Image-Based Placing of Workpiece Machining Operations

Abstract

Techniques are described for machining flat workpieces, such as metal sheets, or three-dimensional workpieces on a processing machine, such as a machine tool or laser cutting machine, including capturing a live image of a workpiece to be machined with an image capturing device for capturing two-dimensional images; displaying at least one workpiece machining operation to be performed in the live image of the workpiece by a predetermined forward transformation of the workpiece machining operation from the three-dimensional machine coordinate system into the two-dimensional live-image coordinate system; repositioning the workpiece machining operation to be performed in the live image of the workpiece; and performing the workpiece machining operation on the workpiece by a predetermined inverse transformation of the repositioned workpiece machining operation from the two-dimensional live-image coordinate system into the three-dimensional machine coordinate system.

Claims

1. A method for machining workpieces by a processing machine, the method comprising: capturing a live image of a workpiece to be machined with an image capturing device for capturing two-dimensional images, wherein the live image of the workpiece to be machined is captured with the image capturing device from a three-dimensional perspective and displayed from the three-dimensional perspective; displaying at least one workpiece machining operation to be performed as a result preview in the live image of the workpiece, wherein the at least one workpiece machining operation to be performed is displayed by a predetermined forward transformation of the at least one workpiece machining operation from a three-dimensional machine coordinate system into a two-dimensional live-image coordinate system; repositioning the at least one workpiece machining operation to be performed in the live image of the workpiece; and performing the at least one workpiece machining operation on the workpiece, wherein the at least one workpiece machining operation is performed by a predetermined inverse transformation of the at least one repositioned workpiece machining operation from the two-dimensional live-image coordinate system into the three-dimensional machine coordinate system.

2. The method of claim 1, wherein, before the capturing of the live image, the image capturing device is used to capture a reference live image having at least three machine reference points, wherein the three-dimensional position of each machine reference point is described in the three-dimensional machine coordinate system, and wherein the forward and inverse transformations between the three-dimensional machine coordinate system and the two-dimensional live-image coordinate system are determined on the basis of the at least three machine reference points and their associated reference image points in the reference live image.

3. The method of claim 2, wherein at least a fourth machine reference point, the three-dimensional position of which is described in the three-dimensional machine coordinate system, is captured or a distortion factor for the correction of optical distortions of the image capturing device is determined, and wherein the forward and inverse transformations between the three-dimensional machine coordinate system and the two-dimensional live-image coordinate system are determined on the basis of the at least four machine reference points or on the basis of the at least three machine reference points and the distortion factor, and also on the basis of the associated reference image points in the reference live image.

4. The method of claim 2, wherein at least one of the reference image points corresponding to the machine reference points in the reference live image is assigned manually by an operator.

5. The method of claim 3, wherein at least one of the reference image points corresponding to the machine reference points in the reference live image is assigned manually by an operator.

6. The method of claim 2, wherein at least one of the reference image points corresponding to the machine reference points in the reference live image is assigned by an automatic image recognition.

7. The method of claim 3, wherein at least one of the reference image points corresponding to the machine reference points in the reference live image is assigned by an automatic image recognition.

8. The method of claim 2, wherein at least one of the machine reference points is formed by a movable machine component that is moved to a position described in the three-dimensional machine coordinate system before the capture of the reference live image.

9. The method of claim 8, wherein the movable machine component is a laser machining head.

10. The method of claim 1, wherein the forward and inverse transformations for the at least one workpiece machining operation on a three-dimensional workpiece are determined as follows from the forward and inverse transformations for workpiece machining operations on flat workpieces: displaying at least a part-CAD representation of the three-dimensional workpiece in the live image of the workpiece by the forward transformation of a CAD representation for the flat workpieces from a three-dimensional CAD coordinate system into the two-dimensional live-image coordinate system, the CAD representation that is displayed in the live image being differently scaled according to its position in the live image; and adapting the forward and inverse transformations for the flat workpieces to the three-dimensional workpiece by displacing the position-dependent CAD representation of the three-dimensional workpiece in the live image of the workpiece until, in the live image, the CAD representation at least partially congruently superposes the workpiece.

