Methods and apparatus for handheld tool

• US 10,005,312 B2
• Filed: 04/16/2016
• Issued: 06/26/2018
• Est. Priority Date: 03/02/2012
• Status: Active Grant

• Current Assignee: Massachusetts Institute of Technology
• Original Assignee: Massachusetts Institute of Technology
• Inventors: Zoran, Amit, Paradiso, Joseph, Shilkrot, Roy
• Primary Examiner(s): Lin, Jason
• Application Number:
  US15/130,973
• Publication Number:
  US 20160231734A1
• Time in Patent Office: 801 Days
• Field of Search: None
• CPC Class Codes: B44B 3/009 using a computer control means
• CPC Class Codes: G05B 19/4099 Surface or curve machining, making 3D objects, e.g. desktop manufacturing
• CPC Class Codes: G05B 2219/35134 3-D cad-cam
• CPC Class Codes: G05B 2219/49023 3-D printing, layer of powder, add drops of binder in layer, new powder
• CPC Class Codes: G06F 30/00 Computer-aided design [CAD]
• CPC Class Codes: Y02P 90/02 Total factory control, e.g. smart factories, flexible manufacturing systems [FMS] or integrated manufacturing systems [IMS]
• CPC Class Codes: Y02T 10/82 Elements for improving aerodynamics

Abstract

In exemplary implementations of this invention, a computer-assisted, handheld machining tool allows even an inexperienced user to carve a complex 3D object, while maintaining artistic freedom to modify the sculpture from an initial CAD design. The tool prevents the user from unintentionally removing material from a volume defined by the CAD design. It does so by slowing or halting spindle rotation as the bit approaches or penetrates the protected volume. The user can override this protective feature. The tool may operate in at least three interaction modes: (i) a static mode in which a static CAD model is used, where the computer assists by preventing the user from damaging the static model; (ii) a dynamic mode where the computer dynamically modifies the CAD model during the sculpting process; and (iii) an autonomous mode where the computer can operate independently of the user, for tasks such as semi-automatic texture rendering.

Claims

1. Apparatus comprising a machining tool and a tracking system, wherein:

(a) the tracking system is configured to track position of a bit of the machining tool relative to an object; and

(b) the machining tool;

(i) includes a shaft that is attached to the bit;

(ii) is configured to be held by a human user while effecting physical removal of material from the object, such that the weight of the tool is supported solely by a hand of the user during the removal,

(iii) is configured to be controlled depending on the tracked position of the bit relative to the object, to prevent the bit from entering a protected region, by causing the shaft to undergo retraction, such that during the retraction the shaft moves relative to a handle of the machining tool; and

(iv) is configured to calculate, in response to a movement of the bit relative to the object during the physical removal of material, a change in the boundary of the protected region;

wherein the protected region is defined by a computer-aided design (CAD) model.

2. The apparatus of claim 1, wherein the bit moves away from the protected region during the retraction.

3. The apparatus of claim 2, wherein the machining tool is configured such that, after the retraction, the shaft is returned to an original position.

4. The apparatus of claim 1, wherein the shaft is moveable, in multiple degrees of freedom, relative to a handle of the apparatus.

5. The apparatus of claim 4, wherein the shaft is moveable laterally, relative to the handle.

6. The apparatus of claim 1, wherein the apparatus includes multiple-axis bearings configured such that the shaft is moveable, in multiple degrees of freedom, relative to a handle of the apparatus.

7. The apparatus of claim 1, wherein the apparatus includes a button for accepting input that comprises an instruction that overrides computer control that would otherwise prevent the bit from entering the protected region.

8. The apparatus of claim 1, wherein:

(a) the apparatus includes a pressure sensor for measuring pressure;

(b) the bit is a rotary bit and the machining tool includes a motor for powering the rotary bit; and

(c) the motor is configured to have a motor speed that is a linear factor of parameters that include the pressure.

9. The apparatus of claim 1, wherein the change in a boundary of the protected region minimizes the volume of material that needs to be removed from the object to achieve a target shape.

10. The apparatus of claim 1, wherein the change in the boundary of the protected region is computed by selecting, out of a set of virtual models of protected regions, a model that minimizes the volume of material that needs to be removed from the object to achieve a target shape.

11. A method comprising:

(a) a tracking system tracking position of a bit of a machining tool relative to an object;

(b) a machining tool physically removing material from an object;

(c) controlling the machining tool, depending on the tracked position of the bit relative to the object, to prevent the bit from entering a protected region, by retracting a shaft that is attached to the bit, such that during the retracting the shaft moves relative to a handle of the machining tool; and

(d) calculating, in response to a movement of the bit relative to the object during the physical removal of material, a change in the boundary of the protected region;

wherein

(i) the tool is configured to be supported solely by a hand of a user during the removal of material, and

(ii) the protected region is defined by a computer-aided design (CAD) model.

12. The method of claim 11, wherein, the bit moves away from the protected region during the retracting.

13. The method of claim 12, wherein the machining tool is configured such that, after the retracting, the shaft is returned to an original position.

14. The method of claim 11, wherein the shaft is moveable, in multiple degrees of freedom, relative to a handle of the apparatus.

15. The method of claim 11, wherein the shaft is moveable laterally, relative to the handle.

16. The method of claim 11, wherein the machining tool includes multiple-axis bearings configured such that the shaft is moveable, in multiple degrees of freedom, relative to a handle of the apparatus.

17. The method of claim 11, wherein the machining tool includes a button that accepts input, which input overrides computer control that would otherwise prevent the bit from entering the protected region.

18. The method of claim 11, wherein:

(a) a pressure sensor in the machining tool measures pressure;

(b) the bit is a rotary bit;

(c) a motor in the machining tool powers the rotary bit; and

(c) the motor has a motor speed that is a linear factor of parameters that include the pressure.

19. The method of claim 11, wherein the change in a boundary of the protected region minimizes the volume of material that needs to be removed from the object to achieve a target shape.

20. The method of claim 11, wherein the change in the boundary of the protected region is computed by selecting, out of a set of virtual models of protected regions, a model that minimizes the volume of material that needs to be removed from the object to achieve a target shape.