Camera-Calibrated Sheet Loading for Precise Flatbed Machine Alignment
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Solution Overview
Problem
The existing methods for loading sheet materials into flatbed machine tools, such as laser cutting machines, are inefficient and lack flexibility, often requiring manual alignment with stops and lacking precise positioning, especially for larger sheets.
Innovation Solution
A method utilizing a camera system spatially calibrated to the machine coordinate system to generate images of the sheet storage device, determining the actual panel position, and adjusting it to a target position, optionally with a lifting device, ensuring precise alignment and automated or semi-automated placement.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If manual loading with stops is used, then the loading process is simple, but positioning precision and alignment accuracy deteriorate
Solution Approach 1:
The patent replaces the mechanical stop-based alignment system with an optical measurement system (camera) and computational correction. The camera captures the actual sheet position, and the control unit calculates deviations from the target position, enabling precise digital alignment measurement without mechanical contact.
Solution Approach 2:
The patent creates a digital copy of the sheet's actual position through camera imaging. This optical copy is then processed by the control unit to determine positional deviations, allowing virtual alignment verification and correction planning without physical measurement tools.
2Productivity
If lifting device is used for larger sheets, then loading capability is improved, but device complexity increases
Solution Approach 1:
The patent makes the camera system and control unit serve multiple functions: they not only measure sheet position for alignment but also track the lifting device's movement and coordinate with it for precise positioning. This multi-functionality justifies the added complexity by providing comprehensive control and measurement capabilities.
Solution Approach 2:
The patent implements a feedback loop where the camera continuously monitors the sheet's actual position during loading, the control unit calculates deviations from the target position, and this information feeds back to guide the lifting device's positioning actions, enabling closed-loop precise control.
3Manufacturing precision
If camera system and image evaluation are implemented, then positioning precision is improved, but measurement and detection difficulty increases
Solution Approach 1:
The patent enables the system to self-measure and self-correct positioning deviations. The camera automatically captures images, the control unit autonomously evaluates the sheet position and calculates deviations, and the system self-adjusts by guiding the lifting device to the correct position without requiring external measurement tools or manual intervention.
Solution Approach 2:
The patent replaces complex manual measurement and alignment procedures with automated optical detection and computational analysis. The camera system and image processing algorithm substitute for traditional mechanical measurement tools, simplifying the operational process despite the sophistication of the underlying technology.
4Manufacturing precision
If automated positioning based on deviation recording is used, then loading accuracy is improved, but process time increases
Solution Approach 1:
The patent performs preliminary measurement and deviation calculation immediately when the sheet is loaded, capturing the position data early in the process. This allows the control unit to pre-calculate the required corrections and guide the lifting device efficiently, minimizing the time needed for alignment adjustments.
Solution Approach 2:
The patent maintains continuous operation by integrating the measurement, evaluation, and correction processes into a seamless workflow. The camera continuously monitors, the control unit continuously processes data, and the lifting device continuously adjusts position, eliminating idle time between measurement and correction actions.
Data Source
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AI summary
Disclosed is a method for loading a sheet placement device of a flat bed machine tool (1) with a material sheet (9), wherein the material sheet (9) is supplied to the machining operation carried out by the flat bed machine tool (1), starting from a target position (57) assigned to the machining operation in a machine coordinate system, and the flat bed machine tool (1) comprises a camera system having at least one camera (15). The camera system is designed to produce captured images (22) of the sheet placement device, which are calibrated three-dimensionally in relation to the machine coordinate system of the flat bed machine tool (1). The method comprises the steps: producing (step 101) a captured image (22) of the material sheet (9) in the region of the sheet placement device; evaluating (step 103) the captured image (22) to determine an actual sheet position (55) in the machine coordinate system; measuring (step 105) a deviation of the determined actual sheet position (55) from the target position (57); and using (step 107) the measured deviation to align and position the material sheet (9).