Structured Light Surface Mapping for CNC Fabrication Alignment
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Solution Overview
Problem
Computer numerically controlled (CNC) machines face challenges in accurately measuring and processing complex surfaces due to surface irregularities, which can lead to errors in fabrication and require extensive calibration and alignment procedures.
Innovation Solution
The use of structured light projected onto the surface within a CNC machine to determine characteristics such as size, distance, height, and absorptivity, allowing for the generation of surface maps that aid in calibration, alignment, and optimization, and enable precise processing by adjusting the electromagnetic energy delivery.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If traditional manufacturing techniques are used, then simple shapes can be produced, but complex surfaces cannot be accurately measured and processed
Solution Approach 1:
The patent replaces traditional mechanical contact-based measurement systems with optical projection and imaging systems. Structured light patterns are projected onto the surface and captured by sensors to create digital surface maps, eliminating the need for physical contact and enabling measurement of complex, irregular surfaces that mechanical probes cannot access.
Solution Approach 2:
The system dynamically adjusts parameters such as electromagnetic energy power levels, focal positions, and exposure settings based on real-time surface characteristics. This allows the system to adapt to varying surface complexities, maintaining measurement accuracy across different geometries and material properties.
2Measurement precision
If extensive calibration and alignment procedures are performed, then measurement accuracy improves, but processing time increases
Solution Approach 1:
The system performs preliminary surface mapping using projected structured light patterns before actual fabrication begins. This initial characterization provides the foundation for subsequent processing, eliminating the need for repeated calibration during production and reducing overall processing time while maintaining accuracy.
Solution Approach 2:
The system uses the workpiece itself as the measurement target, projecting patterns directly onto the surface to be processed. The surface features automatically provide reference information for alignment and calibration, eliminating the need for separate calibration artifacts or additional alignment procedures.
3Productivity
If electromagnetic energy is delivered to process the material, then fabrication is achieved, but surface irregularities cause errors
Solution Approach 1:
The system continuously captures images of the surface during electromagnetic energy delivery and updates the surface map in real-time. This feedback loop allows the system to detect and compensate for surface irregularities, maintaining fabrication accuracy even when processing complex or irregular surfaces.
Solution Approach 2:
The system dynamically adjusts electromagnetic energy parameters such as power, focal position, and exposure time based on real-time surface characteristics. This dynamic adaptation ensures consistent processing quality across surfaces with varying irregularities, maintaining both productivity and precision.
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 method enables accurate measurement and processing of complex surfaces, reducing errors and improving the precision of CNC operations by providing detailed surface maps that inform adjustments to the CNC machine's components and energy delivery.
Implementation Method 1
receiving, from one or more sensors, a first image of a structured light projected on a surface within a computer numerically controlled machine having a head configured to deliver an electromagnetic energy, the structured light forming a pattern on the surface
Implementation Method 2
The one or more characteristics may include... an absorptivity of the surface
Data Source
AI summary
A method may include projecting, onto a surface within a computer numerically controlled machine, a structured light having a known property. One or more sensors may generate an image of the structured light projected on the surface within the computer numerically controlled machine. One or more characteristics of the surface may be determined by comparing a property of the structured light shown in the image to the known property of the structured light. Examples of characteristics include a size, a distance to the surface, a height, a thickness, an angle of the surface, edges, surface properties, jigs, fiducial alignment markers, patterns encoding data, and visual designs on the surface of the material that are intended for reproductions. A surface map indicating the characteristics of the surface at various locations may be generated to enable, for example, a calibration, alignment, and/or optimization of the computer numerically controlled machine.