CNC Machine Camera Calibration for Accurate Pixel-to-Coordinate Mapping
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Solution Overview
Problem
Existing CNC machines face challenges in accurately mapping image details to real-space coordinates, particularly in complex machining operations, due to variations in optical and mechanical systems, which affect precision and output quality.
Innovation Solution
A method involving image capture by cameras inside the CNC machine enclosure, creating a mapping relationship between pixel locations and physical parameters, enabling precise spatial coordinate mapping and complex machine instructions based on 2-D images.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If image capture and mapping are implemented to improve spatial coordinate precision, then manufacturing precision is improved, but device complexity increases due to additional cameras and calibration systems
Solution Approach 1:
The patent uses camera images (optical copies) of the material bed to create mapping relationships that correspond to physical coordinates. Instead of directly measuring physical positions, the system captures images and maps pixel coordinates to real-world coordinates through calibration patterns, replacing direct physical measurement with optical copying and computational mapping.
Solution Approach 2:
The patent introduces calibration patterns (checkerboard patterns, circular patterns, or linear patterns) as intermediaries between the camera and the material bed. These patterns serve as reference objects that enable the establishment of mapping relationships between image coordinates and physical coordinates, acting as a mediator that facilitates precise spatial correspondence.
2Measurement precision
If calibration patterns are used to improve mapping accuracy, then measurement precision is improved, but ease of operation deteriorates due to additional setup steps
Solution Approach 1:
The calibration patterns are designed to be automatically detected and processed by the camera system. The system captures images of the calibration patterns and automatically computes mapping relationships through image processing algorithms, eliminating the need for manual coordinate measurement and calculation by operators.
Solution Approach 2:
The calibration patterns are placed on the material bed before the actual machining operation begins. The mapping relationship is established in advance through image capture and computational processing, so that when the machining operation starts, the coordinate system is already calibrated and ready for precise control.
3Manufacturing precision
If multiple camera angles are used to improve comprehensive spatial mapping, then manufacturing precision is improved, but loss of time increases due to multiple image captures and processing steps
Solution Approach 1:
The calibration process is divided into discrete steps: placing the calibration pattern, capturing the image, processing the image to detect pattern features, computing the mapping relationship, and storing the calibration data. This segmentation allows for systematic optimization of each step and enables the process to be performed efficiently and repeatably.
Solution Approach 2:
The calibration process is designed to be performed once during setup, and the resulting mapping relationship is stored and reused for all subsequent machining operations. This eliminates the need for repeated calibration during production, making the initial time investment worthwhile by enabling continuous precise operation without recurring calibration delays.
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.