One Touch Workpiece Verification System for CNC Machining Using a Low-Cost Computer Vision Approach

2016 ◽  
Author(s):  
Maxwell K. Micali ◽  
Hayley M. Cashdollar ◽  
Zachary T. Gima ◽  
Mitchell T. Westwood
Keyword(s):  
Computer Vision ◽  
Low Cost ◽  
Cnc Machining ◽  
Potential Operator ◽  
Cnc Milling ◽  
Machining Processes ◽  
Loop Control ◽  
Operator Error ◽  
Verification System ◽  
Milling Machines

While CNC programmers have powerful tools to develop optimized toolpaths and machining plans, these efforts can be wholly undermined by something as simple as human operator error during fixturing. This project addresses that potential operator error with a computer vision approach to provide coarse, closed-loop control between fixturing and machining processes. Prior to starting the machining cycle, a sensor suite detects the geometry that is currently fixtured using computer vision algorithms and compare this geometry to a CAD reference. If the detected and reference geometries are not similar, the machining cycle will not start, and an alarm will be raised. The outcome of this project is the proof of concept of a low-cost, machine/controller agnostic solution that is applied to CNC milling machines. The Workpiece Verification System (WVS) prototype implemented in this work cost a total of $100 to build, and all of the processing is performed on the self-contained platform. This solution has additional applications beyond milling that the authors are exploring.

Computing the Global Visibility Map Using Slice Geometry for Setup Planning

2017 ◽  
Vol 139 (8) ◽  
Author(s):  
Guangyu Hou ◽  
Matthew C. Frank
Keyword(s):  
High Performance ◽  
Cnc Machining ◽  
Numerical Control ◽  
Cnc Milling ◽  
Setup Planning ◽  
Visibility Map ◽  
Axis Of Rotation ◽  
Milling Machines ◽  
Hard Problems ◽  
Rotation Map

This paper introduces a new method that uses slice geometry to compute the global visibility map (GVM). Global visibility mapping is a fundamentally important process that extracts geometric information about an object, which can be used to solve hard problems, for example, setup and process planning in computer numerical control (CNC) machining. In this work, we present a method for creating the GVM from slice data of polyhedron models, and then show how it can help determine around which axis of rotation a part can be machined. There have been various methods of calculating the GVM to date, tracing back to the well-known seminal methods that use Gaussian mapping. Compared to the considerable amount of work in this field, the proposed method has an advantage of starting from feature-free models like stereolithography (STL) files and has adjustable resolution. Moreover, since it is built upon slicing the model, the method is embarrassingly parallelizable in nature, thus suitable for high-performance computing. Using the GVM obtained by this method, we generate an axis of rotation map to facilitate the setup planning for four-axis CNC milling machines as one implementation example.

Low-cost closed-loop control of a 3D printer gantry

2015 ◽  
Vol 21 (5) ◽  
pp. 482-490 ◽  
Author(s):  
Benjamin Weiss ◽  
Duane W. Storti ◽  
Mark A. Ganter
Keyword(s):  
Closed Loop ◽  
Low Cost ◽  
Path Following ◽  
Cnc Machining ◽  
Practical Significance ◽  
Closed Loop Control ◽  
3D Printer ◽  
Content Type ◽  
Loop Control ◽  
Acceleration Rate

Purpose – The purpose of this paper is to explore the improvements in speed and precision achievable using straightforward closed-loop control for the gantry motion in additive manufacturing machines. The authors designed and built an economically viable demonstration system to quantify the performance improvement. Design/methodology/approach – The authors develop and evaluate a low-cost closed-loop controller for the X and Y axes of an entry-level three-dimensional (3D) printer. The system developed captures and compensates for the dynamics of the motor and the belt-driven stage and detects mechanical errors, such as skipped motor steps. Findings – The system produces path-following precision improvements of 40 and 75 per cent for two different sample trajectories. Correcting for skipped steps increases reliability and allows for more aggressive tuning of motion parameters; time savings of up to 25 per cent are seen by doubling acceleration rate. Research limitations/implications – The system presented provides an appropriate platform for further investigation into more complex, application-specific controllers and inclusion of more details of the printer dynamics that could produce still greater improvements in speed and accuracy. Practical implications – The performance, low cost (40 USD/axis) and applicability to the majority of sub-2000USD 3D printer designs make this work of practical significance. Originality/value – The CNC machining industry has for many years used similar approaches, but application to 3D printers has not been explored in the literature. This paper demonstrates the value of even a simple controller applicable to almost any 3D printer, while maintaining cost-effectiveness of the solution in a competitive market.

scholarly journals Establishment of an Improved Material-Drilling Power Model to Support Energy Management of Drilling Processes

