Structured Light Surface Mapping for CNC Fabrication Calibration
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Solution Overview
Problem
Computer numerically controlled (CNC) machines face challenges in accurately measuring and processing complex surfaces due to surface irregularities, which can lead to errors in fabrication and require extensive calibration and alignment procedures.
Innovation Solution
The use of structured light projected onto the surface within a CNC machine to determine characteristics such as size, distance, height, and absorptivity, enabling the generation of surface maps that aid in calibration, alignment, and optimization, and subsequent processing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If traditional manufacturing techniques are used, then simplicity of operation is maintained, but manufacturing precision deteriorates due to surface irregularities
Solution Approach 1:
The patent replaces complex mechanical calibration and alignment procedures with an optical measurement system. Structured light is projected onto the surface, and cameras capture the deformed light patterns to automatically determine surface characteristics, eliminating the need for manual mechanical calibration while improving measurement precision.
Solution Approach 2:
The patent creates an optical copy or map of the surface by projecting structured light and capturing the deformed patterns with cameras. This optical copying process automatically records surface irregularities without requiring physical contact or complex mechanical alignment, thereby improving measurement accuracy while reducing procedural complexity.
2Manufacturing precision
If extensive calibration procedures are performed, then manufacturing precision improves, but loss of time increases
Solution Approach 1:
The patent performs preliminary surface mapping by projecting structured light and capturing images before the actual manufacturing process. This advance measurement automatically determines surface characteristics without requiring time-consuming calibration during production, thereby improving precision while reducing time loss.
Solution Approach 2:
The measurement system is self-calibrating through the structured light projection and camera capture process. The system automatically determines surface characteristics by analyzing the deformed light patterns, eliminating the need for operator-performed calibration procedures and significantly reducing the time required while maintaining high precision.
3Productivity
If electromagnetic energy is delivered to process the material, then productivity increases, but manufacturing precision may deteriorate due to unaccounted surface irregularities
Solution Approach 1:
The patent uses the captured surface map as feedback to adjust the electromagnetic energy delivery process. The surface characteristics determined from the structured light measurement are fed back into the manufacturing process to compensate for irregularities, allowing high-speed processing while maintaining precision through real-time adaptation.
Solution Approach 2:
The patent performs preliminary surface mapping before delivering electromagnetic energy for material processing. This advance knowledge of surface irregularities allows the system to pre-compensate for variations in the manufacturing process, enabling both high productivity and precision by avoiding the need for slow, iterative adjustments during actual processing.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This method allows for precise determination of surface characteristics, improving the accuracy of CNC processing by accounting for irregularities and optimizing the delivery of electromagnetic energy, thereby enhancing the consistency and quality of the final product.
Implementation Method 1
a first image of a structured light projected on a surface within a computer numerically controlled machine... the structured light forming a pattern on the surface
Data Source
AI summary
A method may include projecting, onto a surface within a computer numerically controlled machine, a structured light having a known property. One or more sensors may generate an image of the structured light projected on the surface within the computer numerically controlled machine. One or more characteristics of the surface may be determined by comparing a property of the structured light shown in the image to the known property of the structured light. Examples of characteristics include a size, a distance to the surface, a height, a thickness, an angle of the surface, edges, surface properties, jigs, fiducial alignment markers, patterns encoding data, and visual designs on the surface of the material that are intended for reproductions. A surface map indicating the characteristics of the surface at various locations may be generated to enable, for example, a calibration, alignment, and/or optimization of the computer numerically controlled machine.