Cutting Trajectory Alignment Using Projected Pattern Overlay
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Solution Overview
Problem
Existing methods for aligning cutting trajectories with graphic patterns on deformable materials like fabrics and leathers fail to achieve high precision due to positional discrepancies between theoretical and actual cutting paths, despite the use of reference systems.
Innovation Solution
An alignment apparatus comprising a support table, a projector, and a camera, which projects a reference image of the cutting trajectory or graphic pattern onto the material, allowing for precise alignment by superimposing virtual and real images using a user interface and electric motors to adjust the projector's orientation, ensuring accurate positioning before cutting.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If reference systems are used on the support table to help position the flat element, then the ease of operation is improved, but the manufacturing precision deteriorates due to inability to ensure consistent positioning
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 aligned with the cutting trajectory coordinates. This optical copying approach allows precise measurement and alignment without physical contact that might deform the material.
Solution Approach 2:
The patent replaces manual positioning and mechanical alignment methods with an automated optical and computational system. The camera captures the pattern, the processor aligns the image with the cutting trajectory coordinates, and the system automatically determines the correct positioning, eliminating reliance on manual reference system alignment.
2Ease of operation
If the flat element is manipulated and positioned on the support table, then the ease of operation is improved, but the manufacturing precision deteriorates due to displacement from theoretical position
Solution Approach 1:
The system performs preliminary alignment by capturing an image of the graphic pattern before cutting begins. The processor then aligns this image with the cutting trajectory coordinates, allowing any displacement from theoretical positioning to be detected and corrected before the actual cutting operation starts.
Solution Approach 2:
The camera provides visual feedback by capturing the actual position of the graphic pattern on the flat element. This image data is fed back to the processor, which compares it with the theoretical cutting trajectory coordinates and determines the necessary alignment adjustments, creating a closed-loop feedback system for precision positioning.
3Manufacturing precision
If alignment systems are used to correct position differences, then the manufacturing precision is improved, but the device complexity increases
Solution Approach 1:
Instead of complex mechanical alignment mechanisms, the patent uses a simple camera to capture the graphic pattern and creates a digital copy for alignment. This optical copying approach achieves precise alignment with minimal mechanical complexity, as the alignment is performed computationally rather than mechanically.
Solution Approach 2:
The patent replaces complex mechanical alignment systems with an automated optical and computational approach. The camera and image processing system provide the alignment function with far fewer moving parts and mechanical components, reducing overall system complexity while maintaining or improving precision.
Data Source
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AI summary
A method of aligning a cutting trajectory (2) of a flat element (3) with respect to a graphic pattern (4) on said flat element, comprises the steps of: positioning the flat element to be cut on a support table (10); projecting onto the flat element, by means of a projector device (22), the image of a reference figure (6) uniquely associated with coordinates of the cutting trajectory and/or coordinates relative to the graphic pattern; framing, by means of a camera (24), at least a portion of the flat element wherein there is present at least a part of the graphic pattern (4) and at least a part of said image of the reference figure (6); displaying on a monitor the image (8) framed by the camera and a virtual image of the graphic pattern (4') defined by the coordinates relative to the graphic pattern; moving the image of the reference figure (6) or the virtual image of the graphic pattern (4') until a portion of the said virtual image of the graphic pattern coincides with the corresponding real image of the graphic pattern taken by the camera.