Vision-Guided Workpiece Positioning for Low-Downtime Cut Optimization
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Solution Overview
Problem
Traditional machine centers require costly and time-consuming upgrades for optimization, involving the purchase of scanners/optimizers and upgrades to motion axis controls, leading to high expenses and downtime.
Innovation Solution
A dynamically directed workpiece positioning system that uses sensors and computer systems to detect and reposition workpieces based on actual and desired positions, allowing for continuous scanning and optimization, reducing the need for costly upgrades by integrating with existing systems.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If conventional scanner/optimizer and control upgrades are implemented, then optimization capability is improved, but cost and installation time increase significantly
Solution Approach 1:
The patent uses vision sensors to create a digital representation (copy) of the workpiece geometry and uses this virtual model for positioning calculations, eliminating the need for physical scanner/optimizer hardware. The computer system processes images to generate positioning instructions based on the virtual workpiece model.
Solution Approach 2:
The patent replaces complex mechanical positioning systems with a computer-vision-based system. Instead of using physical scanners and mechanical optimizers, the system uses cameras to capture workpiece images and computer algorithms to calculate positioning, substituting mechanical complexity with computational processing.
2Adaptability or versatility
If complete infeed replacement is performed, then optimization is achieved, but downtime and installation cost increase
Solution Approach 1:
The patent segments the optimization function into a separate computer-vision module that can be added independently of the existing infeed system. Instead of replacing the entire infeed, the system adds sensors and a computer that work alongside existing components, allowing incremental implementation without complete system replacement.
Solution Approach 2:
The patent creates a universal positioning system that can work with various types of workpieces and existing infeed mechanisms. The computer vision system is designed to be adaptable to different machine centers and workpiece geometries, eliminating the need for custom replacements for each specific application.
3Manufacturing precision
If motion axis control upgrades are implemented, then positioning precision is improved, but cost and complexity increase
Solution Approach 1:
The patent implements a feedback loop where vision sensors continuously monitor workpiece position, the computer compares actual position with desired position, and positioning instructions are generated to correct any deviations. This closed-loop feedback system achieves high precision without requiring complex motion control upgrades.
Solution Approach 2:
The system enables the workpiece to essentially position itself by using its own visual features (detected by the vision system) as reference points. The computer calculates positioning based on the workpiece's inherent geometry rather than requiring external positioning mechanisms, allowing the workpiece to self-align through the vision-guided process.
Data Source
AI summary
In various embodiments, a dynamically directed workpiece positioning system may include a transport, a sensor positioned to detect a workpiece on the transport, a cutting member positioned along or downstream of the transport, and a computer system. The sensor may scan the workpiece as the workpiece is moved relative to the transport by a human operator or a positioning device. Based on the scan data, the computer system may generate commands to guide the human operator or positioning device in moving the workpiece to a desired position corresponding to a cut solution for the workpiece. Optionally, the computer system may cause the cutting member to be repositioned while the workpiece is being moved relative to the transport. Once the workpiece is in the desired position, the transport may be used to move the workpiece toward the cutting member. Corresponding methods and apparatuses are also disclosed.