Vision system for training an assembly system through virtual assembly of objects

A method for virtual assembly of an object using an assembly system having at least a first station containing a first workpiece, the assembly system assembling a second workpiece to the first workpiece in alignment therebetween, the method comprising the steps of:

• acquiring an image, with one or more vision system cameras and a vision system processor assembly, of the first workpiece and the second workpiece, the plurality of cameras being calibrated to a common coordinate system;
• generating at least one of images and features of the first workpiece and the second workpiece in the common coordinate system;
• automatically manipulating the second workpiece with respect to the first workpiece so as to align at least one of images and features of the first workpiece and the second workpiece;
• and
• computing an assembly error based on a degree of manipulation of the first workpiece and the second workpiece during the virtual assembly process.

A system for virtual assembly of an object in an assembly system having at least a first station containing a first workpiece, the assembly system assembling a second workpiece to the first workpiece in alignment therebetween, the system comprising:

• one or more vision system cameras and a vision system processor assembly arranged to image the first workpiece and the second workpiece, the plurality of cameras being calibrated to a common coordinate system, wherein the second workpiece is imaged at a second station remote from the first station;
• an alignment process that generates at least one of images and features of the first workpiece and the second workpiece in the common coordinate system;
• a manipulation process, having vision tools that locate a first set of features on the first workpiece and a second set of features on the second workpiece, that automatically aligns the first set of features with respect to the second set of features so as to align at least one of images and features of the first workpiece and the second workpiece;
• and
• an assembly error computation module that computes an assembly error based on a degree of manipulation of the first workpiece and the second workpiece by the manipulation process during the virtual assembly process;
• and
• at least a third workpiece, the vision system cameras imaging the third workpiece, the alignment process generating at least one of images and features of the third workpiece in the common coordinate system, the manipulation process being arranged to allow manipulation of the third workpiece with respect to at least one of the first workpiece and the second workpiece so as to align at least one of images and features of the third workpiece with at least one of images and features of at least one of the first workpiece and the second workpiece, and wherein the assembly error computation module computes an assembly error based on a degree of manipulation of the third workpiece with respect to at least one of the first workpiece and the second workpiece.