Camera-Calibrated Panel Loading for Precise Flatbed Alignment
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Solution Overview
Problem
Manual loading of material panels in flatbed machine tools, such as laser cutting machines, is prone to errors due to the need for precise alignment and positioning, which can be time-consuming and unreliable, especially when handling large or heavy panels.
Innovation Solution
A method utilizing a camera system spatially calibrated to the machine coordinates of the flatbed machine tool to acquire and evaluate images of the material panel, detect deviations from the target position, and automatically align and position the panel, potentially with the assistance of a lifting device, to ensure accurate and efficient loading.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If manual loading is used for material panels, then flexibility in handling different panel sizes is maintained, but positioning accuracy and alignment precision deteriorate
Solution Approach 1:
The patent replaces manual mechanical positioning with an optical measurement system (camera) that captures panel position and automatically calculates alignment deviations. The system substitutes human judgment and manual adjustment with automated image processing and coordinate transformation algorithms, achieving precise positioning without sacrificing the flexibility to handle various panel formats.
2Manufacturing precision
If manual alignment is performed to achieve correct panel positioning, then positioning accuracy can be improved, but loading time increases
Solution Approach 1:
The system enables self-service positioning by automatically capturing the panel's actual position through the camera, calculating deviations from the target position using coordinate transformations, and providing alignment guidance without requiring manual measurement or adjustment. The panel loading process becomes self-correcting through automated feedback, simultaneously improving precision and reducing the time required for alignment operations.
3Reliability
If stops are provided on the pallet to ensure fixed position loading, then positioning reliability is improved, but the complexity of the loading system increases
Solution Approach 1:
The patent replaces mechanical stops with an optical measurement and calculation system. Instead of relying on physical fixtures to enforce positioning, the camera captures the panel's actual position, and software algorithms calculate the deviation from the target position based on coordinate transformations. This substitution eliminates the need for complex mechanical stopping mechanisms while maintaining or improving positioning reliability through automated measurement and feedback.
Data Source
AI summary
Disclosed is a method for loading a sheet placement device of a flat bed machine tool with a material sheet, wherein the material sheet is supplied to the machining operation carried out by the flat bed machine tool, starting from a target position assigned to the machining operation in a machine coordinate system, and the flat bed machine tool comprises a camera system having at least one camera. The camera system is designed to produce captured images of the sheet placement device, which are calibrated three-dimensionally in relation to the machine coordinate system of the flat bed machine tool. The method comprises the steps: producing a captured image of the material sheet in the region of the sheet placement device; evaluating the captured image to determine an actual sheet position in the machine coordinate system; measuring a deviation of the determined actual sheet position from the target position; and using the measured deviation to align and position the material sheet.