Machining System 3D Shape Generation via Multi-Position Camera Imaging
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Solution Overview
Problem
Existing machining systems face challenges in accurately generating three-dimensional shapes due to tool wear, as they rely on pre-stored shape data that may not reflect the actual tool condition during machining.
Innovation Solution
A machining system that includes a machine tool and a three-dimensional shape generating apparatus, where a camera moves relative to the spindle or table to capture images from different positions, allowing for the generation of accurate three-dimensional shapes by determining feature points and relative distances, and comparing pre- and post-machining shapes to estimate tool wear or chip attachment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If pre-stored shape data is used for three-dimensional shape generation, then the system complexity is reduced, but the measurement precision deteriorates due to tool wear causing deviation from actual tool shape
Solution Approach 1:
The patent captures images of the tool at multiple predetermined positions before machining begins, storing these images for later three-dimensional shape generation. This preliminary capture ensures the shape data reflects the actual tool condition at the time of machining, not a potentially outdated pre-stored model, thereby maintaining measurement precision without requiring complex real-time sensing systems during machining.
Solution Approach 2:
The patent creates a three-dimensional shape model by synthesizing images captured at multiple positions around the tool. This optical copying approach generates an accurate digital representation of the tool's actual geometry without requiring physical measurement devices, balancing measurement precision with system simplicity by using image processing rather than complex sensing hardware.
2Device complexity
If a single camera is used for image capture, then the device complexity is reduced, but the measurement precision deteriorates due to limited viewing angles
Solution Approach 1:
The patent divides the image capture process into multiple discrete positions around the tool (e.g., front, rear, left, right views). By capturing images at these segmented positions sequentially with a single camera, the system achieves complete geometric coverage equivalent to multiple cameras, maintaining measurement precision while using simpler single-camera hardware.
Solution Approach 2:
The patent adds the time dimension to the imaging process by capturing images at multiple positions sequentially rather than simultaneously. This temporal sequencing allows a single camera to gather three-dimensional information from multiple angles, achieving the same measurement precision as multi-camera systems without the complexity of synchronizing multiple devices.
3Device complexity
If the camera remains stationary during image capture, then the device complexity is reduced, but the measurement precision deteriorates due to inability to capture multiple positions
Solution Approach 1:
The patent merges the camera's movement with the existing table or spindle movement of the machining system. By utilizing the already-present motion capabilities of the machine tool to reposition the camera, the system achieves multi-position imaging without adding independent camera positioning mechanisms, maintaining device simplicity while enabling accurate three-dimensional shape capture.
Solution Approach 2:
The patent makes the camera part of the movable components of the machining system, allowing it to serve dual functions: both imaging and participating in the coordinated motion with the table or spindle. This multi-functionality enables the camera to capture images at multiple positions using the machine's existing motion control, avoiding the need for separate complex positioning systems.
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
This approach enables accurate and easy generation of three-dimensional shapes, improving machining precision by accounting for tool wear and chip attachment, thereby enhancing the accuracy of machined workpieces.
Implementation Method 1
a camera configured to move together with the table relative to the spindle so as to take an image of the spindle side, or to move together with the spindle relative to the table so as to take an image of the table side
Data Source
AI summary
A machining system includes a machine tool having a camera, and a three-dimensional shape generating apparatus. The three-dimensional shape generating apparatus includes an image capture unit that captures a first image from the camera at a first relative position and captures a second image from the camera at a second relative position, and a shape generator that generates a three-dimensional shape of at least one subject, based on the first image, the second image and a distance between the first relative position and the second relative position.