Contactless Surface Sensing for Precise Workpiece Machining

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Solution Overview

Problem

Existing wood processing machines face issues with mechanical sensing devices causing damage to sensitive workpiece surfaces and requiring additional installation space, which affect machining quality and efficiency.

Innovation Solution

Implementing contactless sensing using distance sensors and cameras to control the machining tool's position relative to the workpiece, eliminating the need for mechanical sensing devices and allowing precise, automated machining operations.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Manufacturing precision

If a mechanical sensing device is used to guide the machining tool, then the machining precision can be maintained, but the workpiece surface may be damaged and additional installation space is required

Engineering Contradiction:

Improvemachining precisionVSAvoidworkpiece surface damage

Core Design Contradiction:

Manufacturing precisionVSObject-affected harmful factors

Solution Approach 1:

The patent replaces mechanical sensing devices with optical sensors (cameras) and distance sensors to detect workpiece surface position and contours. This substitution eliminates mechanical contact between the sensing device and workpiece surface, preventing surface damage while maintaining machining precision through non-contact measurement and real-time tool position control.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The patent introduces an intermediary control system that receives detection data from optical sensors and distance sensors, processes the information to determine optimal tool positions, and sends control signals to the machining tool. This intermediary system enables precise tool guidance without direct mechanical contact with the workpiece surface.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Ease of operation

If a mechanical sensing device is used to guide the machining tool, then the machining operation can be controlled, but the device complexity and installation space increase

Engineering Contradiction:

Improvemachining operation controlVSAvoiddevice structure

Core Design Contradiction:

Ease of operationVSDevice complexity

Solution Approach 1:

The patent replaces complex mechanical sensing devices with optical sensors and distance sensors that have simpler structures and require less installation space. The mechanical components are substituted with electronic and optical systems that achieve the same control function with reduced physical footprint and simplified device architecture.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The patent uses optical sensors to create an optical copy or digital representation of the workpiece surface geometry and position. This digital model is then used by the control system to guide the machining tool, eliminating the need for complex mechanical sensing structures while maintaining accurate machining operation control.

Inventive Principle:

Principle #26Copying

3Object-affected harmful factors

If contactless sensing is used to control the machining tool, then the workpiece surface is protected and space requirements are reduced, but the system requires sensor devices and control mechanisms

Engineering Contradiction:

Improveworkpiece surface damageVSAvoidsensor device and control system

Core Design Contradiction:

Object-affected harmful factorsVSDevice complexity

Solution Approach 1:

The patent replaces mechanical contact-based sensing with optical and electromagnetic sensing systems. Although this introduces sensor devices and control mechanisms, the overall system complexity is reduced compared to mechanical sensing devices, and the benefits of non-contact operation (surface protection, reduced installation space) outweigh the added electronic system requirements.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

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

Ensures high machining quality by preventing surface damage and reducing space requirements while enabling precise control of machining profiles and tools.

Implementation Method 1

a sensor device (15) for contactless detection of a surface (16) of the workpiece (11) to be machined

Methodology Applied

Scientific EffectOptical detection: Light

Implementation Method 2

The sensor device may comprise at least one distance sensor, at least one camera and/or the like, and may be configured to detect a distance to the surface

Methodology Applied

Scientific EffectDistance measurement: LIDAR

Data Source

PatentUS20260027747A1Machining device and method for machining a workpiece

Publication Date: 2026.01.29 HOMAG GMBH

AI summary

A machining device (10) for machining a workpiece (11) that preferably consists at least in parts of wood, wood materials, plastic or the like, comprising at least one machining unit (13, 14) with a tool device (21) for machining the workpiece (11), a sensor device (15) for contactless detection of a surface (16) of the workpiece (11) to be machined, wherein the tool device (21) can be controlled to carry out a machining operation based on a detection result of the sensor device (15).