11. The method of claim 10, wherein the part-CAD representation comprises at least the underside of the workpiece.

12. The method of claim 10, wherein a complete CAD representation of the workpiece is displayed in the live image of the workpiece.

13. The method of claim 10, wherein the position-dependent CAD representation of the workpiece is displaced manually in the live image of the workpiece.

14. A processing machine for machining workpieces, the processing machine comprising: at least one image capturing device arranged to perform a two-dimensional capture, from a three-dimensional perspective, of an image of a workpiece to be machined; a transformation unit arranged to perform forward and inverse transforming between a three-dimensional machine coordinate system and a two-dimensional live-image coordinate system; a monitor arranged to display a live image of the workpiece to be machined and to display a result preview from the three-dimensional perspective of a workpiece machining operation to be performed; an operator control unit arranged to reposition the workpiece machining operation to be performed in the live image; and a machine control programmed to control workpiece machining, including performing the workpiece machining operation on the workpiece, wherein the workpiece machining operation is performed by a predetermined inverse transformation of the repositioned workpiece machining operation from the two-dimensional live-image coordinate system into the three-dimensional machine coordinate system.

15. The processing machine of claim 14, wherein the operator control unit is further arranged to displace a CAD representation of a three-dimensional workpiece in the live image of the workpiece.

16. One or more computer-readable storage media storing instructions which, when executed by at least one computer, instruct the at least one computer to perform operations comprising: receiving a live image of a workpiece to be machined, the live image captured with an image capturing device for capturing two-dimensional images, wherein the live image of the workpiece to be machined is captured with the image capturing device from a three-dimensional perspective and displayed from the three-dimensional perspective; displaying at least one workpiece machining operation to be performed as a result preview in the live image of the workpiece, wherein the at least one workpiece machining operation to be performed is displayed by a predetermined forward transformation of the at least one workpiece machining operation from a three-dimensional machine coordinate system into a two-dimensional live-image coordinate system; repositioning the at least one workpiece machining operation to be performed in the live image of the workpiece; and performing the at least one workpiece machining operation on the workpiece, wherein the at least one workpiece machining operation is performed by a predetermined inverse transformation of the at least one repositioned workpiece machining operation from the two-dimensional live-image coordinate system into the three-dimensional machine coordinate system.

17. The one or more computer-readable storage media of claim 16, the operations further comprising: receiving a reference live image captured by the image capturing device, the reference live image having at least three machine reference points, wherein the three-dimensional position of each machine reference point is described in the three-dimensional machine coordinate system, and wherein the forward and inverse transformations between the three-dimensional machine coordinate system and the two-dimensional live-image coordinate system are determined on the basis of the at least three machine reference points and their associated reference image points in the reference live image.

18. The one or more computer-readable storage media of claim 17, wherein at least a fourth machine reference point, the three-dimensional position of which is described in the three-dimensional machine coordinate system, is captured or a distortion factor for the correction of optical distortions of the image capturing device is determined, and wherein the forward and inverse transformations between the three-dimensional machine coordinate system and the two-dimensional live-image coordinate system are determined on the basis of the at least four machine reference points or on the basis of the at least three machine reference points and the distortion factor, and also on the basis of the associated reference image points in the reference live image.

19. The one or more computer-readable storage media of claim 18, wherein at least one of the reference image points corresponding to the machine reference points in the reference live image is assigned manually by an operator.

20. The one or more computer-readable storage media of claim 18, wherein at least one of the reference image points corresponding to the machine reference points in the reference live image is assigned by an automatic image recognition.

Description

DESCRIPTION OF DRAWINGS

[0033] FIG. 1 shows a laser cutting machine suitable for carrying out the machining operation according to the embodiments disclosed herein with the image-based placing of workpiece machining operations in a live image of the workpiece.

[0034] FIG. 2 shows the laser cutting machine of FIG. 1 when calibrating a live-image coordinate system.

[0035] FIG. 3 shows the pushing out of a canted workpiece part by an ejector pin of the laser cutting machine.

