DE102005014979B4 - Method and arrangement for planning production facilities - Google Patents

Abstract

A method of planning manufacturing equipment using means for visual recording, at least one data processing device, and at least one visually detectable reference mark (103, 203) for an object to be guided through the manufacturing devices, the at least one visually detectable reference mark (103, 203) being at least partially guided by the production facilities and recorded by the means for visual recording and the recording of the at least one visually perceptible reference mark (103, 203) evaluated by at least one computer program installed on the at least one data processing device and depending on the results of the evaluation, a computer-internal representation of a model calculates the passing of the at least one visually detectable reference mark (103, 203) by the production facilities with at least one sensor for distance measurement at least is partially detected and determined by evaluating computer-internal representations of the model and at least part of the sensor data positional relationships of the object in the manufacturing device for the case that the object in the by the at least one visually perceptible reference mark (103, 203) predetermined manner the manufacturing device is guided, characterized in that the at least one visually perceptible reference mark (103, 203) and the at least one sensor for distance measurement are installed on a workpiece carrier and are guided through it by the production device.

Description

The invention relates to a method and an arrangement for the planning of production facilities, which are particularly useful for planning or controlling the passage of a workpiece or tool by a manufacturing facility.

• - durch eine 3D-Simulation,
• - durch eine Störkantenanalyse mit realen Bauteilen,
• - durch eine Störkantenanalyse mit Referenzmodellen,
• - unter Einsatz von Augmented-Reality- (AR) Technologie.

A well-known process for the planning of manufacturing facilities is the so-called Störkantenanalyse. An edge analysis can be performed in different ways:

• - through a 3D simulation,
• - by a Störkantenanalyse with real components,
• - by interfering edge analysis with reference models,
• - using Augmented Reality (AR) technology.

For an interference edge analysis using a 3D simulation, a large part of the production facility and the workpiece or tool passing through the production facility must be available as actual 3D data records. Workpieces are usually available in digital form, as they have already been computer-aided, so that the relevant data sets can be used for the 3D simulation. However, this is generally not the case for the production facility or the tools. It would then be necessary to subsequently capture and digitize the manufacturing facility or the tool. For this reason, a Störkantenanalyse using the 3D simulation is very time consuming and costly.

In the interference edge analysis with real components or reference models (Styrofoam models or similar) you do not need 3D data of the manufacturing plant. However, production may have to be interrupted for the interference edge analysis because, if interference edges (collisions) occur, the real component or reference model must be removed from the system and, if necessary, damage occurs that must be repaired. In addition, this method is very inflexible, since a new model must be produced for each component.

The DE 101 28 015 A1 describes a method and system for planning a changed production environment, in particular a manufacturing environment for vehicle components. The virtual planning results are superimposed on the real manufacturing environment with the help of an augmented reality system.

The DE 102 40 392 A1 discloses a system and method for determining distances of virtual objects to real objects through the use of augmented reality technology. This is done by coupling an augmented reality system with another surveying system or by positioning reference geometries in space.

When using the AR technology, a reference mark is moved through the production device instead of the workpiece or tool and recorded with a camera. The movement of the reference mark through the manufacturing device can thus be observed on a monitor. In this representation on the monitor, the tool or workpiece is virtually displayed as a model, the reference mark serves as a reference system. While in this way the virtual workpiece or tool is guided through the manufacturing facility, one can recognize critical situations on the screen, for example, areas in which the workpiece or tool would collide with parts of the manufacturing facility. A disadvantage of this procedure, however, is that the interference edge analysis is performed here by the visual assessment of a two-dimensional representation. This can lead to misjudgments or necessitate the repeated passage of the workpiece or tool through the production device, for example with altered camera constellation, in order to dispel ambiguities.

The object of the invention is thus to provide a method and an arrangement for the planning of production facilities, which avoid the aforementioned disadvantages and in particular allow a largely automated Störkantenanalyse.

This object is achieved by the features in claims 1 and 10. Advantageous embodiments of the invention are contained in the subclaims.

