Wire Bending Machine Vision Calibration for Accurate Bend Angles
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Solution Overview
Problem
Automated wire bending machines face challenges in accurately calibrating bend angles and rotation commands due to material properties variations, such as springback and torsional stiffness, which require time-consuming and labor-intensive manual adjustments, especially when dealing with different batches of wire.
Innovation Solution
A digital camera system is integrated into the wire bending machine to capture and measure actual bend angles, allowing for automated calibration and adjustment of programmed angles, thereby compensating for sources of bending error like springback and rotational errors.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If manual calibration methods are used to adjust bend angles and rotation commands, then the machine can accommodate material property variations, but the calibration process becomes time-consuming and labor-intensive
Solution Approach 1:
The patent replaces manual mechanical calibration operations with an automated vision system using digital cameras and image processing algorithms. The system automatically captures images of bent wire, measures actual bend angles through image analysis, and adjusts calibration parameters without manual intervention, thereby eliminating the time-consuming and labor-intensive nature of manual calibration while maintaining or improving measurement precision.
Solution Approach 2:
The calibration system performs self-calibration by automatically measuring its own performance through the vision system and adjusting its control parameters accordingly. The machine uses the measured actual bend angles from captured images to automatically update calibration data, enabling the system to self-correct and adapt to material variations without external manual calibration operations.
2Manufacturing precision
If manual calibration adjustments are performed for different wire batches, then accuracy can be maintained, but labor costs and setup time increase
Solution Approach 1:
The patent replaces manual calibration operations with an automated vision-based measurement and control system. Digital cameras capture images of the bent wire, and image processing algorithms automatically determine bend angles and update calibration parameters, eliminating the need for manual measurements and adjustments. This automation maintains part consistency across different wire batches while dramatically improving setup efficiency and reducing labor requirements.
Solution Approach 2:
The system implements a feedback mechanism where the vision system continuously measures actual bend angles from captured images and uses this information to automatically adjust calibration parameters. This closed-loop feedback ensures that part consistency is maintained across different wire batches by dynamically adapting to material variations without requiring manual intervention for each batch change.
3Productivity
If automated calibration using vision systems is implemented, then labor costs and setup time are reduced, but the device complexity increases
Solution Approach 1:
The patent introduces a vision system with digital cameras and image processing capabilities to replace manual calibration operations. While this increases device complexity by adding optical and computational components, it dramatically improves calibration speed and automation. The system uses standard digital cameras combined with software algorithms to automatically measure bend angles and update calibration parameters, making the complexity manageable through the use of commercially available components rather than custom-designed complex mechanisms.
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 reduces labor costs and setup time by accurately measuring and storing actual angles, enabling the machine to efficiently produce consistent parts across varying wire batches with reduced manual intervention.
Implementation Method 1
A digital camera system is integrated into the wire bending machine to capture and measure actual bend angles
Data Source
AI summary
An apparatus and method for calibrating an automated wire bending machine is provided that includes a camera system comprising a camera and a lens configured with a focal plane fixedly positioned relative to a bending surface provided on the automated wire bending machine. The disclosed apparatus and method further includes a processor device configured to interpret images captured by the camera system. The apparatus and method measures an actual angle formed in a wire while a bent portion of the wire is substantially within the focal plane of the camera system, and a memory device stores values generated during a calibration sequence of the automated wire bending machine. The values correspond to the actual angle and a target angle provided for the calibrating of the automated wire bending machine.