Position-Sensing Tool Guidance for Precise Edge Machining
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Solution Overview
Problem
Visual guides drawn on material are difficult for users to follow manually, and determining the position of a tool on the material is challenging, especially when working with flat facets or smooth contours.
Innovation Solution
A system with a rig or frame, sensors, cameras, and positioning logic to accurately determine and guide a tool's position on a material, using techniques like lateral probing, probe geometry, and force detection to align with a desired coordinate, and includes features for dust management and edge detection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of information
If visual guides are drawn on material, then users can see the cutting path, but users still have difficulty following the guides manually and determining tool position
Solution Approach 1:
The patent replaces manual visual following with an automated optical sensing system. A camera captures images of the material surface and fiducial markers, while image processing algorithms automatically determine tool position and guide the cutting operation, eliminating the need for manual interpretation of visual guides.
Solution Approach 2:
The patent introduces fiducial markers as intermediary elements between the visual guides and the tool positioning system. These markers serve as reference points that the camera system detects to calculate precise tool positions, acting as a mediator that transforms visual information into actionable positioning data.
2Device complexity
If manual following of visual guides is used, then no additional equipment is needed, but tool position determination becomes challenging and inaccurate
Solution Approach 1:
Fiducial markers serve as intermediary reference elements that enable precise measurement. The camera system detects these markers to establish a coordinate system and determine tool position with high accuracy, transforming a complex measurement problem into a straightforward marker detection task.
Solution Approach 2:
The system creates a digital copy of the physical workspace through image capture and processing. By mapping the physical material surface and fiducial markers into a digital image space, the system can perform precise position calculations and guide the tool with sub-millimeter accuracy.
3Measurement precision
If automated sensing systems are implemented, then tool position can be determined accurately, but device complexity increases with sensors, cameras, and positioning logic
Solution Approach 1:
The system implements a feedback loop where the camera continuously monitors tool position relative to fiducial markers, and the control system adjusts tool movements based on this feedback. This closed-loop control maintains high positioning accuracy while allowing for systematic and manageable system complexity.
Solution Approach 2:
The camera system serves multiple functions: capturing fiducial marker positions for tool guidance, detecting material edges, and monitoring the cutting process. This multi-functionality reduces the need for separate specialized sensors, managing overall system complexity while maintaining measurement precision.
4Manufacturing precision
If probing techniques are used to detect edges, then accurate edge detection is achieved, but the process time increases due to multiple measurement points
Solution Approach 1:
The system performs preliminary scanning of the material surface to detect edges and features before the actual cutting operation begins. This preliminary action allows the system to pre-calculate tool paths and positions, ensuring manufacturing precision while minimizing time loss during the actual cutting process.
Solution Approach 2:
The camera system continuously captures images during material handling and setup, performing edge detection and position calculation in parallel with other operations. This continuity eliminates idle time, maintaining high measurement precision without adding to the overall process time.
Data Source
AI summary
A position sensing tool for enabling topographical measurements of a working surface is provided. The tool includes sensors for mapping the tool environment and for positioning of the tool within the environment. The tool enables tracking of tool activity within the environment. The tool enables design and fabrication collaboration with other computer systems. The tool enables user and tool environment safety using tool positional, user position and tool environment awareness. Certain embodiments of the tool permit automated guidance of tasks in the tool environment.