Vision-Based Workpiece Setup for CNC Machine Tools
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Solution Overview
Problem
The existing work piece setup process in CNC machine tools is time-consuming and inefficient, especially when performed manually by unskilled operators, occupying 50% of the total process time and requiring frequent adjustments due to changes in work pieces and tools.
Innovation Solution
A method that uses a camera to photograph the work piece and tool, processes images to calculate the start point and offset value of the tool, allowing for automatic setup by converting pixel coordinates to mechanical coordinates, thereby reducing setup time and improving efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If manual work piece setup operation is performed by operator using setting-up apparatus and probe, then setup operation can be completed, but time consumption increases significantly occupying 50% of entire process
Solution Approach 1:
The patent replaces the manual mechanical setup operation with an automated vision-based system. A camera captures images of the work piece and tool, image processing algorithms automatically calculate the start point coordinates and tool offset values, eliminating the need for manual measurement and input operations. This substitution of mechanical/manual operations with automated optical and computational processes directly resolves the time consumption issue.
Solution Approach 2:
The vision-based setup system enables the machine tool to perform setup operations autonomously without operator intervention. The system automatically captures images, processes them to extract geometric information, calculates coordinates and offset values, and inputs them into the CNC controller. This self-service capability eliminates dependency on operator skill and significantly reduces setup time.
2Ease of operation
If manual work piece setup is performed, then setup operation can be completed, but operation efficiency decreases when unskilled operator performs the task
Solution Approach 1:
The patent replaces manual setup operations with an automated vision-based system that captures images of the work piece and tool, processes them through image processing algorithms, and automatically calculates setup parameters. This eliminates the need for operator skill in manual measurement and calculation, making the operation equally efficient regardless of operator expertise level.
3Adaptability or versatility
If frequent work piece and tool changes occur, then adaptability is maintained, but setup time accumulates significantly
Solution Approach 1:
The vision-based setup system performs automatic image capture and processing immediately when a work piece or tool is changed, calculating the necessary coordinates and offset values without requiring manual re-measurement. This preliminary automated action for each change prevents time accumulation, maintaining adaptability while minimizing cumulative setup time.
Data Source
AI summary
According to an exemplary embodiment of the present disclosure, a method of setting up a work piece based on a vision is present. The method of setting up a work piece based on a vision comprises: calculating a start point of a work piece from the image of a work piece within a vision screen formed by a camera; capturing an image when a tool is captured in the vision screen; and calculating an offset value of the tool from the captured image.