A particular advantage of the method according to the invention is that a clutter edge analysis can be performed fully automatically by performing planning of manufacturing devices using means for visual recording, at least one data processing device and at least one visually perceptible reference mark for an object to be guided through the manufacturing devices, wherein the at least one visually detectable reference mark is at least partially guided through the manufacturing devices and recorded by the means for visual recording, and the Recording the at least one visually perceptible reference mark evaluated by at least one computer program installed on the at least one data processing device and calculates a computer-internal representation of a model of the object depending on the results of the evaluation, passing the at least one visually perceptible reference mark through the production devices with at least one sensor Distance measurement is at least partially detected and determined by evaluation of computer-internal representations of the model and at least part of the sensor data positional relationships of the object in the manufacturing facility for the case that the object is guided in the predetermined by the at least one visually perceptible reference mark through the manufacturing facility , According to the invention, the at least one visually perceptible reference mark and the at least one sensor for distance measurement on a factory tückträger is installed and is guided by this through the manufacturing facility.

Compared to conventional solutions, the planning method according to the invention has the advantage that a digital modeling of the production device is not undertaken or a reference model of the tool or workpiece does not have to be made. In addition, the current production process is not affected by the test method according to the invention.

In a preferred embodiment of the method according to the invention, it is provided that such positional relationships are signaled, in which a predefinable distance value between the production device and the object is reached or undershot. This represents a considerable advantage over the merely visual assessment of the free movement or accessibility of the tool or workpiece when using conventional AR technology.

In another preferred embodiment of the method according to the invention it is provided that additional means for imaging data output are used and by evaluating the recording of the at least one visually detectable reference mark data for a pictorial representation of the computer-generated model of the object determines the pictorial representation of the computer-generated model of the object and superimposing the record of the at least one visually detectable reference mark on output by the imaging data output means. As a result, the purely sensor-supported interference edge analysis is supported by visual assessment of the tool relationship or workpiece situation within the production facility. In this case, the tool or workpiece situation can be placed in a wider context than would be possible with a purely computer-aided solution, since the complex conditions within the production facility are simulated by computer technology only by the models (as already mentioned above) with relatively great effort can.

It also proves to be advantageous if the at least one visually perceptible reference mark and the computer-generated model of the object are linked to one another by a reference coordinate system. This allows the model of the object to be easily aligned and visualized according to the position and orientation dictated by the visually observable reference mark (and its coordinate system). Computer-internally, the model and the visually perceptible reference mark are virtually rigidly interconnected.

In a further preferred embodiment of the method according to the invention, it is provided that a 3D scanner, preferably so-called time-of-flight (TOF) scanner, or a stereo camera are used as the sensor for distance measurement. This gives a surface profile of a large part of the environment. This can be used particularly advantageously by linking at least a part of the pixels (pixels) of the pictorial representation to a distance value of the object represented by the pixel when outputting via the means for visual data output. This approach can be advantageously used to control image acquisition by controlling the visual record through at least a portion of the data provided by the distance measurement sensors.

A particularly advantageous field of application of the method according to the invention lies in vehicle construction. The objects are therefore in particular motor vehicles that are guided through the production facility. A preferred embodiment of the method according to the invention therefore provides that a planning of production facilities of the vehicle production is carried out and as an object a tool or workpiece, in particular a motor vehicle, is modeled. Since the vehicles are usually guided on so-called skids through the production facility, it proves to be advantageous to install the at least one reference mark on a skid or a workpiece carrier.

An arrangement for planning production facilities according to the invention comprises means for visual recording, at least one data processing device and at least one visually perceptible reference mark, wherein the Arrangement is arranged such that a method according to claim 1 is executable.

The invention thus makes available, in particular, a flexible system for interfering edge analysis in planning, especially re-planning or integration in the field of systems engineering and materials handling technology. 3D data of the manufacturing facility is no longer required. A particular advantage of the invention is that the production during the analysis process does not have to be interrupted, for example by the occurrence of interference edges (collision). This reduces the cost of the overall process. The costs are further reduced by the system according to the invention requires only a single investment, since it is applicable by reprogramming for different models (objects).

• 1 die Funktionsweise eines videobasierten Augmented-Reality-Systems und
• 2 eine beispielhafte Ausführung eines erfindungsgemäßen Werkzeugträgersystems.

