Cutting Edge Position Detection via Multi-Step Image Scanning
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Solution Overview
Problem
Current methods for precisely positioning the cutting edge in machine tools, such as roll lathes, are labor-intensive and prone to errors due to manual alignment, especially when multiple tools are used, requiring submicron precision which is difficult to achieve with existing optical systems.
Innovation Solution
A cutting-edge position detecting method and apparatus that uses camera-based image processing to determine a measurement reference point, perform sampling scanning operations, and apply least-squares methods to recognize edge lines, obtaining precise coordinates of the cutting edge through multiple scanning operations, improving accuracy and reducing manual error.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If manual alignment method is used to position the cutting edge, then the positioning process can be performed with existing optical systems, but the positioning error increases and operational time is extended
Solution Approach 1:
The patent replaces the manual mechanical alignment operation with an automated image processing system. The camera captures the cutting edge image, and the image processing unit automatically detects edge positions and calculates coordinates, substituting the manual mechanical alignment process with an automated optical-digital hybrid system.
Solution Approach 2:
The system performs self-positioning by automatically detecting the cutting edge position through image capture and processing. The image processing unit autonomously identifies edge points, fits lines, and calculates intersection coordinates without requiring manual intervention, enabling the system to service itself in the positioning task.
2Measurement precision
If manual alignment operation is performed, then the existing optical system can be used, but positioning error occurs due to manual operation
Solution Approach 1:
The patent replaces the manual mechanical alignment operation with an automated image processing system. The camera captures the cutting edge image, and the image processing unit automatically detects edge positions and calculates coordinates, substituting the manual mechanical alignment process with an automated optical-digital hybrid system.
Solution Approach 2:
The system creates a digital copy of the cutting edge through camera imaging. Instead of directly manipulating the physical cutting edge position, the system captures an optical copy (image) and performs position detection on this copy through image processing, thereby eliminating manual positioning errors while maintaining measurement capability.
3Manufacturing precision
If submicron precision positioning is required for multiple tools, then the machining quality can be maintained, but the existing optical systems cannot achieve the required precision
Solution Approach 1:
The patent transitions from direct physical measurement to optical image space measurement. By capturing the cutting edge in a two-dimensional image plane and performing coordinate calculations in this digital dimension, the system achieves submicron precision that exceeds the capabilities of direct physical measurement systems.
Solution Approach 2:
The patent replaces the manual mechanical alignment operation with an automated image processing system. The camera captures the cutting edge image, and the image processing unit automatically detects edge positions and calculates coordinates, substituting the manual mechanical alignment process with an automated optical-digital hybrid 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
This method allows for precise detection of the cutting edge position with submicron accuracy, reducing operational time and error, and maintaining high precision even when tools are exchanged, enhancing machining quality in complex patterns like prism sheets.
Implementation Method 1
an image of a cutting edge is taken by a microscope (optical system) connected to an apparatus
Implementation Method 2
an image of a cutting edge is taken by a microscope (optical system) connected to an apparatus
Data Source
AI summary
The cutting-edge position detecting method includes the steps of: under a condition in which the cutting edge of the tool is positioned in an image that is taken by a camera, performing first sampling scanning operations for the image in a predetermined scanning direction at predetermined first intervals, and recognizing points on an upper edge line of the cutting edge of the tool and points on a lower edge line thereof, based on brightness changing points upon the first scanning operations; connecting the recognized points on the respective two edge lines, so as to obtain two first-level approximate linear lines by a least-squares method; performing second sampling scanning operations for the respective two first-level approximate linear lines in directions perpendicular thereto at predetermined second intervals, and newly recognizing points on the upper edge line of the cutting edge of the tool and points on the lower edge line thereof, based on brightness changing points upon the second scanning operations; connecting the newly recognized points on the respective two edge lines, so as to obtain two second-level approximate linear lines by a least-squares method; and obtaining a coordinate of an intersection of the second-level approximate linear lines, as the position of the cutting edge of the tool, with respect to the measurement reference point.