Stone Slab Layout Mirroring for Upside-Down CNC Cutting
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Solution Overview
Problem
Positioning a stone slab upside down for cutting is challenging when the machine is programmed for a slab cut pattern based on the top polished face, as it is difficult to align the slab relative to the software-generated layout.
Innovation Solution
A system comprising an imaging device, controller, and CNC slab processing machine that uses adhered reference markers and a laser projector to mirror image the slab layout, allowing precise alignment and cutting of the slab upside down.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If the slab is positioned upside down for cutting, then the cutting machine can access the slab from below, but it becomes difficult to align and position the slab relative to the software-generated layout based on the top polished face
Solution Approach 1:
The patent creates a digital copy of the slab layout and uses image processing to generate a virtual representation of the slab's bottom surface. This digital copy includes projected images of the top surface features (grain patterns, vein patterns) onto the bottom surface, allowing the operator to align the physical slab with the digital layout without needing to see the top surface directly. The system overlays the layout design onto the processed images of the bottom surface, enabling precise positioning even when the slab is upside down.
Solution Approach 2:
The patent introduces an intermediary system consisting of image processing software and digital visualization tools. This intermediary creates a bridge between the physical slab (which cannot be directly viewed from the top while positioned upside down) and the digital layout. The system captures images of the bottom surface, processes them to show projected top surface features, and overlays the cutting layout onto these processed images, serving as an intermediary visualization layer that enables accurate alignment.
2Manufacturing precision
If the slab cut layout is generated based on the top polished face image, then the vein pattern matching is optimized, but the positioning becomes challenging when the slab is turned upside down for cutting
Solution Approach 1:
The patent inverts the traditional approach by capturing images of the bottom surface instead of the top surface, and by projecting the top surface features onto the bottom surface. Instead of requiring the operator to align the top surface features directly with the layout (which is difficult when upside down), the system projects the top surface grain and vein patterns onto the bottom surface images, allowing the operator to align these projected patterns with the layout while the slab is positioned upside down for cutting.
Solution Approach 2:
The system creates a digital copy of the top surface features (grain patterns, vein patterns) and projects them onto images of the bottom surface. This digital copying allows the layout to be overlaid onto the bottom surface images, enabling the operator to see and align the vein patterns even though the actual top surface is not visible. The digital copy serves as a virtual representation that maintains the vein pattern information needed for matching while allowing upside-down positioning.
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 accurate positioning and cutting of stone slabs upside down by projecting mirror-imaged reference markers, ensuring precise alignment and efficient cutting operations.
Implementation Method 1
a laser projector configured to project the mirror imaged locations of the reference markers
Data Source
AI summary
A system processes a stone slab having a top polished face and bottom surface. An imaging device receives and displays a digital image of the top polished face of the slab. A controller overlays a slab cut layout on the digital image of the top polished face, generates a digital slab layout file containing digital data representative of the top polished face and its slab cut layout referenced to the top end of adhered reference markers, mirror images the digital slab layout file, and projects the mirror imaged locations of the reference markers to facilitate alignment of the bottom ends of the adhered laser markers with the respective projected reference marker locations when the slab is upside down for cutting in a slab cutting position.