[0036] FIGS. 4A, 4B, 4C, 4D and-4E show a live image of a three-dimensional workpiece with a superposed CAD representation of the three-dimensional workpiece, the CAD representation being superposed at various positions of the live image.

DETAILED DESCRIPTION

[0037] The laser cutting machine 1, represented perspectively in FIG. 1 as a flat-bed machine, comprises a laser beam generator 2, which is configured for example as a CO.sub.2 laser, diode laser, or solid-state laser, a laser machining head 3, which is movable in the X direction and the Y direction, and a workpiece support 4. The laser beam generator 2 generates a laser beam 5, which is guided by means of an optical-fiber cable (not shown) or a deflecting mirror (not shown) from the laser beam generator 2 to the laser machining head 3. The laser beam 5 is directed by means of a focusing optic, which is arranged in the laser machining head 3, onto a workpiece (for example a metal sheet) 6, which rests on the workpiece support 4.

[0038] The laser cutting machine 1 is additionally supplied with process gases 7, for example oxygen and nitrogen. The process gas 7 is fed to a process gas nozzle 8 of the laser machining head 3, from which it leaves together with the laser beam 5.

[0039] The laser cutting machine 1 serves for the laser cutting of workpiece parts 9.sub.1, 9.sub.2 from the workpiece 6, the workpiece machining operations (cutting contours) that are required for this being represented by 10.sub.1, 10.sub.2. The three-dimensional machine coordinate system XYZ is denoted overall by 11. The laser machining head, or part thereof, may act as an ejector pin, which pushes down a workpiece part 9.sub.3 that has been cut but has not fallen because of canting, at a suitable location to discharge it, as shown in FIG. 3. The associated workpiece machining operation, that is to say the pushing out of the workpiece 9.sub.3 by the ejector pin, is denoted by 10.sub.3.

[0040] The laser cutting machine 1 also comprises an image capturing device 12, of a known location on the machine side and fixedly arranged here, in the form of a camera, for the two-dimensional capture of an image of the workpiece support 4 or of the workpiece 6 resting on it. The viewing range of the image capturing device 12 is represented by dotted lines. The captured image is displayed on a display 13a of an operator interface 13 of the machine 1 as a live image 14 of the workpiece 6. The two-dimensional live-image coordinate system XY of the display 13a is denoted overall by 15. The laser cutting machine 1 also comprises a transformation unit 16 for the forward and inverse transforming T, T.sup.1 between the three-dimensional machine coordinate system 11 and the two-dimensional live-image coordinate system 15, and also a machine control 17.

[0041] In the following, the new methods disclosed herein are described for the image-based repositioning (placing) of a workpiece machining operation 10.sub.1, 10.sub.2, 10.sub.3 to be performed.

[0042] First, an image of the workpiece 6 to be machined is recorded by the image capturing device 12 (from a 2D or 3D perspective) and displayed in the display 13a as a two-dimensional live image 14 of the workpiece 6. A workpiece machining operation 10.sub.1, 10.sub.2, 10.sub.3 to be performed, which is in the three-dimensional machine coordinate system 11 for example as an executable machine program (computer numerical control

[0043] (CNC) program), is transformed in the transformation unit 16 by a predetermined forward transformation T from the three-dimensional machine coordinate system 11 into the two-dimensional live-image coordinate system 15 and likewise displayed in the display 13asuperposed on the live image 14 of the workpiece 6. The desired workpiece machining operation 10.sub.1, 10.sub.2 is therefore superposed as a result preview in the live image 14 of the workpiece 6, so that it is immediately evident whether error-free production with good material utilization is possible.

[0044] If required, the displayed workpiece machining operation 10.sub.1, 10.sub.2, 10.sub.3 can then be repositioned directly in the live image 14 of the workpiece 6 by the operator by means of an input device (keyboard, mouse) 13b of the operator interface 13. The manual repositioning may be, for example, the turning or displacing of a workpiece part 9.sub.1, 9.sub.2 to be cut, or its cutting contour, the aligning (nesting) of a number of workpiece parts 9.sub.1, 9.sub.2 to be cut, or the turning and/or displacing and/or adjusting in height of a raising or pushing-out element (for example a sucker, a magnetic, electroadhesive or pincer gripper, or an ejector pin), or the positioning of a separating cut or of teaching points for other manual machining or setting-up operations.

