Cutting Trajectory Alignment Using Projected Pattern Superposition
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Solution Overview
Problem
Existing cutting machines struggle to achieve high precision in aligning cutting trajectories with graphic patterns on deformable materials like fabrics and leathers, due to dimensional deformability and variability in positioning.
Innovation Solution
An alignment method and apparatus that uses a projector and camera system to project a virtual image of the cutting trajectory and graphic pattern onto the material, allowing for precise alignment by translating the virtual image until it superimposes with the real image, thereby adjusting the cutting trajectory coordinates.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If traditional reference systems on the support table are used to position the flat element, then the positioning process is simple, but the cutting trajectory is displaced by several millimeters or centimeters from the theoretical position
Solution Approach 1:
The patent uses a camera to capture an image of the graphic pattern on the flat element and creates a digital copy (image data) that can be processed and compared with the theoretical cutting trajectory. This allows precise measurement of actual positioning without adding complex physical alignment mechanisms.
Solution Approach 2:
The patent replaces traditional mechanical reference systems and manual alignment procedures with an optical system (camera) and digital image processing. The coordinate transformation is performed computationally rather than through mechanical adjustment mechanisms.
2Adaptability or versatility
If the cutting trajectory coordinates are fixed based on theoretical design, then the manufacturing process is efficient, but the cutting trajectory cannot adapt to actual material deformation and positioning variability
Solution Approach 1:
The patent implements a feedback mechanism where the camera captures the actual position of the graphic pattern, the processing unit calculates the displacement between theoretical and actual coordinates, and the cutting trajectory is adjusted based on this feedback. This closed-loop system adapts to material deformation while maintaining efficiency.
Solution Approach 2:
The patent performs preliminary image capture and coordinate calculation before the cutting operation begins. The displacement values are pre-calculated and stored, allowing the cutting machine to execute adjusted coordinates without real-time interruptions during the actual cutting process.
3Manufacturing precision
If high precision alignment systems are implemented to correct positioning differences, then cutting precision improves, but the system complexity and cost increase significantly
Solution Approach 1:
The patent uses a simple camera to capture an image of the graphic pattern and creates a digital representation that can be precisely analyzed. This optical copying approach achieves high measurement precision without requiring complex mechanical alignment devices or specialized sensors.
Solution Approach 2:
The patent replaces complex mechanical alignment systems with a computational approach using standard camera technology and image processing algorithms. The coordinate transformation and displacement calculation are performed digitally, eliminating the need for precision mechanical adjustment mechanisms.
Data Source
AI summary
A method for aligning a cutting trajectory of a flat element with respect to a graphic pattern present on the flat element, includes positioning the flat element to be cut on a support table, projecting onto the flat element the image of a reference figure uniquely associated with coordinates of the cutting trajectory and/or of the graphic pattern, framing, by a camera, a portion of the flat element where at least one part of the graphic pattern and of the image of the reference figure are present, displaying on a monitor the image framed by the camera and a virtual image of the graphic pattern defined by coordinates of the graphic pattern, and moving the image of the reference figure or the virtual image of the graphic pattern until a portion of the virtual image of the graphic pattern coincides with the corresponding real image of the graphic pattern.