Vision-Guided Board Milling for Variable Blank Geometry
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Solution Overview
Problem
The manufacturing of board bodies such as skateboards, wakeboards, and snowboards faces challenges due to the indefinite shape of wooden blanks, which are affected by temperature and humidity, leading to variations in shape and requiring high precision for fitting recesses, resulting in reduced manufacturing accuracy and efficiency.
Innovation Solution
A system and method that utilize a machining robot to mill recesses for fittings and a printing robot to apply images, with a vision system creating a virtual image of the blank's shape for precise cutting and printing, allowing for accurate and efficient production of board bodies with customizable features.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If manual manufacturing methods are used to account for blank shape variations, then manufacturing accuracy can be maintained, but manufacturing efficiency and productivity are reduced
Solution Approach 1:
The patent replaces manual mechanical manufacturing with an automated system that uses optical scanning to capture blank geometry and robotic milling to execute precise cutting operations. The vision system creates a digital model of each blank's actual shape, which is then used to generate adaptive toolpaths for the milling robot, eliminating the need for manual measurement and adjustment while maintaining high precision.
Solution Approach 2:
The system dynamically adjusts machining parameters based on the actual measured geometry of each blank. The vision system measures the precise dimensions and shape variations of individual blanks, and this data is used to modify the cutting toolpaths in real-time, allowing the automated system to adapt to each blank's unique characteristics and achieve consistent high precision across all workpieces.
2Productivity
If automated milling is used for fitting recesses, then manufacturing efficiency is improved, but manufacturing precision deteriorates due to blank shape variations
Solution Approach 1:
The system implements a closed-loop feedback mechanism where the vision system first scans and measures the actual geometry of each blank, creating a digital model. This measured data is then fed back into the control system to generate adaptive toolpaths that compensate for shape variations. The robotic miller executes these adjusted paths, ensuring high precision fitting recesses are created despite variations in blank geometry.
Solution Approach 2:
The vision system performs preliminary measurement and characterization of each blank's shape before the milling operation begins. This advance knowledge of the blank's actual geometry allows the system to pre-calculate the necessary toolpath adjustments, so when the automated milling starts, it is already optimized for that specific blank, ensuring both efficiency and precision.
3Productivity
If multiple blanks are pressed at the same time in the same mold, then productivity is improved, but manufacturing precision deteriorates due to shape variations
Solution Approach 1:
The system enables each blank to effectively customize its own machining parameters through the vision-guided approach. The vision system measures each blank's unique shape, and the control system automatically generates specific toolpaths tailored to that individual blank's geometry. This self-adaptation allows the system to handle shape variations from batch pressing without requiring manual intervention, maintaining precision while preserving the productivity benefits of batch production.
Data Source
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AI summary
The present invention relates to a method and a system for manufacturing a board body (10), such as a skateboard, from a blank (20) having an indefinite shape. The blank (20) with the indefinite shape is collected by a handling robot (50). The shape of the blank (20) is scanned in three dimensions by means of a vision system (47) and a virtual image of said blank (20) is stored in a memory and used to calculate a three dimensional cutting path for milling the blank (20) into said board body (10).