Multi-Camera Laser Fabrication Preview With Distortion Correction
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Solution Overview
Problem
Computer numerical controlled (CNC) machines, particularly laser cutter/engravers, face challenges in safely routing electromagnetic radiation and preventing light from entering or escaping, which complicates the use of machine vision for monitoring and control due to regulatory guidelines and the risk of material destruction if uncontrolled.
Innovation Solution
Incorporating a wide-angle viewing system with cameras inside the CNC machine, including a movable head and interlock systems to prevent electromagnetic energy emission when the openable barrier is not closed, allowing for image generation and processing to remove distortion, enhance contrast, and map pixels to physical locations, enabling real-time monitoring and control.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Difficulty of detecting and measuring
If a wide-angle viewing system with cameras is incorporated inside the CNC machine, then real-time monitoring and control capability is improved, but the complexity of safely routing electromagnetic radiation and preventing light leakage worsens
Solution Approach 1:
The system divides the monitoring function into multiple segments: cameras positioned at strategic locations (including on the movable head and stationary positions), separate interlock systems for different barriers, and distributed image processing capabilities. This segmentation allows real-time monitoring without requiring a single complex centralized system.
Solution Approach 2:
The patent introduces an intermediary processing system that receives images from multiple cameras, processes them to remove distortion and enhance quality, and then uses the processed information for monitoring and control. This intermediary layer simplifies the overall system by centralizing the complex image processing functions while keeping the camera placement relatively simple.
2Area of stationary object
If cameras are positioned to capture the entire working area, then measurement coverage is improved, but distortion and image quality issues worsen
Solution Approach 1:
The system transitions from using a single wide-angle lens to using multiple cameras positioned at different locations and angles. By capturing the working area from multiple perspectives and then stitching the images together, the system achieves both comprehensive coverage and high measurement precision, eliminating the distortion inherent in single wide-angle lenses.
Solution Approach 2:
The patent creates multiple copies of the imaging function through multiple cameras, each capturing a portion of the working area. These multiple image copies are then processed and combined to form a complete, high-accuracy representation of the entire working area, replacing the need for a single imperfect wide-angle image.
3Object-affected harmful factors
If the openable barrier is kept closed to prevent light leakage, then safety is improved, but access for loading and unloading material worsens
Solution Approach 1:
The interlock system provides feedback about the barrier position to the electromagnetic energy emission control. When the barrier is open, the system automatically prevents emission, and when closed, emission is permitted. This feedback mechanism ensures safety without requiring manual intervention, making the access process simpler and faster.
Solution Approach 2:
The system performs self-service safety checking through the interlock mechanism that automatically detects whether the barrier is closed and controls electromagnetic energy emission accordingly. This eliminates the need for manual safety checks by operators, streamlining the material loading and unloading process while maintaining safety.
4Object-affected harmful factors
If electromagnetic energy emission is prevented when barrier is open, then operator safety is improved, but operational efficiency worsens
Solution Approach 1:
The interlock system enables continuous operation by automatically managing the emission control based on barrier position. Operators can quickly open the barrier for material access knowing the system will automatically prevent emission, then close it to resume operation. This continuous automatic control maintains safety without creating manual intervention delays, preserving operational efficiency.
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 safe and accurate real-time monitoring and control of the CNC machine's operations, improving the precision and safety of the manufacturing process by preventing electromagnetic radiation leakage and allowing for image processing to enhance image quality and data extraction.
Implementation Method 1
an openable barrier that attenuates transmission of light between the interior space and an exterior of the computer numerically controlled machine when the openable barrier is in a closed position
Implementation Method 2
An image is generated including at least half of the working area with at least one camera
Data Source
AI summary
A computer numerically controlled machine may include a movable head configured to deliver electromagnetic energy to a part of a working area in which the movable head may be commanded to cause delivery of the electromagnetic energy. The interior space may be defined by a housing and may include an openable barrier that attenuates transmission of light between the interior space and an exterior of the computer numerically controlled machine when the openable barrier is in a closed position. The computer numerically controlled machine may include an interlock that prevents emission of the electromagnetic energy when detecting that the openable barrier is not in the closed position. The commanding may result in the computer numerically controlled machine executing operations of a motion plan for causing movement of the movable head to deliver the electromagnetic energy to effect a change in a material at least partially contained within the interior space.