3D Depth-Guided Machining Control Without Pre-Set Cutting Programs
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Solution Overview
Problem
Preparing a processing program for a workpiece is challenging, and even with a created program, cutting errors occur due to the characteristics of the processing machine, requiring repeated pre-processing and correction.
Innovation Solution
A processing machine equipped with a depth camera, position measurement unit, position matching unit, cutting amount determination unit, and tool control unit, which calculates the three-dimensional position of the workpiece and target shape, determines the cutting amount based on depth differences, and controls the tool without a pre-prepared processing program.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a processing program is prepared and executed by an actual processing machine, then the workpiece can be processed according to the desired shape, but cutting errors occur due to characteristics of the processing machine requiring repeated pre-processing and correction
Solution Approach 1:
The system performs preliminary measurement of the workpiece using a depth camera to obtain actual three-dimensional position data before processing. This preliminary action captures the real state of the workpiece, enabling the generation of a corrected processing program that anticipates and compensates for machine characteristics, thereby eliminating the need for repeated pre-processing and correction cycles
Solution Approach 2:
The system implements feedback by measuring the actual three-dimensional position of the workpiece surface using a depth camera, comparing it with the target shape, calculating the difference, and using this information to correct the processing program. This closed-loop feedback mechanism ensures cutting precision while reducing the need for repeated pre-processing
2Productivity
If a processing program is created based on target shape and executed by actual processing machine, then the workpiece can be processed, but cutting errors occur due to characteristics of the processing machine
Solution Approach 1:
The system replaces the traditional mechanical trial-and-error approach with an optical measurement system (depth camera) and computational processing. By using optical fields to measure the workpiece and computational algorithms to calculate cutting amounts, the system achieves both high productivity and high cutting accuracy without repeated physical pre-processing
Solution Approach 2:
The system changes the processing parameters by using actual three-dimensional position data obtained from depth camera measurements to dynamically adjust cutting amounts. This parameter adaptation based on real measurements ensures cutting accuracy while maintaining processing efficiency through automated correction
3Ease of operation
If traditional processing program preparation is used, then processing can be performed, but it is not easy to prepare the processing program and requires repeated correction
Solution Approach 1:
The system enables self-service by allowing the workpiece itself to provide measurement data through depth camera scanning. The workpiece's actual geometry is automatically captured and used to generate the processing program, eliminating the need for manual program preparation and reducing operational complexity
Solution Approach 2:
The system uses depth information (analogous to color changes in visual spectrum) to encode the three-dimensional position data of the workpiece surface. By converting physical geometry into measurable depth data, the system simplifies the process of understanding and processing workpiece characteristics for program generation
Data Source
AI summary
A processing machine includes a tool configured to perform machine processing on a workpiece, and a depth camera configured to be installed such that the workpiece lies within an imaging range and to capture a depth of a subject. A position measurement unit calculates a three-dimensional position of a surface of the workpiece based on a depth image captured by the depth camera. A position matching unit, based on three-dimensional data representing a target shape of the workpiece and a three-dimensional position of the workpiece, calculates a three-dimensional position of the target shape in a case in which the workpiece and the target shape are superimposed. A cutting amount determination unit determines a cutting amount at each of a plurality of points on the surface of the workpiece based on a difference in a line-of-sight direction between the three-dimensional position of the surface of the workpiece and a three-dimensional position of a surface of the target shape in a case in which the workpiece is viewed from a predetermined viewpoint. A tool control unit moves the tool based on the determined cutting amount.