Hand-eye system with three-dimensional vision and microgripper for handling flexible wire

A three-dimensional hand-eye system has been specially developed for handling, forming, and inserting flexible wires in electronic assemblies. The system consists of a vision system capable of measuring three-dimensional positions and a gripper capable of microforce control. The hand-eye system performs its tasks based on visual and force sensor data. The vision system uses a camera, a multiplanar laser light projector, and a video-rate image processor to measure the three-dimensional position of a flexible wire on a complex background. The projector consists of multiplanar light beams and a single-planar light beam and is robot-mountable. The single-planar light is used to simplify the matching of the multiplanar light beams and projection images. This is one of the most important features of our method. The measurement time is within 1.2 s for 20 positions on the wire, which is less than one robot cycle. The measurement accuracy is better than 0.2 mm in the plane for a 100 × 100 mm scene and is better than 1 mm perpendicular to the plane for a depth of 500 mm. The microgripper has 3-axis sensors capable of detecting three types of forces: grasping, pulling, and pushing. The dynamic range of the grasping force is 0.005 to 0.6 N, enabling high-resolution control. Two piezoelectric actuators are used in the microgripper fingers and a 3-mm stroke is achieved by amplifying the actuator's displacement using a two-stage lever. This system has been used for wire handling in magnetic disk slider manufacture, which is a difficult and delicate task. Measurement, grasping, and upper-stage insertion had a 100 percent success rate using autorecovery, making the hand-eye system feasible. This paper discusses design concepts, the range measurement principle, the system itself, and wire-handling applications.