Energies ◽  
2018 ◽  
Vol 11 (8) ◽  
pp. 2013 ◽  
Author(s):  
Shun Jia ◽  
Qingwen Yuan ◽  
Wei Cai ◽  
Qinghe Yuan ◽  
Conghu Liu ◽  
...  
Keyword(s):  
Machine Tool ◽  
Manufacturing Industry ◽  
Experimental Studies ◽  
Energy Modeling ◽  
Cnc Machining ◽  
Power Model ◽  
Cnc Milling ◽  
Machining Processes ◽  
Proposed Model ◽  
Process Energy

Drilling processes, as some of the most widely used machining processes in the manufacturing industry, play an important role in manufacturing process energy-saving programs. However, research focus on energy modeling of drilling processes, especially for the modeling of material-drilling power, are really scarce. To bridge this gap, an improved material-drilling power model is proposed in this paper. The obtained material-drilling power model can improve the accuracy of the material-drilling power and lay a good foundation for energy modeling and optimization of drilling processes. Finally, experimental studies were carried out on an XHK-714F CNC machining center (Hangzhou HangJi Machine Tool Co., Ltd., Hangzhou, China) and a JTVM6540 CNC milling machine (Jinan Third Machine Tool Co., Ltd., Jinan, China). The results showed that predictive accuracies with the proposed model are generally higher than 96% for all the test cases.

A Decision Support System for Capturing CNC Operator Knowledge

2011 ◽  
Vol 5 (5) ◽  
pp. 655-662 ◽  
Author(s):  
Wikan Sakarinto ◽  
◽  
Hiroshi Narazaki ◽  
Keiichi Shirase
Keyword(s):  
Decision Support ◽  
Cnc Machining ◽  
Numerical Control ◽  
Cnc Milling ◽  
Machining Processes ◽  
Product Data ◽  
Know How ◽  
Milling Operations ◽  
Data Assessment ◽  
Computer Aided

The main job of Computer Numerical Control (CNC) operators is to capture and use knowledge to assess product data. CNC operators assess Computer-Aided Manufacturing (CAM) files before proceeding to CNC machining processes. Decision Support Systems (DSS), for these operators, is provided by Expert Systems (ES) designed to manage and learn intelligently from previous data and information and produce recommended actions and decisions. The purpose of the DSS is (i) to assist inexperienced operators in assessment using stored know-how of experienced operators and to collect additional knowledge in interaction between the DSS and experienced operators during semiautomatic assessment, and (ii) to present collected knowledge to users based on contexts or constraints the user must deal with in product data assessment. After outlining the DSS, the discussion is about its usefulness in dealing information and knowledge discrepancies between CAM and CNC operators - an important problem in practice that has been rather neglected so far - focusing on CNC milling operations.

Frame Work of LV-UTHM: An ISO 14649 Based Open Control System for CNC Milling Machine

2013 ◽  
Vol 330 ◽  
pp. 619-623 ◽  
Author(s):  
Yusri Yusof ◽  
Kamran Latif
Keyword(s):  
Control System ◽  
High Efficiency ◽  
Low Cost ◽  
Numerical Control ◽  
Milling Machine ◽  
Cnc Milling ◽  
Real Time Control ◽  
Machining Processes ◽  
Cnc Milling Machine ◽  
Open Control

Open control is a well known term in the field of machine control. This paper presents a framework of STandard for the Exchange of Product Data-compliant Numerical Control (STEP-NC) based open control system for Computer Numeric Control (CNC) milling machine. Real time control, high efficiency and low cost have been the main focus of proposed open control system. A method that develops open control system is composed of hardware and software platforms. Proposed open control system helps in to improves the quality of machining, increase productivity, saves times, avoid machine accidents, increase tool life and enables monitoring/inspection/control system for various machining processes and parameters online/offline.

scholarly journals An Automated Light Trap to Monitor Moths (Lepidoptera) Using Computer Vision-Based Tracking and Deep Learning

Sensors ◽  
2021 ◽  
Vol 21 (2) ◽  
pp. 343
Author(s):  
Kim Bjerge ◽  
Jakob Bonde Nielsen ◽  
Martin Videbæk Sepstrup ◽  
Flemming Helsing-Nielsen ◽  
Toke Thomas Høye
Keyword(s):  
Computer Vision ◽  
Deep Learning ◽  
Vision System ◽  
Low Cost ◽  
Light Trap ◽  
Automatic Monitoring ◽  
Light Sources ◽  
Monitoring Methods ◽  
Computer Vision System ◽  
Substantial Investment

Insect monitoring methods are typically very time-consuming and involve substantial investment in species identification following manual trapping in the field. Insect traps are often only serviced weekly, resulting in low temporal resolution of the monitoring data, which hampers the ecological interpretation. This paper presents a portable computer vision system capable of attracting and detecting live insects. More specifically, the paper proposes detection and classification of species by recording images of live individuals attracted to a light trap. An Automated Moth Trap (AMT) with multiple light sources and a camera was designed to attract and monitor live insects during twilight and night hours. A computer vision algorithm referred to as Moth Classification and Counting (MCC), based on deep learning analysis of the captured images, tracked and counted the number of insects and identified moth species. Observations over 48 nights resulted in the capture of more than 250,000 images with an average of 5675 images per night. A customized convolutional neural network was trained on 2000 labeled images of live moths represented by eight different classes, achieving a high validation F1-score of 0.93. The algorithm measured an average classification and tracking F1-score of 0.71 and a tracking detection rate of 0.79. Overall, the proposed computer vision system and algorithm showed promising results as a low-cost solution for non-destructive and automatic monitoring of moths.

