Tool Verification via Image Collation for Machining Accuracy
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Solution Overview
Problem
Existing machining methods lack an effective way to ensure that the correct tool is used during machining, leading to potential errors and inefficiencies, as they rely on manual judgment or image processing that may not accurately determine the tool's identity or position.
Innovation Solution
A method that involves selecting a tool, imaging it, and comparing the captured image with pre-stored collation images to determine if the correct tool is assembled, using image processing techniques to verify the tool's identity and position, thereby preventing wrong cutting and ensuring accurate machining.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If manual judgment or traditional image processing is used to verify tool identity, then the system is simple to operate, but the accuracy of tool identification is insufficient leading to potential machining errors
Solution Approach 1:
The patent creates a collation image (copy) of the correct tool configuration and compares it with the actual tool image. This copying approach enables automatic verification of tool identity without requiring complex manual judgment processes, thereby improving identification accuracy while keeping the system relatively simple
Solution Approach 2:
The patent replaces manual visual judgment with an automated image processing system that captures tool images, compares them with collation images, and automatically determines whether the correct tool is installed. This substitution eliminates human error in tool identification while maintaining operational simplicity
2Reliability
If no tool verification is performed, then the machining process is fast and continuous, but wrong tools may be used causing machining errors
Solution Approach 1:
The patent performs tool verification before machining begins by capturing an image of the installed tool, comparing it with the collation image, and confirming tool identity in advance. This preliminary verification ensures machining accuracy is established before the process starts, preventing errors without significantly impacting overall productivity
Solution Approach 2:
The patent implements a feedback mechanism where the image processing result is returned to control the machining process. If the tool verification fails, the system can alert the operator or stop the machining process, providing feedback that ensures reliability while maintaining efficient operation when verification succeeds
3Measurement precision
If tool verification is performed for every machining operation, then tool identification accuracy is improved, but the time required for each machining cycle increases
Solution Approach 1:
The patent performs only the necessary image capture and comparison operations required for tool verification, avoiding excessive processing steps. By focusing on the essential comparison between the actual tool image and the collation image, the system achieves accurate verification with minimal time loss
Solution Approach 2:
The use of pre-stored collation images as references enables rapid comparison with actual tool images. This copying approach allows for quick verification without requiring complex real-time analysis, thereby maintaining high verification accuracy while minimizing the time added to each machining cycle
Data Source
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AI summary
A laser projection method, a laser projection apparatus, and a machining method, wherein the laser projection method comprises: a first step of irradiating, from a laser projection unit (9), a workpiece (26) that is a measurement object, with a laser (1) while controlling a plurality of mirror angles (109a); a second step of imaging the workpiece (26) with a stereo camera (8), extracting a contour (24a, 24b, 24c) of the workpiece (26), and calculating a three-dimensional coordinate (108a); a third step of calculating a positional relationship between the laser projection unit (9) and the workpiece (26) by comparing the three-dimensional coordinate (108a) of the workpiece contour (24a, 24b, 24c) calculated in the second step with the mirror angle (109a); and a fourth step of performing coordinate transformation of CAD data information and drawing CAD data (22) from the laser projection unit (9) to the workpiece (26), based on the positional relationship between the laser projection unit (9) and the workpiece (26) calculated in the third step. Moreover, the machining method of the present invention comprises: a first step of selecting a component of a tool (335, 336, 337, 338, 339); a second step of assembling the component selected in the first step; a third step of imaging the tool (335, 336, 337, 338, 339) assembled in the second step; and a fourth step of determining, by collating a collation image, which is prepared in advance from an image of a tool (335, 336, 337, 338, 339) having a correct component correctly assembled therein, with an image captured after assembly in the third step, whether or not a desired tool (335, 336, 337, 338, 339) has been assembled.