Machining Nozzle Edge Contour Detection Under Changing Illumination
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Solution Overview
Problem
Existing methods for identifying the edge contour of processing nozzles in laser processing machines are time-consuming and costly, lacking robustness against disturbances, which can lead to varying cutting results due to wear and deformation during machining.
Innovation Solution
A method involving sequential image recording of partial regions around the nozzle opening, with changing brightness properties between images, allowing for comparative evaluation to accurately identify the edge contour, even during machining, using multiple images and differential image processing to enhance accuracy and robustness.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If manual checking of the processing nozzle is performed, then the cutting result quality can be maintained, but time-consuming and costly downtimes occur
Solution Approach 1:
The system performs self-diagnosis by automatically capturing images of the processing nozzle opening and analyzing its geometry. The evaluation device autonomously determines the opening diameter and circularity, and compares them against reference values to detect wear or deformation, eliminating the need for manual operator intervention and maintaining continuous production.
Solution Approach 2:
The manual visual inspection and physical measurement process is replaced by an automated optical measurement system. A camera captures images of the nozzle opening, and image processing algorithms automatically analyze the geometry, substituting human operators with an automated vision-based measurement system that operates without stopping the machine.
2Measurement precision
If illumination is used to improve image quality for edge contour identification, then measurement accuracy increases, but reflections and disturbances affect the identification
Solution Approach 1:
The system varies illumination parameters (intensity, angle, color temperature) to optimize the visibility of the edge contour while minimizing reflections. By adjusting these illumination parameters, the system enhances the contrast between the opening edge and surrounding areas, improving measurement accuracy without being adversely affected by harmful reflections.
3Reliability
If continuous monitoring is implemented, then defects can be detected immediately, but the system complexity increases
Solution Approach 1:
The monitoring system is integrated into the existing processing machine structure, sharing hardware components such as the camera and illumination devices with other machine functions. The evaluation device utilizes the same image processing capabilities for multiple purposes including quality control, wear detection, and alignment verification, thereby reducing overall system complexity while maintaining continuous monitoring capability.
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 immediate detection of defects and interventions, reducing rejects by providing high accuracy and robustness against disturbances like reflections, allowing for continuous operation without manual checks.
Implementation Method 1
sequential recording of a plurality of images, each of which is a partial region of an area observed through the opening and at a distance from the processing head, preferably illuminated reference surface
Data Source
Figure 1
Figure 2~3
AI summary
The invention relates to a method for identifying an edge contour (9) of an opening (7) on a machining head (3), in particular an opening (7) in a machining nozzle (6), said method involving: successively capturing a plurality of images containing a subarea of a preferably illuminated reference surface (8) which is viewed through the opening (7) and is located at a distance from the machining head (3) as well as a region on the machining head (3) that surrounds the opening (7), the brightness properties of the reference surface (8) being modified between the points in time when the images are captured; and identifying the edge contour (9) by comparatively analyzing the captured images. The invention also relates to a machining tool (1) for carrying out said method.