The invention will be explained in more detail with reference to the figures of the drawings of an embodiment. Show it:

• 1 the operation of a video-based augmented reality system and
• 2 an exemplary embodiment of a tool carrier system according to the invention.

In the following, the invention will be explained in more detail by way of example on the interference edge analysis in motor vehicle production. The invention is integrated in an augmented reality (AR) system. The following briefly describes the operation of such an AR system.

In short, AR technology is based on the fact that data, for example, by standard recording systems such as cameras 101 are obtained from real objects, with data of virtual objects, for example, as 3D datasets of CAD models in databases 102 stored are linked. In the case of the interference edge analysis described here by way of example in a production facility for motor vehicle production, the production facility itself, the tool carrier (skid) and the reference mark installed on the tool carrier 103 the objects that provide the data for the real environment (compare 1 ). Manufacturing facility, tool carrier and reference mark 103 are in a simple embodiment by a camera 101 recorded. A tracking system 104 evaluates these records, especially the record of the reference mark 103 , and as a result provides information indicating the orientation and position of the reference mark 103 describe analytically. This can be, for example, the x, y, z position of the reference mark 103 be, together with angle indications which describe the viewing direction in which the reference mark 103 on a display device 105 a viewer appears. As a display device 105 Both Head Mounted Displays (HMD) and ordinary monitors are used. These data or information (video image, x, y, z position and viewing direction) become a scene generator 106 to hand over. The scene generator 106 also has access to a database 102 from CAD models 107 of vehicles or vehicle parts. From this database 102 The scene generator 106 extracts information about the 3D geometry of the CAD model 107 which is to be linked to the reference mark 103. The link between the reference mark 103 and CAD model 107 is via a reference coordinate system. Because position and orientation of the reference mark 103 through the tracking system 104 have been determined and are thus known, the CAD model can also 107 of the vehicle from the scene generator 106 in the right place in the on the display device 105 inserted scene and on the display device 105 be reproduced. As a result, on the display device 105 (HMD, monitor, or the like), the one from the camera appears 101 recorded real scene together with the displayed virtual object 108 so that with the help of such an AR system already at this stage it is possible to examine visually how the real vehicle would behave in the production facility. The from the camera 101 recorded scene and / or the scene generator 106 generated scene can for later evaluation or for archiving or documentation by recording devices 109 to be recorded.

This purely visual system is inventively extended by the use of additional sensors (see 2 ). These sensors can do both on the skid 201 (Workpiece carrier) or installed in the manufacturing facility. In particular, sensors are used for the measurement of the environment and the distance measurement, such as 3D laser scanners, stereo cameras or the like.

• - Aufnahmeeinrichtungen (zum Beispiel Videokameras 202, Fotokameras, IR-Kameras, Mikrofone oder dergleichen) an unterschiedlichen Positionen, fest oder beweglich (intern oder extern gesteuert);
• - Sensorik für Umfeld- und Abstandsvermessung (zum Beispiel 3D-Laserscanner, Stereo-Kameras oder dergleichen);
• - Markierungen, Referenzmarken 203 oder interne beziehungsweise externe Marker;
• - Aufzeichnungsgeräte 204 wie beispielsweise Videorekorder oder DAT-Rekorder;
• - Lampen zur Beleuchtung des Umfeldes und des Skids 201 (Licht, Infrarot oder dergleichen);
• - Steuereinheit 205 zur Synchronisation der Aufzeichnungsgeräte 204, der Bewegungssteuerung oder dergleichen;
• - Signalübertragung zu externen Stellen;
• - Signalaustausch mit Skid-externen Markern;
• - Energieversorgung 206;
• - Schutzeinrichtung gegen Umwelteinflüsse wie Temperatur, Feuchtigkeit, Staub, die in verschiedenen Bereichen wie beispielsweise einer Lackierstraße auftreten können.

In an exemplary embodiment, a workpiece carrier (for example Skid 201 ) equipped with the following components:

• - Recording equipment (for example video cameras 202 , Photo cameras, IR cameras, microphones or the like) in different positions, fixed or movable (controlled internally or externally);
• - Sensors for environment and distance measurement (for example, 3D laser scanners, stereo cameras or the like);
• - Marks, reference marks 203 or internal or external markers;
• - Recording devices 204 such as VCR or DAT recorder;
• - Lamps for lighting the environment and the skid 201 (Light, infrared or the like);
• - Control unit 205 for synchronization of the recording devices 204 , the motion control or the like;
• - Signal transmission to external points;
• - Signal exchange with skid-external markers;
• - Power supply 206 ;
• - Protection against environmental influences such as temperature, humidity, dust, which can occur in various areas such as a paint line.

