Tool-NC Program Matching via 2D Image Recognition
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Solution Overview
Problem
Human errors in mounting cutting tools on machine tools can lead to mismatches between NC programs and tools, resulting in inefficient and potentially hazardous machining processes, increasing production costs and risks.
Innovation Solution
A matching recognition system that uses an imaging device to capture 2-dimensional images of cutting tools, extracts feature points and postures, and compares them with tool demands from NC programs to generate matching strings, minimizing human intervention and ensuring precise tool placement.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If human operators manually mount and inspect cutting tools according to pre-machining scheme sheets, then flexibility and adaptability are maintained, but human errors occur leading to mismatches between NC programs and tools
Solution Approach 1:
The patent replaces the manual mechanical inspection process with an automated image recognition system. The system uses imaging devices to capture images of mounted tools, automatically identifies tool types and mounting positions, and verifies matching with NC programs, eliminating human error while maintaining operational flexibility
Solution Approach 2:
The system enables self-verification by automatically comparing the actual tool mounting status with the required NC program specifications. The image recognition system performs self-inspection without human intervention, identifying mismatches and alerting operators, thus making the mounting process self-correcting
2Reliability
If automated image recognition is implemented to verify tool mounting, then matching accuracy improves and human errors are reduced, but system complexity increases
Solution Approach 1:
The patent introduces an image recognition system as an intermediary between tool mounting and NC program execution. This intermediary automatically captures images, identifies tools, and verifies matching, serving as a bridge that simplifies the overall process while improving reliability
Solution Approach 2:
The system creates a digital copy (image) of the physical tool mounting status and compares it with the digital NC program specifications. This copying approach allows automated verification without physically manipulating the tools, reducing system complexity while maintaining high accuracy
3Productivity
If manual inspection of tool mounting is performed, then system simplicity is maintained, but production time is lost due to potential rework from mismatches
Solution Approach 1:
The patent performs tool mounting verification immediately after mounting using image recognition, before the machining process begins. This preliminary verification prevents mismatches from going undetected, eliminating the need for time-consuming rework during production and improving overall efficiency
Solution Approach 2:
The system provides immediate feedback by comparing the captured tool mounting status with NC program requirements and alerting operators to any mismatches. This real-time feedback mechanism prevents defective machining operations, reducing rework time and improving productivity
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
The system reduces human errors, ensuring precise matching of tools with NC programs, enhancing machining quality and safety by automating the recognition process before actual machining.
Implementation Method 1
a step of using an imaging device to capture 2-dimensional images from the cutting tools mounted at the corresponding numbered tool holders on machine tools
Data Source
AI summary
A matching recognition method for an NC program and corresponding cutting tools includes a step of using an imaging device to capture 2-dimensional images from the cutting tools mounted at the corresponding numbered tool holders on a machine tool, a step of based on the 2-dimensional images to extract outline feature points and assembling postures of cutting tools and converting into corresponding tool-assembling strings, a step of obtaining tool demands from each of the sequential machining steps in the NC program and converting into corresponding stepwise tool-demanding strings, and a step of performing matching upon the tool-assembling strings and the stepwise tool-demanding strings to generate and output corresponding step-and-tool matching strings. In addition, an associated matching recognition system is provided to include an imaging device, an image-processing module, a step-decoding module and a matching and comparing module.