[0045] Finally, the workpiece machining operation 10.sub.1, 10.sub.2, 10.sub.3 repositioned in the live image 14 is transformed in the transformation unit 16 by a predetermined inverse transformation T.sup.1 from the two-dimensional live-image coordinate system 15 back into the three-dimensional machine coordinate system 11 and, after creating an associated NC program, then performed on the workpiece 6. The machine control 17 is programmed to control the workpiece machining according to this method.

[0046] Before the superposed display of the workpiece 6 and the workpiece machining operation 10.sub.1, 10.sub.2, 10.sub.3 in the display 13a, the workpiece thickness may be captured by measurement or manual input, to display the planned workpiece machining operation 10.sub.1, 10.sub.2, 10.sub.3 in the live image 14 of the workpiece 6 not at the supporting level (underside) of the workpiece 6, but on the upper side facing the image capturing device 12 (machining level) of the workpiece 6. This allows workpiece machining operations 10.sub.1, 10.sub.2, 10.sub.3 to be placed in the live image 14 at the actual machining level instead of at the supporting level, which is relevant in particular in the case of thick metal sheets. Alternatively, the machine reference points P1-P4 may be arranged directly on the surface of the workpiece 6, for example by adding machine reference points P1-P4 by machining operations in a workpiece 6, for example by markings or cutting out circles of holes. It is also possible to use the contours of previously cut workpiece parts of a previous machining as machine reference points P1-P4. In addition, one or more machine reference points may be produced by projection of a point or a geometry onto one or more locations of the surface of the workpiece 6, for example with one or more (movable) laser diodes. As a result, the surface of the workpiece 6 (that is facing the image capturing device 12) forms the reference level.

[0047] In at least some embodiments, a precondition for the described method for the image-based repositioning of workpiece machining operations 10.sub.1, 10.sub.2, 10.sub.3 is the determination of the forward and inverse transformation T, T.sup.1 for the calibration of the image capturing device 12 with view to the workpiece 6, in order to assign spatial points in the machine coordinate system 11 (machine working space) unique image points in the live-image coordinate system 15 or in the live image 14.

[0048] FIG. 2 shows, by way of example, how the image capturing device 12 can be calibrated in advance. First, the image capturing device 12 is used to capture a reference image having at least three (here four) machine reference points P1-P4 the three-dimensional position of which is in each case known in the machine coordinate system 11, and it is displayed as a reference live image 18 in the display 13a. On the basis of the machine reference points P1-P4 and their associated reference image points R1-R4 in the reference live image 18, the forward and inverse transformations T, T.sup.1 between the three-dimensional machine coordinate system 11 and the two-dimensional live-image coordinate system 15 can be determined. The reference image points R1-R4 corresponding to the machine reference points P1-P4 in the reference live image 18 may for example be assigned by the operator manually or by an automated image recognition 19. The movable laser machining head 3 may also form one of the machine reference points P1-P4, if it has been moved to a position known in the machine coordinate system 11 before the capture of the reference live image 18.

[0049] Instead of the one image capturing device 12 that is shown, a number of image capturing devices 12 with overlapping or respectively adjacent viewing ranges may also be used. It is also possible however for one or more movable image capturing devices 12 to be provided, for example by arrangement of the image capturing devices 12 on a machining element, such as for example the laser head 3, or by an axis of motion that can be moved separately therefrom.

[0050] The forward transformation T obtained from three to four machine reference points is sufficient to project a two-dimensional and three-dimensional representations on the basis of a desired reference level (supporting level) into the two-dimensional live image 14. However, depending on at which position this representation is displayed in the live image 14, the representation projected in the live image 14 is differently scaled. In order to display the projected representation at the correct position in the live image 14, the forward transformation T must therefore be correspondingly scaled in advance. To determine the associated scaling factor, a CAD representation of the three-dimensional workpiece at the supporting level may be displayed in the live image 14, and the operator (or another image recognition) then displaces the CAD representation until it is congruent with the displayed image of the workpiece in the live image 14.

