Tool Blade Edge Detection via Camera Zoom and Positioning
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Solution Overview
Problem
Existing machine tools face challenges in accurately detecting the position and shape of tool blade edges due to variations in tool holder types and short or long distances to the blade edge, leading to distorted images and inaccurate registration of tool correction values, which increases operator workload and risk of tool damage.
Innovation Solution
A camera with optical zoom function is used to acquire initial images with a wide visual field, then adjusts the tool post position to center the blade edge within the frame, allowing for high-resolution detection of the blade edge's position and shape, and employs advanced image analysis to remove background interference and distinguish adjacent tools, enabling automatic registration of tool correction values and shapes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Area of stationary object
If the visual field of the camera is widened to capture the blade edge, then the blade edge can be included in the image, but the image becomes distorted and the position cannot be accurately detected
Solution Approach 1:
The patent applies dynamics by making the camera's visual field adjustable rather than fixed. The camera switches between a wide visual field mode (for initial capture) and a narrow visual field mode (for precise measurement). This dynamic adjustment allows the system to first locate the blade edge within the wide field, then zoom in for accurate position detection, thereby resolving the contradiction between field of view and measurement precision.
2Ease of operation
If the tool post position is not adjusted, then the imaging process is simple, but the blade edge cannot be centered in the visual field leading to inaccurate detection
Solution Approach 1:
The patent applies preliminary action by first moving the tool post to bring the blade edge within the camera's visual field, then acquiring an initial image to determine the blade edge's position. Based on this preliminary information, the system calculates the required adjustment to center the blade edge. This preliminary positioning action enables subsequent precise centering and accurate measurement, resolving the contradiction between operational simplicity and measurement precision.
3Reliability
If manual registration of tool correction values is performed, then the registration process can be completed, but the operator workload increases and tool damage risk increases
Solution Approach 1:
The patent applies self-service by implementing an automatic registration system that uses the camera to capture images of the blade edge, automatically detects the blade edge position through image processing, calculates the tool correction values, and registers them in the control device without operator intervention. This automated process eliminates manual input errors, reduces operator workload, and ensures consistent accurate registration, resolving the contradiction between reliability and ease of operation.
Data Source
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AI summary
To provide a technique of accurately detecting blade edges of various tools attached to a tool post of a machine tool. A first image is acquired when a tool post having a tool attached thereto moves to a camera installation position. When the position of the blade edge is separated from a visual field center of the camera, the tool post is automatically moved while the position thereof is corrected so that the blade edge moves to the visual field center of the camera. Desirably, a normal image is acquired by a zoom-up function, and the position or shape of the blade edge of the tool is detected by image analysis of the normal image. The position or shape of the detected blade edge can be used as a tool shape when a tool correction value is calculated or interference between the tool and the other member is checked.