Machine Tool Tool Profiling via Point Cloud Image Processing
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Solution Overview
Problem
Existing techniques face difficulties in accurately grasping the shape and state of tools used in machine tools, which hinders precise machining and increases operational burdens.
Innovation Solution
An image processing device that receives image data from an imaging unit attached to a machine tool, generates point cloud data for the tool's profile, and creates profile image data representing a two- or three-dimensional profile, enabling accurate tool shape and state analysis.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If conventional image capture methods are used to examine a tool, then the imaging process is simple, but it is difficult to accurately grasp the shape and state of the tool
Solution Approach 1:
The patent transforms two-dimensional image data into three-dimensional point cloud data and profile representations. By converting flat images into 3D spatial coordinates and generating profile images that show tool geometry from multiple angles, the system achieves accurate tool shape and state measurement without requiring complex multi-camera setups or specialized measurement devices.
Solution Approach 2:
The patent creates digital copies of the tool's physical shape through point cloud data and profile images. Instead of directly measuring the physical tool with complex sensors, the system captures images and generates accurate digital replicas (point clouds and profiles) that can be analyzed computationally, simplifying the physical measurement process while maintaining high precision.
2Measurement precision
If special operations are performed to grasp the tool shape and state, then measurement accuracy improves, but operation burden and time increase
Solution Approach 1:
The system enables automatic tool examination by processing images captured during normal machining operations. The control device automatically generates point cloud data and profile images from routinely captured images, eliminating the need for operators to perform special manual measurement operations. This self-service approach maintains high measurement precision while reducing operational time and burden.
Solution Approach 2:
The patent generates tool profile data and point cloud representations in advance during normal operation cycles. By creating these measurements proactively rather than waiting for special examination requests, the system has tool shape and state information ready when needed, reducing delays and operational interruptions.
3Manufacturing precision
If multiple image processing steps are implemented, then tool profile accuracy improves, but processing complexity increases
Solution Approach 1:
The patent divides the image processing task into distinct sequential steps: generating point cloud data from images, creating profile images from point clouds, and extracting tool shape information. This segmentation allows each processing stage to be optimized independently while maintaining overall system manageability and accuracy.
Solution Approach 2:
The patent introduces point cloud data as an intermediary representation between raw images and final tool profile measurements. Images are first converted to point clouds (spatial coordinate data), which then serve as the basis for generating accurate profile images. This intermediary step simplifies the transformation process and improves measurement accuracy by providing a structured intermediate format.
Data Source
AI summary
An image processing device (10) includes: a reception unit (101) configured to receive a plurality of pieces of image data of a tool imaged by an imaging unit attached inside a machine tool that machines a workpiece by using the tool; a point cloud data generating unit (102) configured to generate, from the plurality of pieces of image data received by the reception unit, point cloud data that is profile information relating to a profile of the tool; and a profile image forming unit (103) configured to generate, from the point cloud data, profile image data indicating a two- or three-dimensional profile of the tool.