Background and Buyer
Wants An internationally famend bike producer confronted vital hurdles within the uncooked materials dealing with part of their casting course of. The road required processing aluminum ingots stacked 21 layers excessive, with every lengthy ingot weighing 7kg. The consumer urgently sought an automatic answer integrating robotic arms and AI imaginative and prescient to interchange handbook labor, aiming to resolve excessive labor prices and enhance positioning accuracy.
Challenges
- Labor Depth & Harm Threat:
Repetitive lifting of 7kg masses and fixed bending posed extreme occupational harm dangers, compounded by a labor scarcity. - Subject of View (FOV) Limitations:
Because of the prolonged size of the ingots, an ordinary digital camera lens couldn’t seize the whole object in a single body at shut vary. - Complicated Stacking:
The ingots had been stacked in an alternating sample throughout 21 layers with reflective surfaces, making depth and place detection tough for conventional imaginative and prescient programs. - Value Constraints:
The consumer sought an economical different to costly 3D digital camera programs.
Answer
We deployed a high-performance AI imaginative and prescient answer that leveraged software program capabilities to beat {hardware} limitations:
- AI Occasion Segmentation (2D over 3D):
As a substitute of expensive 3D cameras, we utilized AI Occasion Segmentation know-how. Via deep studying, the system precisely identifies the contours and layers of stacked ingots utilizing normal 2D imaging, considerably decreasing {hardware} prices. - Proprietary Positioning Algorithm:
To deal with the FOV limitation, we developed a specialised algorithm that detects the “high” and “backside” ends of the lengthy ingot individually. The system then robotically calculates the middle coordinates, making certain the robotic arm grips the middle of gravity with precision.
Outcomes & Advantages
- Enhanced Productiveness:
A single robotic arm now helps a workspace overlaying 4 pallets, attaining a dealing with charge of 100 ingots per hour. - Value-Efficient Deployment:
By changing costly {hardware} with superior AI algorithms, the consumer realized substantial financial savings on gear funding. - Zero-Harm Office:
Automation has fully taken over heavy lifting, eliminating the chance of occupational accidents brought on by long-term bending and load-bearing, making a safer atmosphere for workers.
Conclusion
This case research demonstrates how superior AI software program can successfully overcome bodily {hardware} limitations. Via exact algorithms and an economical 2D imaginative and prescient answer, we not solely solved the advanced problem of aluminum ingot dealing with but in addition helped the consumer obtain a win-win state of affairs in each manufacturing effectivity and office security inside their casting course of.
