Laser cutting with feature location placement registration

Abstract

A galvanometric laser for cutting and/or etching textile embellishments such as transfers or applique's and a method of operation thereof that is capable of visually capturing an incoming graphic image and referencing a cut pattern to the captured image and dynamically adjusting the cut pattern during cutting, etching and/or application of energy from the laser to thereby compensate for distortions in the fabric. The device includes a conveyor with an imaging station at which the graphic product is indexed under a high-resolution static camera with color recognition capability for the purposes of image capture. A high intensity bottoms-up light source resident at the imaging station provides ample illumination regardless of whether the design elements are face up toward the camera or face down toward the light source, or a combination of both. The system includes a computer at which the captured product image is analyzed, and the analytics are used to adjust the input cut file specifying the location and power settings for laser application. The product is then advanced in a controlled manner by means of the conveyor into a galvanometric cutting station where laser energy is applied. After completion the product is advanced out of the galvanometric cutting station for packaging.

Claims

1. A method of cutting and etching textiles having graphic elements thereon, comprising the steps of: placing a graphic product on a conveyor; conveying said graphic product on said conveyor to an imaging station; illuminating said imaging station from beneath said conveyor; imaging said graphic product as it sits atop said conveyor in the imaging station with high intensity bottoms-up light; storing an RGB raster image file of said graphic product within a three-dimensional frame of reference; inputting a separate cut file for laser cutting of said graphic product; analyzing the stored RGB raster image file by feature-recognition software comprising computer instructions stored on non-transitory media for identifying an actual product feature within the RGB raster image file and an actual location of said identified product feature within said three-dimensional frame of reference, and adjusting said input cut file dynamically in registration to the actual location of said identified product feature within said three-dimensional frame of reference; advancing said graphic product on said conveyor to a galvanometric laser cutting station; applying laser energy to said graphic product in accordance with said adjusted cut file; and advancing said graphic product out of the galvanometric cutting station on said conveyor for packaging.

2. The process according to claim 1, wherein said conveyor is a belt conveyor.

3. The process according to claim 1, further comprising a step of inputting a separate etch file for laser etching of said graphic product.

4. A galvanometric laser system for cutting and etching textile embellishments, comprising: a continuous linear conveyor; an imaging station along said conveyor; a high-resolution color camera above the image station of said conveyor; a high intensity bottoms-up light source beneath the imaging station of said conveyor; a cutting station along said conveyor downstream of said imaging station; a galvanometric laser cutting system for applying laser energy at said cutting station; and a computer including a processor and non-transitory computer memory, and software stored on said computer memory for inputting a cut file for laser cutting of said graphic product, capturing an RGB raster image of said graphic product from said high-resolution color camera, analyzing said RGB raster image from said high-resolution color camera, identifying a feature of said RGB raster image relative to a frame of reference by feature-recognition, calculating an offset parameter based on a location of said identified feature within said frame of reference, and adjusting said input cut file dynamically by said offset parameter.

5. The galvanometric laser system according to claim 4, wherein said continuous linear conveyor is a belt conveyor.

6. The galvanometric laser system according to claim 4, wherein said high intensity bottoms-up light source comprises an LED array.

7. The galvanometric laser system according to claim 4, wherein said computer is in communication with said galvanometric laser cutting system.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

(1) Other objects, features, and advantages of the present invention will become more apparent from the following detailed description of the preferred embodiments and certain modifications thereof when taken together with the accompanying drawings in which

(2) FIG. 1 shows a partial side plan view of the described invention.

(3) FIG. 2 is a block diagram of the method of the described invention.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT

(4) The present invention is a system and process for producing textile products that require precise application of laser energy to transform or cut through materials.

(5) FIG. 1 is a partial side plan view of the described invention. As shown in FIG. 1, the system generally includes a freestanding floor stand 10 supporting a horizontal conveyor 20 at approximately waist height. A high-intensity light source 30 is mounted beneath the conveyor 20 to one side of the conveyor 20. Light source 30 may be an emitter of high-intensity white light over a rectangular scanning geometry, such as a rectangular array of Cree™ LEDs. An imager 60 is mounted directly above the conveyor 20 and light source 30. The imager 60 is preferably a high-resolution digital camera with an 8 mm zoom lenses, which provides a FOV of about 40 degrees which allows a higher resolution capture of an imaging square which can be zoomed in on at the center of the shot. A suitable camera is an AXIS® P3915-R with 1080p resolution producing images with 1920×1080 pixels per unit.

