3D Workpiece Surface Scanning for Precise Tool Path Control
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Solution Overview
Problem
Conventional workpiece processing systems face challenges in accurately locating workpiece surfaces in dirty environments with varying surface conditions, leading to inaccuracies and inefficiencies in processing operations due to limitations in sensing capabilities and the inability to detect surface variability effectively.
Innovation Solution
A system employing a movable sensor carriage with a light source and camera to generate a three-dimensional point representation of the workpiece surface, allowing for precise control of processing tools and monitoring of gas usage to optimize processing operations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If conventional sensing systems are used to locate workpiece surfaces, then the system is simpler and cheaper, but measurement precision deteriorates in dirty environments with varying surface conditions
Solution Approach 1:
The patent transitions from 2D camera imaging to 3D surface mapping by introducing a laser line projector. The laser projects structured light patterns (lines or grids) onto the workpiece surface, and the camera captures the deformed light patterns from a different angle. Through triangulation calculations, the system reconstructs the complete 3D geometry of the workpiece surface, enabling precise location detection even in dirty environments with varying surface conditions.
Solution Approach 2:
The patent introduces laser projected light patterns as an intermediary between the camera and the workpiece surface. The structured light acts as a mediator that carries geometric information from the surface to the camera, enabling indirect measurement of surface topology without direct contact. This intermediary light field allows the system to overcome challenges from dirty environments and varying surface reflectivity.
2Manufacturing precision
If a movable sensor carriage with light source and camera is used to generate 3D surface representation, then manufacturing precision improves, but device complexity increases
Solution Approach 1:
The patent combines multiple functions into a single integrated sensor carriage: the laser line projector, the camera, and the positioning system are merged into one movable unit. This consolidated carriage can be positioned along the workpiece using a rail or guide system, capturing 3D data from multiple locations. The merging of these components reduces overall system complexity compared to having separate stationary sensors throughout the workspace.
Solution Approach 2:
The patent employs a movable sensor carriage that can dynamically reposition along the workpiece length. This dynamic positioning capability allows the same sensor suite to scan different sections of the workpiece, replacing the need for multiple fixed sensors. The carriage movement is controlled by a positioning system that coordinates with the data acquisition, enabling flexible and adaptive measurement of varying workpiece geometries.
3Productivity
If detailed surface representation is generated for precise tool control, then productivity improves through reduced rework, but loss of time increases during scanning
Solution Approach 1:
The patent uses periodic scanning where the sensor carriage moves along the workpiece in discrete steps or continuous motion, capturing 3D data at regular intervals or along predefined paths. The scanning process is periodic in nature, alternating between data acquisition phases and tool processing phases. This periodic action allows efficient data collection without requiring the entire surface to be scanned at maximum detail levels simultaneously, balancing scanning time with processing accuracy.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The system enables accurate and repeatable processing of workpieces in dirty environments by providing a detailed surface representation, improving tool control and gas management, thus enhancing processing efficiency and reducing waste.
Implementation Method 1
at least one camera that is configured to record the location data of the light beam on a target surface of a workpiece as the sensor carriage moves along the scan axis
Data Source
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AI summary
A system (40) for processing a workpiece includes a support surface (88) for supporting a workpiece (44). The system (40) includes a processing tool (92) movable with respect to a processing path. The system (40) includes a sensor carriage (408) movable along a scan axis and having a light source (476, 515, 550, 586) located to emit a light beam at an angle to the scan axis onto a target surface of a workpiece (44), and a camera (484, 522, 558, 594) configured to record location data of the light beam on a target surface of a workpiece (44) as the sensor carriage (408) moves along the scan axis. The system (40) includes a control system for generating a three-dimensional point representation of a workpiece surface from the light beam location data, to control movement of the processing tool (92) based on the three-dimensional point representation of a workpiece (44).