parts compared to the size of the container / pallet. There should always be several visible and pickable parts on top of the heap / stack.
Very small and/or very deep container.
Tuesday, 18 September 2018

10. Recommended Bin Picking Concept
Following concept is recommended for effective utilization of 3DAS for Bin Picking. Separation of sophisticated Bin Picking in two feasible and easy steps:
Step 1: Simple Bin Picking: separation/isolation of parts only!
Area Sensor Peak Locator or Area Sensor Blob Locator Tool to detect exposed peaks or surfaces of the top parts
Vacuum or magnet or an adaptive mechanical gripper to pick the parts directly at any found positions
Step 2: Centering or accurate offset locating by visual detection of a picked part
Consider using 2nd robot for this task if very high throughput required.
Merits:
No complicated vision settings to handle many different situations (e.g. tilt cases)
Very little effort to setup & tune Area Sensor Peak Locator or Area Sensor Blob Locator Tool
Simple Interference Avoidance
Simple robot programming
Easy, fast (2 to 3 sec/ part) and reliable way to empty the bin completely!
Quite straightforward 2DV application for the 2nd step
Easy to setup, Easy to use, Easy to maintain for integrators
Tuesday, 18 September 2018

11. General Tips Regarding Gripper Design
Ideal End of Arm (EoA) robot tooling for Bin Picking
Strong
It should be strong enough to take and pull out a workpiece partly covered and held by the weight of covering neighbor workpieces.
Magnet or vacuum
Top surface enough to take the part
Depending on the part shape and material, a strong mechanical gripper can be more appropriate, though.
Slim
Maximum range of operation inside the bin while avoiding interference with the bin walls or parts.
Robust & Protected
All parts of the EoA tooling which are subject to potential collisions should be robust enough to withstand these collisions.
Vulnerable parts of the EoA tooling must be hidden or protected.
With integrated collision and overload protection device (e.g. Schunk OPS-100) or function (e.g. Touch Skip).
Mounted on a sufficient long and slightly bended / angled arm extension
To be able to approach and pick low parts close to a bin wall and/or tilted towards the bin wall, while avoiding interference with the bin wall.
Particularly when parts can be picked in different orientations (e.g. round holes)
Tuesday, 18 September 2018