Through-The-Lens Laser Marking With Stitched Field Imaging
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Solution Overview
Problem
Current laser marking systems face challenges in accurately marking large workpieces that exceed the camera's field of view, requiring workpiece-specific fixtures and increased operator training, and external imaging solutions are either slow or inaccurate due to the need for angled imaging or physical movement.
Innovation Solution
A laser marking system that captures multiple images from different locations within the marking field and stitches them into a composite image, allowing for the identification and marking of workpieces larger than the camera's field of view, regardless of orientation, using a through-the-lens camera arrangement that images directly from above, avoiding issues with shading and obstructions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Area of stationary object
If a single camera view is used to capture the marking field, then the system is simple and fast, but it cannot capture workpieces larger than the camera's field of view
Solution Approach 1:
The marking field is divided into multiple overlapping image tiles captured from different locations. These tiles are then stitched together to form a composite image that covers the entire marking field, enabling visualization of workpieces larger than the camera's individual field of view.
Solution Approach 2:
The system transitions from a single 2D camera view to a composite image constructed from multiple 2D views captured at different positions. This dimensional approach allows the system to capture and represent workpieces that exceed the camera's field of view by synthesizing information from multiple spatial perspectives.
2Area of stationary object
If external imaging solutions are used to capture large workpieces, then the field of view is extended, but the accuracy decreases due to angled imaging or physical movement requirements
Solution Approach 1:
The through-the-lens camera serves multiple functions: it captures images through the same optical path as the laser, enabling both marking and vision processing with a single device. This eliminates the need for separate external imaging systems and ensures that the camera views the workpiece from the same perspective as the laser, maintaining accuracy.
Solution Approach 2:
The system uses the same optical path and lens for both laser marking and image capture, creating an accurate optical copy of the workpiece position and orientation. This ensures that the vision system sees exactly what the laser will mark, eliminating discrepancies between imaging and marking perspectives.
3Manufacturing precision
If workpiece-specific fixtures are used to ensure proper orientation, then marking accuracy is maintained, but the device complexity and operator training requirements increase
Solution Approach 1:
The system dynamically adjusts to workpiece orientation by capturing multiple image tiles from different locations and stitching them into a composite image. The vision processing system then identifies the workpiece and determines its orientation automatically, eliminating the need for fixed fixtures that enforce specific orientations.
Solution Approach 2:
The vision system automatically identifies the workpiece, determines its location and orientation, and calculates the appropriate marking position without requiring external fixtures or manual intervention. The system adapts to the workpiece's natural orientation, making the process self-adjusting and reducing fixture dependencies.
4Area of stationary object
If multiple image tiles are captured and stitched to create a composite image, then the field of view is extended to cover large workpieces, but the processing time increases
Solution Approach 1:
The system performs preliminary actions by capturing all necessary image tiles and stitching them into a composite image during the setup phase. Once the composite image is created, the vision processing can quickly identify workpieces and determine marking positions without requiring additional image capture or stitching operations during production.
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
Enables easy training of workpieces for run-time vision processing, reduces job setup time, and allows operators to place workpieces in any orientation, improving alignment accuracy and reducing the need for dedicated fixtures.
Implementation Method 1
a laser, an image capture device, a marking head including electromagnetic energy deflectors and at least one lens, a beam path of the laser and a beam path of the image capture device both passing through the at least one lens
Implementation Method 2
capturing image tiles at each of the multiple different locations with the image capture device
Data Source
Figure 1A
Figure 1B
Figure 1C
AI summary
A laser marking system comprises a laser (140), an image capture device (162), a marking head including electromagnetic energy deflectors (124) and at least one lens (136), a beam path of the laser and a beam path of the image capture device both passing through the at least one lens, and a computer system (150) operable to perform a method comprising capturing image tiles at each of multiple different locations with the image capture device, stitching the image tiles to produce a composite image of the marking field, identifying a location and orientation of an image of a workpiece within the composite image of the marking field, determining a location and orientation of a mark to be applied to the workpiece based on the location and orientation of the image of the workpiece within the composite image of the marking field, and applying the mark to the workpiece (X) with the laser.