Waterjet Cutting Head Alignment via Optical Sensor
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Solution Overview
Problem
Manual alignment processes for multi-axis machines, such as waterjet cutting machines, are laborious, prone to errors, and result in extended downtime due to the need for skilled technicians and physical adjustments, which can introduce misalignment during tool exchange.
Innovation Solution
A method that uses a control system to calculate tool offset values and derive transformation parameters by sequencing the cutting head assembly through various positions and orientations relative to a sensor, allowing for non-contact compensation of misalignment and improving the tool tip path without manual physical adjustments.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If manual alignment processes are used to test and adjust tool positioning, then alignment can be achieved, but the process becomes laborious, error-prone, and results in extended machine downtime
Solution Approach 1:
The patent replaces manual mechanical measurement processes with an automated optical sensing system. A sensor detects the position and orientation of the cutting head assembly through non-contact optical means, eliminating the need for manual dial indicators and physical adjustments. The control system automatically calculates tool offset values and transformation parameters based on sensor data, resolving the contradiction by achieving precise alignment measurement without laborious manual procedures and extended downtime.
Solution Approach 2:
The system enables self-alignment through automated feedback. The sensor automatically detects cutting head position, the control system calculates the necessary corrections, and the transformation parameters are applied without requiring skilled technicians to perform manual adjustments. This self-service capability reduces both the time required and the skill level needed, while maintaining high measurement precision.
2Reliability
If physical adjustments are made to align the tool, then alignment can be corrected, but misalignment may be introduced during tool exchange and skilled labor is required
Solution Approach 1:
The patent replaces physical mechanical adjustments with automated optical detection and computational correction. Instead of manually positioning and securing the tool (which can introduce misalignment), the system uses a sensor to detect the actual position and orientation, then calculates transformation parameters that compensate for any deviations. This eliminates the need for skilled manual adjustment while improving reliability through consistent automated measurement and correction.
Solution Approach 2:
The system creates a digital model of the tool's actual position and orientation through sensor detection, rather than relying on physical adjustment. The control system generates transformation parameters based on this digital copy of the tool's spatial relationship to the machine coordinate system, allowing for precise alignment correction without physical manipulation that could introduce errors.
3Productivity
If automated sensing and calculation methods are used to improve alignment speed, then downtime is reduced, but system complexity increases
Solution Approach 1:
The patent introduces a sensor as an intermediary between the cutting head assembly and the control system. This sensor automatically detects position and orientation data, serving as a mediator that bridges the physical tool and the digital control system. The control system then uses this data to calculate transformation parameters, achieving fast automated alignment while managing complexity through a standardized sensing and calculation approach.
Data Source
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AI summary
A system and method for improving a tool tip path of a machine, such as a waterjet cutting machine, by testing and compensating for tool misalignment. The system and method using a sensor positioned to sense a portion of the machine, such as a cutting head assembly, during a sequence of movements thereof and configured to output information indicative of various positions and orientations of a tool of the machine so as to generate an improved tool tip path based on transformation parameters derived from such information.