3D Model Interference Highlighting for NC Machine Tool Safety
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Solution Overview
Problem
Conventional display apparatuses for NC machine tools do not adequately allow operators to check the movement status and safety of movable structures during manual operations, as they only display the position of tools relative to workpieces and do not provide sufficient information for determining if the movable structures are moving in the intended direction or if there are interfering objects.
Innovation Solution
A display apparatus connected to a machine tool that includes a model data storage unit, a model generation unit, an interference-caution-specifying unit, and an image display unit, which generates three-dimensional models of movable and interfering structures, determines potential interference, and highlights the interference caution portion on the display image to assist operators in performing accurate safety checks.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If only tool position and workpiece image are displayed, then the display apparatus is simple, but the operator cannot perform safety checks or verify movement status
Solution Approach 1:
The patent introduces a three-dimensional virtual model of the movable structure that can be viewed from multiple angles and directions. This dimensional enhancement allows the operator to see behind and around the movable structure, providing comprehensive movement status information without adding physical cameras to all positions. The virtual model complements the two-dimensional video image to provide complete safety check capabilities.
Solution Approach 2:
The patent creates a virtual copy (three-dimensional model) of the movable structure that mirrors its real-time position and orientation. This virtual model serves as an information-rich representation that shows the movement status, including areas not visible in the physical camera view. The virtual model is updated based on position data from the numerical controller, providing continuous movement status information.
2Reliability
If video camera is used to capture images, then the operator can see the workpiece and tool, but cannot determine if the movable structure is moving in the intended direction or detect interfering objects
Solution Approach 1:
The patent merges the video image from the physical camera with the three-dimensional virtual model of the movable structure into a composite display. The video image provides real visual confirmation of the workpiece and tool, while the virtual model overlays spatial context, movement direction, and potential interference information. This combination allows the operator to verify both the visual state and the spatial-movement state simultaneously.
Solution Approach 2:
The three-dimensional virtual model acts as an intermediary that translates numerical controller position data into visual spatial representation. It mediates between the raw position coordinates and the operator's need to understand movement direction and potential interference. The virtual model provides the missing spatial context that neither the video camera alone nor the numerical data alone can provide.
3Loss of information
If multiple cameras are installed to provide comprehensive views, then complete coverage is achieved, but the device complexity and cost increase significantly
Solution Approach 1:
The patent replaces the mechanical system of multiple physical cameras with a computational three-dimensional model generated from numerical controller data. Instead of installing cameras at multiple positions to capture all views, the system uses software-based virtual modeling that can represent the movable structure from any angle. This substitution dramatically reduces hardware complexity while providing equivalent or superior information.
Solution Approach 2:
The three-dimensional virtual model serves multiple functions simultaneously: it shows the current position, indicates movement direction, identifies potential interference zones, and can be viewed from any angle. A single virtual model system replaces what would otherwise require multiple specialized cameras and viewing systems, providing universal access to comprehensive movement information through one integrated interface.
Data Source
AI summary
A display apparatus has a display 40, a model data storage unit 37 storing therein three-dimensional model data of a movable structure and a structure having a possibility of interfere with the movable structure, a model generation unit 33 generating a three-dimensional model in which three-dimensional models of the structures are arranged in a three-dimensional space, an interference-caution-portion specifying unit 34 specifying a portion of the movable structure having a possibility of contact with an interfering structure as an interference caution portion when an interfering structure exists and specifying a leading portion of the movable structure in a moving direction as an interference caution portion when an interfering structure does not exist, and an image display unit 35 generating an image with the interference caution portion highlighted based on the three-dimensional model generated by the model generation unit 33 and displaying the image on the display 40.