Vision-Guided CNC Precision Control for Faster Workpiece Setup
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Solution Overview
Problem
Current CNC machines require complex and time-consuming setup and calibration processes, especially for material positioning and cut location, which limits their efficiency and precision, particularly for novice operators and large material pieces.
Innovation Solution
A system that uses visual indicia on the workpiece to guide a CNC machine's cutting element, with visual input devices detecting markings to determine movement routines and current positions, allowing for automated precision control and simplifying the setup process by associating human-readable markings with predefined series of movements.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If traditional CNC setup procedures are used with work coordinate offsets and manual positioning, then machining precision can be achieved, but the setup time and operator skill requirements increase significantly
Solution Approach 1:
The patent replaces manual mechanical positioning and measurement methods with an automated visual recognition system using cameras and image processing algorithms. The system automatically detects workpiece features, calculates coordinate transformations, and configures machining parameters without manual intervention, thereby reducing setup time while maintaining precision
Solution Approach 2:
The workpiece itself provides positioning information through its geometric features (edges, corners, holes) that the vision system automatically detects. The system performs self-calibration by identifying these features and computing the work coordinate system offsets autonomously, eliminating the need for operator skill in manual positioning
2Measurement precision
If manual positioning and measurement methods are used for material alignment, then accurate cut locations can be achieved, but operator skill requirements and complexity increase
Solution Approach 1:
The patent replaces manual measurement tools (rulers, protractors, calipers) with automated vision-based measurement systems. The camera system captures images of the workpiece and uses image processing algorithms to automatically determine positions and orientations, achieving high measurement precision without requiring operator skill in manual measurement techniques
Solution Approach 2:
The system creates a digital representation (image) of the workpiece and its positioning features, then processes this copy to determine accurate positions. This allows measurement and calculation to be performed on the digital image rather than requiring direct manual measurement of the physical workpiece
3Manufacturing precision
If work coordinate offsets are modified to compensate for material positioning errors, then cut accuracy can be maintained, but the number of parameters and setup complexity increase
Solution Approach 1:
The patent replaces manual calculation and modification of multiple work coordinate offsets with automated image processing and coordinate transformation algorithms. The vision system automatically calculates the transformation parameters needed to align the program coordinate system with the actual workpiece position, reducing setup complexity while maintaining cut accuracy
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
This approach significantly reduces the complexity and time required for CNC machine operation, enabling quicker production of high-precision parts by automating the alignment and cutting processes, thus improving operator efficiency and reducing material waste.
Implementation Method 1
receiving, via at least one visual input device, at least one detectable marking on a workpiece
Data Source
AI summary
A system, method, and device for automated precision control of a computer numerical control (CNC) machine to a workpiece. The system receives via at least one visual input device at least one detectable marking on a workpiece. The system decodes the at least one detectable marking and determines a stored and pre-defined movement routine of a cutting element attached to the CNC machine relative to the workpiece based on the at least one marking. The system then determines, using the at least one visual input device and/or another visual input device, a current position of a working end of the cutting element relative to the at least one marking. Finally, the system performs the pre-defined movement routine including cutting into the workpiece with the cutting element.