scholarly journals Influence of a closed-loop controlled laser metal wire deposition process of S Al 5356 on the quality of manufactured parts before and after subsequent machining

2021 ◽  
Author(s):  
Dina Becker ◽  
Steffen Boley ◽  
Rocco Eisseler ◽  
Thomas Stehle ◽  
Hans-Christian Möhring ◽  
...  
Keyword(s):  
Wall Thickness ◽  
Closed Loop ◽  
Deposition Process ◽  
Metal Wire ◽  
Machining Process ◽  
Machining Processes ◽  
Initial State ◽  
Additive Process ◽  
Shape Accuracy ◽  
Loop Control

AbstractThis paper describes the interdependence of additive and subtractive manufacturing processes using the production of test components made from S Al 5356. To achieve the best possible part accuracy and a preferably small wall thickness already within the additive process, a closed loop process control was developed and applied. Subsequent machining processes were nonetheless required to give the components their final shape, but the amount of material in need of removal was minimised. The effort of minimising material removal strongly depended on the initial state of the component (wall thickness, wall thickness constancy, microstructure of the material and others) which was determined by the additive process. For this reason, knowledge of the correlations between generative parameters and component properties, as well as of the interdependency between the additive process and the subsequent machining process to tune the former to the latter was essential. To ascertain this behaviour, a suitable test part was designed to perform both additive processes using laser metal wire deposition with a closed loop control of the track height and subtractive processes using external and internal longitudinal turning with varied parameters. The so manufactured test parts were then used to qualify the material deposition and turning process by criteria like shape accuracy and surface quality.

Kameraunterstützte Verschwendungsreduktion*/Computer-vision supported waste reduction in lean production

2017 ◽  
Vol 107 (09) ◽  
pp. 572-577
Author(s):  
B. Prof. Lorenz ◽  
I. Kaltenmark
Keyword(s):  
Computer Vision ◽  
Lean Manufacturing ◽  
Lean Production ◽  
Low Cost ◽  
Industrie 4.0 ◽  
Waste Reduction ◽  
Camera System ◽  
New Developments ◽  
Neue Entwicklungen

In modernen Produktionen ist Lean Manufacturing einer der wichtigsten Treiber für Produktivitätssteigerungen. Durch neue Entwicklungen im Bereich Industrie 4.0 können Impulse im Lean Manufacturing gegeben werden. An der OTH Regensburg wird getestet, wie kostengünstige Kamerasysteme helfen können, Verschwendungen sichtbar zu machen und zu minimieren. Es zeigt sich, dass auch mit geringen Investitionskosten neue Potentiale zur Verschwendungsreduktion aufgedeckt werden können.   In modern production lean manufacturing is one of the most effective drivers for productivity. Due to new developments in the Industrie 4.0-campaign new impulses can be given into lean manufacturing. Experiments at OTH Regensburg indicate that a low-cost camera system can help to make waste visible and minimize it. This shows that with low invest costs, new potentials for waste reduction can be revealed.

scholarly journals Enhancement of Teaching Design of CNC Milling Machines

2015 ◽  
Vol 176 ◽  
pp. 571-577 ◽  
Author(s):  
Antonín Max ◽  
Václava Lašová ◽  
Šimon Pušman
Keyword(s):  
Cnc Milling ◽  
Teaching Design ◽  
Milling Machines

FEASIBILITY ANALYSIS OF AN AUTOMATED DETECTION OF PHYSICAL DEFECT VIA COMPUTER VISION

2015 ◽  
Vol 76 (12) ◽  
Author(s):  
Por Jing Zhao ◽  
Shafriza Nisha Basah ◽  
Shazmin Aniza Abdul Shukor
Keyword(s):  
Computer Vision ◽  
Low Cost ◽  
Image Data ◽  
Automated Detection ◽  
Building Construction ◽  
High Demand ◽  
Major City ◽  
Cost System ◽  
Kinect Camera ◽  
Wall Condition

High demand of building construction has been taking places in the major city of Malaysia. However, despite this magnificent development, the lack of proper maintenance has caused a large portion of these properties deteriorated over time. The implementation of the project - Automated Detection of Physical Defect via Computer Vision - is a low cost system that helps to inspect the wall condition using Kinect camera. The system is able to classify the types of physical defects -crack and hole - and state its level of severity.The system uses artificial neural network as the image classifier due to its reliability and consistency. The validity of the system is shown using experiments on synthetic and real image data. This automated physical defect detection could detect building defect early, quickly, and easily, which results in cost saving and extending building life span. 

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