Cutter Calibration via Virtual Coordinate System Offset Correction
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Solution Overview
Problem
Cutting machines face discrepancies between actual and expected cut locations due to manufacturing tolerances, positioning errors, and backlash in the drive unit, which are compounded by variability in cutter shape, location, and orientation, making calibration challenging, especially in automatically positioned cutters.
Innovation Solution
A system comprising a cutter, sensor, and controller that uses a virtual coordinate system to adjust the cutter position based on the offset between actual and expected cut locations, allowing for calibration by detecting the actual cut location and correcting for discrepancies, with the controller including a processor and memory to execute instructions for calibration.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If mechanical alignment mechanisms are used for calibration, then the calibration process is simplified, but the precision and accuracy of cutter positioning are insufficient due to manufacturing tolerances and wear
Solution Approach 1:
The patent replaces mechanical alignment mechanisms with an optical measurement system. A camera captures images of the cutter position, and image processing algorithms calculate the actual cutter location. This substitution eliminates the accumulation of manufacturing tolerances inherent in mechanical linkages while providing high-precision measurement through digital image analysis.
Solution Approach 2:
The patent creates a virtual copy of the physical cutter position through digital imaging. Instead of relying on physical alignment mechanisms, the system captures the cutter's position via camera images and processes these images to determine the actual location. This digital copy allows for precise measurement and calibration without the errors associated with mechanical copying or transmission mechanisms.
2Manufacturing precision
If feedback based calibration is used to determine actual cutter position, then positioning accuracy can be improved, but the system complexity and difficulty of implementation increase significantly
Solution Approach 1:
The patent introduces an intermediary measurement system consisting of a camera and image processing algorithms. Instead of directly measuring the cutter position with complex sensors or encoders, the system uses captured images as an intermediary to infer the cutter's actual position. This intermediary approach simplifies the measurement system while maintaining high accuracy through computational image analysis.
Solution Approach 2:
The patent replaces complex mechanical feedback mechanisms with an optical-digital feedback system. Instead of using encoders, resolvers, or other mechanical position sensors that add system complexity, the system uses a camera to capture position information and processes these images digitally to determine the cutter's actual location, thereby simplifying the overall system architecture.
3Manufacturing precision
If iterative manual calibration is performed, then the cutter can be positioned accurately at the target location, but the calibration time and productivity are reduced
Solution Approach 1:
The patent enables the calibration system to perform self-measurement and self-correction. The camera automatically captures the cutter position, the image processing algorithm automatically calculates the actual location, and the system automatically determines the correction amount. This automated self-service approach eliminates the need for time-consuming manual iterative adjustments while maintaining high positioning accuracy.
Solution Approach 2:
The patent implements an automated feedback loop where the camera continuously monitors the cutter position, the image processing system calculates the deviation from the target position, and the control system automatically applies corrections. This automated feedback mechanism replaces manual iterative calibration, significantly reducing calibration time while maintaining or improving positioning accuracy through continuous real-time adjustments.
Data Source
AI summary
A cutter is positioned at a cutting position according to a virtual coordinate system. Media is cut at the cutting position using the cutter to create a cut. The actual location of the cut in the media is detected and the virtual coordinate system is calibrated based on an offset between the cutting position and the actual cut location.