Machine Tool Imaging for Automated Tool Shape Registration
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Solution Overview
Problem
The registration of tool IDs and shapes in machine tools is burdensome and prone to input errors, particularly due to the varying shapes and sizes of tools, which can lead to tool contact issues during machining.
Innovation Solution
An image processing device captures partial images of tools using a camera and adjusts the relative positions to generate tool shape data by detecting edge-points, allowing for automated tool registration and efficient shape recognition.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If manual registration of tool IDs and shapes is performed, then tool shape data can be obtained, but the workload increases and input errors occur
Solution Approach 1:
The patent replaces the manual mechanical registration process with an automated image recognition system. A camera captures images of the tool, and image processing algorithms automatically extract tool shape data and associate it with the tool ID, eliminating manual data entry and reducing errors.
Solution Approach 2:
The patent creates a digital copy of the tool's physical shape through image capture and processing. The captured images are processed to generate tool shape data that serves as a digital representation, replacing the need for manual measurement and data entry.
2Adaptability or versatility
If tools vary in shape and size, then tool versatility increases, but tool contact issues occur during machining
Solution Approach 1:
The patent implements a feedback mechanism where the machine tool system uses the registered tool shape data to monitor and adjust machining parameters. By comparing actual tool positions with the registered shape information, the system can predict and prevent potential tool contacts with workpieces or other equipment.
Solution Approach 2:
The patent performs preliminary registration of tool shapes before actual machining operations. This advance preparation allows the system to have complete tool geometry information available, enabling proactive collision avoidance strategies during subsequent machining operations.
3Measurement precision
If complete tool images are captured, then shape recognition accuracy improves, but imaging time increases
Solution Approach 1:
The patent divides the tool imaging process into multiple partial images captured from different positions. Instead of attempting to capture the entire tool in a single image, the system captures segmented views and processes them separately, then combines the results to create complete tool shape data.
Solution Approach 2:
The patent transitions from two-dimensional partial images to three-dimensional tool shape representation. By capturing images from multiple positions and processing them to generate 3D shape data, the system achieves comprehensive shape recognition while maintaining efficient imaging throughput.
Data Source
AI summary
An image processing device includes: an imaging execution unit that captures a first partial image including a part of a tool by a camera, a position specifying unit that specifies a next imaging position on the basis of a partial shape of the tool included in the first partial image, and a position control unit that changes the relative positions of the tool and the camera to the specified imaging position. The imaging execution unit captures a second partial image including a part of the tool at the next imaging position.