When using appropriate 3D scanners, such as a so-called time-of-flight (TOF) scanner, a highly accurate distance measurement of the environment of the skid 201 performed and this environment simultaneously recorded visually. As a result of this detection, there is a data record which simultaneously assigns a distance value to each pixel. When inserting the CAD model in the scene, which as described above from the scene generator 106 is carried out, the distance data supplied by the TOF scanner can be compared with the 3D geometry of the inserted CAD model and interference edges can be determined automatically. In the overlay result 207 Thus, it is possible to identify areas that meet certain criteria - in particular so that edges, hard to reach or other critical areas.

It may prove advantageous that the skid 201 how a standard tool carrier of the corresponding production device is executed. Alternatively, the skid 201 but also be designed as an essay for such a standard tool carrier.

LIST OF REFERENCE NUMBERS

101

camera

102

Database

103

reference mark

104

Tracking system

105

display

106

scene generator

107

CAD model

108

virtual object

109

recorder

201

Skid

202

video camera

203

reference mark

204

recorder

205

control unit

206

power supply

207

Superposition result

Claims (10)

A method of planning manufacturing equipment using means for visual recording, at least one data processing device, and at least one visually detectable reference mark (103, 203) for an object to be guided through the manufacturing devices, the at least one visually detectable reference mark (103, 203) being at least partially guided by the production facilities and recorded by the means for visual recording and the recording of the at least one visually perceptible reference mark (103, 203) evaluated by at least one computer program installed on the at least one data processing device and depending on the results of the evaluation, a computer-internal representation of a model calculates the passing of the at least one visually detectable reference mark (103, 203) by the production facilities with at least one sensor for distance measurement at least is partially detected and determined by evaluating computer-internal representations of the model and at least part of the sensor data positional relationships of the object in the manufacturing device for the case that the object in the by at least one visually perceptible reference mark (103, 203) predetermined manner the manufacturing device is guided, characterized in that the at least one visually perceptible reference mark (103, 203) and the at least one sensor for distance measurement are installed on a workpiece carrier and are guided through it by the production device. Method according to Claim 1 , characterized in that such positional relationships are signaled, in which a predeterminable distance value between the manufacturing device and object is reached or fallen below. Method according to Claim 1 or 2 , characterized in that additionally means for the imaging data output are used and - by evaluating the recording of the at least one reference mark (103, 203) determines data for a pictorial representation of the computer-generated model of the object, - the image representation of the computer-generated model of the object and the recording of the at least one reference mark (103, 203) are superimposed upon output by the means for imaging data output. Method according to one of the preceding claims, characterized in that the at least one reference mark (103, 203) and the computer-generated model of the object are linked together by a reference coordinate system. Method according to one of the preceding claims, characterized in that a 3D scanner or a stereo camera are used as a sensor for distance measurement. Method according to one of the preceding claims, characterized in that, when outputting via the means for visual data output, at least a part of the pixels of the pictorial representation is linked to a distance value of the object represented by the pixel. Method according to one of the preceding claims, characterized in that the visual recording is controlled by at least part of the data supplied by the at least one sensor for distance measurement. Method according to one of the preceding claims, characterized in that a planning of production facilities of the vehicle production is carried out and as an object a tool or workpiece, in particular a motor vehicle, is modeled. Method according to Claim 8 , characterized in that the workpiece carrier with - at least one internally or externally controlled, fixed or movably installed receiving device, - sensors for environment or distance measurement, - at least one means for illuminating the environment, - at least one control device, - at least one means for signal transmission external devices, - at least one power supply and / or - at least one protective device against temperature and / or moisture and / or dust is equipped. Arrangement for planning production facilities comprising means for visual recording, sensor for distance measurement, at least one data processing device and at least one visually perceptible reference mark (103, 203), wherein the arrangement is set up such a method Claim 1 perform.

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