Computational visual system to reduce setup time in CNC vertical machining centers
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The presentation did at the XXXVIII Iberian Latin-American Congress on Computational Methods in Engineering regarding a technological approach to enhance machine setup efficiency through computer vision. For further information, please refer to this page: http://bit.ly/cilamce2017
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Computational visual system to reduce setup time in CNC vertical machining centers
- 1. Smart Setup Computational visual system to reduce setup time in CNC vertical machining centers Paulo Araujo, Romulo Lins, Alexandre Acácio, Cedéia Araújo, Rovilson Mafalda November 6, 2017 Federal University of ABC Graduate Program in Engineering and Innovation Management
- 2. Agenda 1. Problem statement 2. CNC machine setup 3. Proposed system 4. Results 5. Conclusions
- 3. Problem statement Setup activities are time-consuming! All steps needed to leave a machine fully operational They are costly and do not add value to the final product
- 4. Problem statement Setup activities are time-consuming! All steps needed to leave a machine fully operational They are costly and do not add value to the final product The faster, the better Less setup time Companies & Customers
- 5. CNC machine setup CNC Computer Numerical Control Machine axis movement controlled by computer
- 6. CNC machine setup CNC Computer Numerical Control Machine axis movement controlled by computer The number of axis may vary depending on the type of machine
- 7. CNC machine setup CNC Computer Numerical Control Machine axis movement controlled by computer z x y The number of axis may vary depending on the type of machine We are focused on 3-D vertical machines
- 8. CNC machine setup Vertical machining center Inner structure of a VMC
- 9. CNC machine setup Machine initialization Machine home definition Tools verification Machine reference definition Part zero definition CNC program loading Program execution Machine shutdown
- 10. CNC machine setup Machine initialization Machine home definition Tools verification Machine reference definition Part zero definition CNC program loading Program execution Machine shutdown Main objective of the project
- 12. CNC machine setup Once the part zero point is defined the machine controller calculate all axis movements relative to it
- 13. CNC machine setup Once the part zero point is defined the machine controller calculate all axis movements relative to it There are different methods to define the part zero point
- 14. CNC machine setup Once the part zero point is defined the machine controller calculate all axis movements relative to it There are different methods to define the part zero point Methods may vary in cost, accuracy, ease of use, etc
- 15. Proposed system
- 16. Proposed system Template to physically locate the part zero point Reference features to facilitate 3-D location recovery Stereo system to recover 3-D data from the scene and locate the part zero point in a single run
- 17. Proposed system Before further investments it was conduct some laboratory experiments 3-D printed template 2 webcams+ Test: Measure the distance between 2 reference features and compare it with the theoretical value Algorithms and cameras’ calibration were implemented using Matlab
- 18. Results Template photographed by the stereo system. Images undistorted to minimize errors during the stereo triangulation
- 19. Results Estimating the radii of the reference features to be detected by the Circular Hough Transform algorithm
- 20. Results Centers of the circles successfully located
- 21. Results Euclidean distance between the upper circles returning 54.855 mm
- 22. Results Theoretical measure = 55.000 mm Deviation = 0.145 mm ≡ 2.64% Factors that may have contributed to this deviation: § Poor cameras quality § 3-D printer precision § Template finishing Experimental measure = 54.855 mm
- 23. Conclusions Once all calibration is done the proposed system showed to be a quick and affordable method to define the position of the part zero.
- 24. Conclusions Once all calibration is done the proposed system showed to be a quick and affordable method to define the position of the part zero. Cheaper materials during the prototype phase resulted in a measurement with small deviation, stimulating further studies on this kind of application.
- 25. Conclusions Once all calibration is done the proposed system showed to be a quick and affordable method to define the position of the part zero. Cheaper materials during the prototype phase resulted in a measurement with small deviation, stimulating further studies on this kind of application. Depending on the final accuracy, this system would be elected for a certain group of manufacturing processes.
- 26. Conclusions Once all calibration is done the proposed system showed to be a quick and affordable method to define the position of the part zero. Cheaper materials during the prototype phase resulted in a measurement with small deviation, stimulating further studies on this kind of application. Depending on the final accuracy, this system would be elected for a certain group of manufacturing processes. Further developments would include the integration of this system with the machine’s controller in order to accelerate even more the machine setup.