[0051] More generally, a CAD representation may comprise at least a single line that is superposed at at least one defined point by a known point of the reference level and at least one further defined point of the workpiece. Thus, it is for example possible for the operator to superpose in the live image a corner of an upright edge of a tilted workplace 6 with a defined point of a line running perpendicularly in the machine coordinate system and to superpose a point at the reference level that is located perpendicularly below the corner with the further defined point. Because of the known scaling factors and orientation of the line, the length of the line between the two defined points establishes a distance, whereby in this case the height of the upright corner can be determined. This height may be used for example to push out the tilted workpiece 6 from a remaining lattice with an implement or ensure that there are no risks of collision with the tool (for example the laser head). This function consequently represents a kind of gage by which dimensions can be determined in the live image to carry out workpiece machining operations more accurately or more reliably.

[0052] FIGS. 4A, 4B, 4C, 4D to 4E, show, by way of example, how the scaled forward and inverse transformations T, T.sup.1 for workpiece machining operations on a three-dimensional workpiece 6 can be determined from the forward and inverse transformations T, T.sup.1 known for workpiece machining operations on flat workpieces 6.

[0053] The image of the three-dimensional workpiece 6 that is recorded with the image capturing device 12, here by way of example a cuboid, is displayed as a live image 14 on the display 13a of the user interface 13. In this live image 14 of the workpiece 6, a CAD representation 20 of the three-dimensional workpiece 6 is displayed by the forward transformation T of the CAD representation 20 that is known for flat workpieces 6 from the three-dimensional CAD coordinate system into the two-dimensional live-image coordinate system 15. Depending on at which position the CAD representation 20 is displayed in the live image 14, the CAD representation 20 displayed in the live image 14 is differently scaled. The displayed CAD representation 20 of the workpiece 6 is displaced manually by the operator or in an automated manner in the live image 14 of the workpiece 6 (FIGS. 4A-4E) and the underlying forward transformation is thereby changed. With the respective displacing position, the size of the displayed CAD representation 20 also changes. When in the live image 14 the displayed CAD representation 20 congruently superposes the displayed image of the workpiece 6

[0054] (FIG. 4e), the sought forward transformations T for the three-dimensional workpiece 6 has been found. This can then also be used to determine the inverse transformation for the three-dimensional workpiece 6.

[0055] The manual or automated displacing of the CAD representation 20 of the three-dimensional workpiece 6 in the live image 14 of the workpiece 6 may be performed for example by way of the operator control unit 13b.

[0056] Instead of displaying the three-dimensional workpiece 6 in the live image 14 as a complete CAD representation 20, as in at least some of the examples of FIGS. 4A-4B, it is also possible for only part, for example the underside, of the workpiece 6 to be displayed as a part-CAD representation 20 in the live image 14 and to be displaced until in the live image 14 the displaced CAD representation 20 congruently superposes the underside of the displayed workpiece 6.

[0057] With the aid of the forward transformation T thus determined, it is possible to transform a workpiece machining operation 10.sub.1, 10.sub.2, 10.sub.3 to be performed, which is in the three-dimensional machine coordinate system 11 for example as an executable machine program (NC program), in the transformation unit 16 by the forward transformation T from the three-dimensional machine coordinate system 11 into the two-dimensional live-image coordinate system 15 and likewise display it in the display 13asuperposing the live image 14 of the workpiece 6. The desired workpiece machining operation 10.sub.1, 10.sub.2 is therefore superposed as a result preview in the live image 14 of the workpiece 6, so that it is immediately evident whether error-free production with good material utilization is possible. Thus, the same method steps that are stated in the description in relation to substantially flat workpieces 6 can be carried out.

Other Embodiments

[0058] A number of embodiments have been described. Nevertheless, it will be understood that various modifications may be made without departing from the spirit and scope of the invention. Accordingly, other embodiments are within the scope of the following claims.