CNC Machine Calibration Using Image-to-Coordinate Mapping
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Solution Overview
Problem
Computer-numerically-controlled (CNC) machines face challenges in accurately calibrating optical and mechanical systems, leading to inconsistencies in precision and complexity of machined objects due to difficulties in mapping image data to real-space coordinates, especially in environments with varying lighting conditions and material thickness.
Innovation Solution
The method involves capturing images of the CNC machine with cameras inside the enclosure, creating a mapping relationship between pixel coordinates and physical locations, compensating for differences in image parameters such as lighting and material shape, and using this mapping to adjust the CNC machine's operations for precise spatial control.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If image data is captured and mapped to real-space coordinates for CNC calibration, then manufacturing precision is improved, but device complexity increases due to the need for additional cameras and calibration systems
Solution Approach 1:
The patent uses a camera to capture an image of the material bed and creates a mapping between pixel coordinates in the image and real-world coordinates on the material bed. This optical copy allows the system to determine physical locations without direct mechanical measurement, improving precision while managing complexity through software-based coordinate transformation.
Solution Approach 2:
The patent introduces an intermediary calibration process that captures images of the material bed and establishes a mapping relationship between image space and physical space. This intermediary mapping layer allows the CNC system to translate between camera coordinates and machine coordinates, resolving the contradiction by adding a software-based translation layer rather than complex hardware modifications.
2Measurement precision
If compensation for lighting conditions and material shape is implemented, then measurement precision is improved, but ease of operation deteriorates due to additional calibration steps
Solution Approach 1:
The patent performs preliminary calibration by capturing images of the material bed before machining operations and establishing the coordinate mapping in advance. This preliminary action creates a reference framework that accounts for lighting conditions and material shape variations, improving measurement precision while allowing the actual machining operations to proceed without repeated calibration steps.
Solution Approach 2:
The patent uses image capture and coordinate mapping as a feedback mechanism to determine the location of material on the material bed. The system captures images, processes them to establish coordinate relationships, and uses this information to adjust machining operations, creating a closed-loop system that improves precision through automatic feedback rather than manual adjustment.
3Measurement precision
If multiple cameras are used to capture images of the material bed, then measurement precision is improved, but loss of time increases due to multiple image captures and processing steps
Solution Approach 1:
The patent captures images of the material bed at specific moments during operation rather than continuously, using partial action to obtain sufficient measurement precision without the time cost of continuous imaging. The system captures images at key points in the machining process, processing only the necessary data to establish coordinate mappings, thereby reducing time loss while maintaining measurement accuracy.
Data Source
AI summary
A method for calibrating a computer-numerically-controlled machine can include capturing one or more images of at least a portion of the computer-numerically-controlled machine. The one or more images can be captured with at least one camera located inside an enclosure containing a material bed. A mapping relationship can be created which maps a pixel in the one or more images to a location within the computer-numerically controlled machine. The creation of the mapping relationship can include compensating for a difference in the one or more images relative to one or more physical parameters of the computer-numerically-controlled machine and/or a material positioned on the material bed. Related systems and/or articles of manufacture, including computer program products, are also provided.