(6) The conveyor 20 is an endless-belt-type conveyor with a carrier belt made of rubber reinforced by steel.

(7) The system includes a galvanometric laser cutting/etching/marking machine 40 that uses high-speed, motor-driven mirrors to steer a laser beam through a lens to a cutting field on conveyor 20. The cutting field is preferably rectangular and identical in size to the camera FOV. Since there are no movable parts (with the exception of the mirrors) the laser beam can be guided over the cutting field at extremely high speeds with high precision and repeatability. The galvo laser 40 is enclosed within a Class 2 enclosure that shrouds the cutting field atop conveyor 20. The galvo laser 40 preferably employs X and Y scanning mirrors defining X and Y laser beam positions on the marking plane and directly corresponding to signals taken from X and Y galvanometric motors controlled by X and Y control signals. Suitable galvo lasers 40 inclide Trotec™ galvo laser marking workstations with cutting fields up to 19.7×19.7 inches (500×500 mm) using CO2 lasers.

(8) The system is controlled by a computer 50 inclusive of a keyboard 52 and a display screen 54, the computer being in communication with the conveyor 20 controller, imager 60 and galvo laser 40.

(9) With reference to FIG. 1, the graphic product would advance through the system from right to left on conveyor 20 to the imaging station FOV, at which point the graphic product is photographed and indexed by high-resolution imager 60. The high intensity bottoms-up light source 30 resident below the imaging station FOV provides ample illumination regardless of whether the design elements of the product are face up toward the imager 60 or face down toward the light source 30, or a combination of both. The computer 50 analyzes the captured product image and the analytics are used to adjust the input cut file specifying the location and power settings for laser 40 application. The product is then advanced in a controlled manner by means of the conveyor 20 into the galvanometric laser 40 to the cutting station where laser energy is applied. After completion the product is advanced out of the galvanometric cutting field for packaging or subsequent processing.

(10) FIG. 2 is a detailed block diagram of the process of the invention. Step 100 is an imaging step where the graphic product is imaged and indexed by high-resolution imager 60 as it sits atop conveyor 20 in the imaging station FOV with high intensity bottoms-up light source 30 illuminating below the imaging station FOV. In an embodiment, the image data is coded and compressed to a prescribed number of colors, e.g., 256 colors and a RGB raster image file is established within a three-dimensional field of reference.

(11) At step 120 a separate cut file (or “peripheral lines” file) is input to computer 50 for cutting the product and, if desired, a separate etch file for etching.

(12) Step 130 is an image analysis step wherein computer 50 analyzes the captured product image and cut file and the analytics are used to adjust the input cut file specifying the location and power settings for laser 40 application. The image analysis step uses feature-recognition software to examine the actual location of product elements such as printing or stitching on the surface of the material. The feature recognition software identifies the shape/position of known print features such as print elements, colors, stitches, or the like. The automated feature recognition algorithm may be any one of the three existing algorithmic approaches for feature recognition: graph-based algorithms, volumetric decomposition techniques, and hint-based geometric reasoning. Each identified product feature is recorded and indexed at a fixed position within the FOV. The recorded features are analyzed and then corrections are made to the input reference graphical files based on the recorded and indexed fixed position within the FOV for the purpose of applying laser energy to the proper location on the material in registration to the actual elements produced in prior manufacturing steps. At step 140 the product is then advanced in a controlled manner by means of the conveyor 20 into the galvanometric laser 40 to the cutting station where laser energy is applied and the adjusted cut file is executed.

(13) At step 150 after completion the product is advanced out of the galvanometric cutting field for packaging or subsequent processing.

(14) The improved method and system applies laser energy with greater precision and speed than previous methods known in the art. The resulting products have precision cuts, etching or conversion of materials through application of laser energy onto the desired locations. The foregoing device and process may be used to decorate or transform physical properties of small quantities of products, as well as large quantities. The above device and process significantly reduces the time and improves the precision for cutting, etching or activating materials using laser energy on products that can be distorted during their manufacturing processes.

(15) The above-described embodiment is for the purpose of promoting an understanding of the principles of the invention. It should nevertheless be understood that no limitation of the scope of the invention is thereby intended, such alternations and further modifications in the illustrated device, and such further applications of the principles of the invention as illustrated herein being contemplated as would normally occur to one skilled in the art to which the invention relates.