Support Bar Geometry Scanning for Worn Projection Detection
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Solution Overview
Problem
Existing methods for determining the actual state of support bars and workpiece supports in machine tools, particularly in laser flatbed machines, fail to effectively monitor functional features like projection height, leading to potential wear and damage that can impair machining processes.
Innovation Solution
The method involves using a light section technique to determine the actual geometry of support projections by projecting a light line onto the support bar, scanning it with a camera, and comparing the results to a defined target geometry, allowing for the assessment of projection height and condition, which informs part assignment and processing adjustments to ensure trouble-free machining.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If support bars are used to support workpieces during machining, then workpiece stability is improved, but support projections become worn and damaged over time, impairing functionality
Solution Approach 1:
The system performs preliminary detection of support projection geometry before machining operations. By scanning and evaluating the actual state of support projections in advance, the system identifies worn or damaged projections before they can cause workpiece instability or machining defects, allowing for preventive maintenance or workpiece positioning adjustments.
Solution Approach 2:
The system implements continuous feedback by repeatedly scanning support projections during machine operation cycles. The actual geometry measurements are compared against target geometry values, and this feedback information is used to adjust workpiece support positioning or alert operators about support bar condition, maintaining workpiece stability despite wear.
2Loss of information
If traditional light barriers or line scan cameras are used to monitor support strips, then transverse extension can be recorded, but functional features like projection height cannot be effectively monitored
Solution Approach 1:
The system transitions from two-dimensional monitoring (transverse extension only) to three-dimensional monitoring by adding height measurement capability. The scanning device projects light lines and captures images from multiple perspectives to determine the actual geometry including projection height, providing comprehensive spatial information about support projections.
Solution Approach 2:
The system replaces traditional mechanical or simple optical sensors with a sophisticated optical scanning system using light line projection and image capture. This substitution enables non-contact, high-precision measurement of projection height and geometry without physical contact that could damage worn projections.
3Device complexity
If support projections are not monitored, then device complexity is reduced, but machining quality deteriorates due to undetected wear and damage
Solution Approach 1:
The scanning device serves multiple functions: it monitors support projection geometry, detects wear and damage, validates workpiece support conditions, and provides data for process optimization. This multi-functionality justifies the added complexity by delivering comprehensive monitoring capabilities that ensure machining quality through a single integrated system.
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 approach enables the detection of worn or deformed support projections, preventing tilting and welding issues, ensuring high-quality machining results by accurately determining the actual geometry of support projections and adjusting machining processes accordingly.
Implementation Method 1
a light source for projecting a light line onto the support bar to be detected
Implementation Method 2
scanning the support bar to be detected with the light line... the long side of the support bar scanned with the light line is detected in the scanned extent by an optical detector, in particular by a camera
Data Source
Figure 1~2
Figure 3~4
AI summary
In the case of methods and devices for determining the actual state of a support bar (18) and/or of a workpiece support (17) for supporting a plate-type workpiece, more particularly a metal sheet, at a machine tool for cutting workpieces by means of a cutting beam, the actual geometry of support protrusions of the support bar(s) is determined using a light section method, in which a light line running in the longitudinal direction of the support bar(s) (18) is projected from a light source onto the longitudinal side of the support bar(s) (18) and the longitudinal side of support bar(s) (18) is scanned by means of the light line in the direction of the height of the support bar over at least part of the height range associated with the support protrusions. The portion of the longitudinal side of the support bar(s) (18) that is scanned by means of the light line is captured by means of an optical detector, an image of the longitudinal side of the support bar(s) thus being produced, and the actual geometry of the support protrusions is determined on the basis of the produced image by means of an evaluation device. The determined actual geometry of the support protrusions is compared with a defined intended geometry of the support protrusions by means of a comparison device.