Camera-Guided CNC Image Tracing for Precise Material Removal
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Solution Overview
Problem
Computer-numerically-controlled (CNC) machines, particularly laser cutters, face challenges in accurately machining complex images due to difficulties in predicting material removal and ensuring safety while operating within regulatory guidelines, which limits their ability to efficiently convert electronic images into physical objects with high precision and detail.
Innovation Solution
The implementation of a method that uses cameras to capture images of the material and generate a machine file for CNC machines, allowing for the creation of a preview showing the expected outcome of machining, enabling digital correction and enhancement of images, and specifying machine instructions for designated portions, thereby overcoming the limitations of traditional CNC machining techniques.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If traditional CNC machining techniques are used to create objects with high detail and precision, then manufacturing precision is improved, but device complexity and difficulty in detecting and measuring increase
Solution Approach 1:
The patent uses camera imaging to capture the material surface and creates a digital copy of the material geometry. This optical copying approach replaces complex mechanical measurement systems, enabling high-precision digital representation of the workpiece without requiring equally complex physical measurement devices.
Solution Approach 2:
The patent substitutes mechanical measurement and detection systems with optical imaging systems. Instead of using complex mechanical sensors and measurement apparatus to detect material geometry, the system uses cameras to capture images and process them into machine files, thereby reducing mechanical device complexity while maintaining measurement capability.
2Productivity
If electronic images are converted into physical objects using CNC machines, then productivity is improved, but manufacturing precision deteriorates due to difficulty in predicting material removal
Solution Approach 1:
The patent implements a feedback loop where the camera continuously images the material surface during machining operations. The captured images are processed to update the machine file in real-time, allowing the system to detect actual material removal and adjust subsequent machining parameters accordingly. This closed-loop feedback ensures accurate material removal prediction and maintains manufacturing precision while enabling efficient automated conversion of images to physical objects.
3Manufacturing precision
If CNC machines operate with high precision and detail, then manufacturing precision is improved, but reliability deteriorates due to safety concerns and regulatory compliance issues
Solution Approach 1:
The patent performs preliminary imaging and creates the machine file before actual machining begins. The camera captures the material surface and the system processes images to generate complete machining instructions in advance. This preliminary action allows safety checks and regulatory compliance verification to be performed on the digital model before physical machining, thereby ensuring reliability and compliance without compromising the precision of the actual machining operation.
Data Source
AI summary
A method may include generating, by a camera having a view of an interior portion of a computer-numerically-controlled machine, an image comprising a pattern. The image can be transformed into a set of machine instructions for controlling the computer-numerically-controlled machine to effect a change in a material. The change can correspond to at least a portion of the pattern. At least one machine instruction from the set of machine instructions can be executed to control the computer-numerically-controlled machine to effect at least a portion of the change. The execution can include operating, in accordance with the at least one machine instruction, a tool coupled with the computer-numerically-controlled machine. The tool can configured to effect the change on the material. Related systems and articles of manufacture, including computer program products, are also provided.