Laser Flatbed Residual Sheet Detection for Collision-Free Nesting
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Solution Overview
Problem
Conventional laser cutting machines face inefficiencies in utilizing residual sheet metal due to the need for precise positioning and rectangular edges, which limits the use of residual areas and increases the risk of collisions during cutting processes.
Innovation Solution
A method utilizing a camera system to capture images of the residual panel, analyze edge profiles and interior cutouts, and generate panel planning geometry data, allowing for the detection of residual areas without markers or specific sheet metal storage requirements, and enabling the creation of cutting plans that avoid overlaps with existing cutouts.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional laser cutting machines use fixed stop positions and require precise positioning, then cutting precision is maintained, but residual sheet utilization is limited and material efficiency decreases
Solution Approach 1:
The system performs preliminary actions by capturing images of the residual sheet before cutting planning, automatically detecting edge profiles and interior cutouts, and pre-calculating optimal cutting paths that utilize available material space, thereby enabling efficient residual sheet usage without compromising cutting precision
Solution Approach 2:
The patent replaces the mechanical positioning system with fixed stop positions with an optical detection system using cameras and image processing. This substitution allows the system to automatically identify the actual sheet position and geometry, enabling flexible utilization of residual sheets without requiring precise mechanical positioning or rectangular edges
2Loss of time
If manual measurements and positioning are used for residual sheets, then setup time is reduced, but the risk of collisions during cutting increases
Solution Approach 1:
The system implements feedback by capturing real-time images of the residual sheet, automatically detecting its actual geometry and position, and using this information to dynamically adjust the cutting plan. This closed-loop approach eliminates manual measurement errors and provides accurate collision avoidance by base on actual sheet configuration
Solution Approach 2:
The patent creates a digital copy of the residual sheet's actual geometry through image capture and processing. This digital model is then used for cutting plan generation and collision detection, replacing manual measurements and providing accurate geometric representation for safe cutting path planning
3Loss of substance
If residual sheets with irregular edges and cutouts are used, then material utilization improves, but the complexity of cutting plan generation increases
Solution Approach 1:
The system performs self-service by automatically detecting the residual sheet's edge profile and interior cutouts through image processing, and autonomously generating the cutting plan based on the detected geometry. This eliminates the need for manual intervention in complex plan generation while maximizing material utilization of irregular sheets
Solution Approach 2:
The patent changes the approach from fixed geometric parameters (rectangular sheets, fixed stop positions) to variable parameters detected through image processing. The system adapts to any sheet geometry by detecting actual edge profiles and cutout positions, then adjusts the cutting plan parameters accordingly, enabling efficient utilization of irregular residual sheets
Data Source
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Figure 5A~5C
AI summary
A method (54) for providing geometrical sheet-planning data (31) for planning a laser cutting operation to be carried out using a flatbed laser machine (1) comprises the following steps: generating (step 55) an image recording (21) of a residual sheet (23) using a camera (9), wherein the residual sheet (23) has been machined by a flatbed laser machine (1) and has inner cutout regions (25), from which cut material has been removed, evaluating (step 57A) the image recording (21) for determining a residual sheet outer contour (23A) of the residual sheet (23), evaluating (step 57B) the image recording (21) for determining an inner cutout region of the residual sheet (23) lying within the residual sheet outer contour (23A), wherein the inner cutout region is determined by an inner cutout contour (23B) identified in the image recording and/or by a threshold value analysis of the image recording, deriving (step 59) a residual area (24) of the residual sheet (23) by using the residual sheet outer contour (23A) and the inner cutout region, wherein the residual area (24) can be based on a laser cutting operation, and outputting (step 61) geometrical sheet-planning data (31) which define the geometry of the residual area (24).