Supporting Bar Position Detection Using Contrast Imaging
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Solution Overview
Problem
Existing methods for detecting the suspension position of supporting bars in flatbed machine tools, such as laser-cutting or plasma-cutting machines, are inefficient due to unproductive downtimes caused by scanning empty pallets, especially under adverse conditions like undefined illumination or worn supporting bar tips.
Innovation Solution
A method that creates a two-dimensional contrast-image dataset of the pallet using Fourier transformation and dark-field illumination, emphasizing supporting bar tips as local pixel-value extremes in a uniform background, allowing for accurate detection of suspension positions without interference from other structures.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If a distance sensor system or laser triangulation is used to detect supporting bar positions, then the supporting bar configuration can be determined, but unproductive downtimes occur due to scanning the empty pallet
Solution Approach 1:
The patent applies preliminary action by capturing an image of the pallet with supporting bars before the machining process begins. The control unit determines the supporting bar configuration from this pre-captured image, eliminating the need for time-consuming scanning during operation. The image data is stored and used directly for workpiece nesting and machining operations.
2Measurement precision
If traditional image analysis is used under undefined illumination or with worn supporting bar tips, then detection accuracy decreases due to interference and erroneous identifications
Solution Approach 1:
The patent applies local quality by using dark-field illumination that selectively highlights only the supporting bar tips (local regions of interest) while keeping the background uniform and dark. This localized enhancement of contrast at the supporting bar tips allows accurate detection even when tips are worn or illumination conditions are undefined, as the illumination is specifically tailored to the detection target rather than uniformly illuminating the entire pallet.
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 robust, quick, and accurate detection of supporting bar positions, reducing erroneous identifications and simplifying image analysis, even under adverse conditions, thereby improving the efficiency of the production and sorting processes.
Implementation Method 1
a camera (5) which is configured to produce a two-dimensional camera image (21) of the pallet (3)
Implementation Method 2
creating a two-dimensional contrast-image dataset of the pallet having a plurality of image pixels, each of the image pixels being assigned a pixel value and a pixel-area unit of the supporting plane
Data Source
AI summary
A method detects a suspension position of a supporting bar in a pallet, having supporting bars along a longitudinal direction, each with multiple supporting bar tips along a main direction of extent. The supporting bar tips define a supporting plane. A two-dimensional contrast-image dataset of the pallet is created, its pixels being assigned a pixel value and a pixel-area unit of the supporting plane. The contrast-image dataset has regions that are assigned to the supporting bar tips as local pixel-value extremes in a uniform pixel-value background. A longitudinal position is determined in the contrast-image dataset of the regions that are assigned to the supporting bar tips a supporting bar using the local pixel-value extremes. The suspension position of the supporting bar in the pallet is deduced based on the longitudinal position in the contrast-image dataset and an extent of the pixel-area unit in the longitudinal direction.