Sheet Metal Edge Imaging With Adjustable Lateral Illumination
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Traditional image acquisition apparatuses in sheet metal processing plants struggle to precisely detect the position of sheet metal edges, especially those with deformed and rounded corners, leading to significant position errors that compromise the precision of laser cutting operations.
Innovation Solution
The apparatus features a camera and an illuminator with adjustable positions, where the illuminator can be moved closer to the sheet metal to laterally illuminate the edges, using light sources with a horizontal axis to improve detection sensitivity, reducing position errors between the detected and actual edges.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If the illuminator is positioned at a fixed height above the sheet metal with vertical light cones, then the apparatus structure is simple and easy to manufacture, but the detection precision of deformed and rounded edges is poor due to light diversion
Solution Approach 1:
The illuminator is made movable relative to the camera along the optical axis, allowing dynamic adjustment between a first position (for standard scanning) and a second position (closer to the sheet metal for lateral illumination of deformed edges). This dynamic positioning enables the system to adapt to different edge conditions without requiring multiple fixed apparatus configurations, thus improving detection precision while maintaining reasonable structural complexity.
Solution Approach 2:
The invention changes the illumination parameters by adjusting the illuminator's position and light emission direction. When detecting deformed edges, the illuminator is moved to emit light laterally (horizontally) rather than vertically, changing the illumination angle parameter to optimize edge detection. This parameter adjustment allows precise detection of rounded corners and deformed edges without fundamentally redesigning the entire apparatus structure.
2Measurement precision
If the illuminator emits light with vertical cones orthogonal to the sheet metal surface, then the illumination system is simple to implement, but the detection accuracy of curved surfaces and rounded corners is compromised due to light reflection away from the lens
Solution Approach 1:
The illuminator's position along the optical axis is made adjustable, allowing it to move between a first position (easier to manufacture and implement) and a second position (closer to the sheet metal for improved precision). This dynamic capability enables the system to switch between ease of manufacture and detection accuracy based on the specific application requirements.
Solution Approach 2:
The illumination system changes its operational parameters by adjusting the light emission direction from vertical to lateral (horizontal) when detecting deformed edges. This parameter change allows the system to maintain ease of manufacture while achieving high detection accuracy by simply repositioning and reorienting the illuminator rather than redesigning the entire illumination system.
3Adaptability or versatility
If the camera and illuminator are moved together parallel to the sheet metal surface, then the scanning operation is straightforward, but the ability to adapt to different edge conditions and detection requirements is limited
Solution Approach 1:
The illuminator is given independent movement capability relative to the camera, allowing it to adjust its position along the optical axis while the camera remains stationary or moves differently. This dynamic independence enables the system to adapt to various detection conditions (standard scanning vs. deformed edge detection) while maintaining relatively simple operation through automated or semi-automated control sequences.
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
This configuration achieves more precise edge position detection, with errors reduced to less than one tenth of a millimeter, enhancing the accuracy of laser cutting operations and maintaining operational simplicity at a comparable cost to traditional systems.
Implementation Method 1
The illuminator can be moved closer to the sheet metal to laterally illuminate the edges, using light sources with a horizontal axis to improve detection sensitivity
Data Source
AI summary
The present invention relates to a plant for processing sheet metal, comprising a conveyor for moving sheet metal; at least one image acquisition apparatus placed above a horizontal plane defined by said conveyor. The apparatus in turn comprises a camera comprising a lens; first moving means for moving the camera parallel to the horizontal plane; an illuminator that is placed beneath the camera and is equipped with a plurality of light sources to illuminate a portion of said horizontal plane located beneath the camera. Said apparatus further comprises second moving means for moving said illuminator with respect to said camera perpendicularly to said horizontal plane supporting the sheet metal.