Overview Camera Cutting for Registration-Based Path Accuracy
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Solution Overview
Problem
Existing cutting machines are inefficient in terms of speed, automation, accuracy, and waste production when handling objects with graphic designs and optical registration features.
Innovation Solution
The cutting machine incorporates a first camera unit with a field of view encompassing the entire work surface, a processing unit for recognizing registration features, and a movable cutting device, along with additional cameras and sensors for calibration and high-contrast imaging to define precise cutting paths.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If a camera unit with field of view encompassing the entire work surface is used, then cutting path definition accuracy is improved, but device complexity increases
Solution Approach 1:
The camera system is divided into a main overview camera for capturing the entire work surface and additional detail cameras for capturing specific areas requiring higher precision. This segmentation allows the system to achieve high measurement precision for cutting path definition while managing device complexity by using a basic overview camera plus optional detail cameras only where needed.
2Productivity
If automated recognition of registration features is implemented, then productivity is improved, but device complexity increases
Solution Approach 1:
The system uses the existing overview camera to capture images that serve dual purposes: both for overview and for automated recognition of registration features. The processing unit automatically identifies registration features and defines cutting paths without human intervention, making the system self-sufficient and improving productivity while avoiding the need for separate dedicated recognition devices.
3Measurement precision
If multiple images are captured and superimposed, then measurement precision is improved, but loss of time increases
Solution Approach 1:
Instead of capturing and processing multiple complete images of the entire work surface, the system captures a single overview image and only processes specific regions containing registration features. This partial action approach maintains measurement precision for position determination while significantly reducing the time loss associated with processing multiple full images.
4Manufacturing precision
If reference features are added to the work surface, then manufacturing precision is improved, but ease of operation deteriorates
Solution Approach 1:
The reference features are designed to match the visual characteristics of the graphic designs on the objects being cut. By making the reference features homogeneous in appearance with the existing graphics, they blend into the overall design and do not create additional operational complexity or difficulty, while still providing the necessary precision for accurate cutting path definition.
Data Source
Figure 1
Figure 2a
Figure 2b~2c
AI summary
Cutting machine (1), designed for cutting objects (40, 40') with a flat surface, the surface having a graphic design (44, 44') with optical registration features, comprising a work surface (10) designed to receive at least one object (40, 40'), a first camera unit (20) arranged relative to the work surface (10) such that its field of view covers the entire work surface (10), a work assembly (12) movably arranged above the work surface (10) and comprising at least one cutting device (15) for cutting the at least one object (40, 40'), and a computing unit (30) with a circuit and program code for controlling the cutting machine (1), comprising a storage unit for storing orders for cutting specific objects (40, 40'),wherein the computing unit (30) comprises a circuit and program code for evaluating images (50) of the first camera unit (20) and is configured to recognize registration features of the at least one object (40, 40') in an image (50) of the first camera unit (20), and is configured to define a cutting path (45, 45') for the cutting device (15) according to at least one stored order and based on the positions of the registration features (42) in the image (50) as well as based on information about the material thickness of the object (40, 40') to be cut.