Automatically guided tools

• US 10,067,495 B2
• Filed: 06/09/2016
• Issued: 09/04/2018
• Est. Priority Date: 05/19/2011
• Status: Active Grant

• Current Assignee: Shaper Tools, Inc.
• Original Assignee: Shaper Tools, Inc.
• Inventors: Rivers, Alec Rothmyer, Moyer, Ilan Ellison
• Primary Examiner(s): Dunn, Darrin D
• Application Number:
  US15/178,376
• Publication Number:
  US 20160291567A1
• Time in Patent Office: 817 Days
• CPC Class Codes: B23Q 9/0042 the guide means being fixed only on the workpiece
• CPC Class Codes: G05B 19/19 characterised by positioning or contouring control systems, e.g. to control position from one programmed point to another or to control movement along a programmed continuous path
• CPC Class Codes: G05B 2219/36429 Power assisted positioning

Abstract

A position correcting system, method and tool for guiding a tool during its use based on its location relative to the material being worked on. Provided is a system and tool which uses its auto correcting technology to precisely rout or cut material. The invention provides a camera which is used to track the visual features of the surface of the material being cut to build a map and locate an image on that map used to reference the location of the tool for auto-correction of the cutting path.

Claims

1. A computer implemented method of positioning a working member of a rig, comprising:

capturing, using a camera, a first set of captured images, wherein the first set of captured images includes one or more images of one or more markers on a marked surface;

determining a first set of marker data based at least in part upon the first set of captured images, wherein the first set of marker data includes marker identification information and marker position information for each marker in a first set of markers, and each of the markers in the first set of markers appears in at least one of the images in the first set of captured images;

registering a design to marker identification information and marker position information in the first set of marker data for at least one marker in the first set of markers;

determining an intended path for the working member based at least in part upon the design;

capturing, using the camera, a first image of at least one of the one or more markers on the marked surface after registering the design;

determining a second set of marker data based at least in part upon the first image, wherein the second set of marker data includes marker identification information and marker position information for each marker in a second set of markers, each of the markers in the second set of markers appears in the first image, and at least one marker in the second set of markers is in the first set of markers;

providing motor control information that controls one or more motors to position the working member at a first target point on the intended path based at least in part upon a position of the camera, wherein the position of the camera is based at least in part upon the first set of marker data and the second set of marker data;

capturing, using the camera, a second image of at least one of the one or more markers on the marked surface after capturing the first image, wherein the rig is located at a first location when capturing the first image, the rig is located at a second location when capturing the second image, and the first location is different from the second location;

determining a third set of marker data based at least in part upon the second image, wherein the third set of marker data includes marker identification information and marker position information for each marker in a third set of markers, each of the markers in the third set of markers appears in the second image, and at least one marker in the third set of markers is in the first set of markers; and

providing additional motor control information that controls the one or more motors to position the working member at a second target point on the intended path based at least in part upon a second position of the camera, wherein the first target point and the second target point are different points on the intended path, and the second position of the camera is based at least in part upon the first set of marker data and the third set of marker data.

2. The method of claim 1, comprising:

providing first information for displaying, via a display, a representation of at least a portion of the intended path.

3. The method of claim 2, comprising:

providing second information for displaying, via the display, a representation of a target range within which the working member may be positioned by the one or more motors.

4. The method of claim 3, comprising:

providing third information for displaying, via the display, a representation of a position of the working member.

5. The method of claim 1, comprising:

stitching a second set of captured images together to generate a photo mosaic, wherein each image in the second set of captured images is in the first set of captured images;

providing first information for displaying, via a display, a representation of at least a portion of the photo mosaic; and

providing second information for displaying, via the display, a representation of a position of the working member.

6. The method of claim 1, comprising:

obtaining the design from a remote computer system.

7. The method of claim 1, wherein the motor control information and the additional motion control information cause the working member to engage a material along the intended path to remove some of the material.

8. The method of claim 1, wherein the working member is a cutting bit and the motor control information causes the one or more motors to move the cutting bit to the first target point.

9. The method of claim 8, wherein the intended path is based at least in part upon a width of the cutting bit.

10. The method of claim 1, wherein the working member is a saw blade and the motor control information causes the one or more motors to orient the saw blade at the first target point.

11. The method of claim 1, wherein the one or more markers comprise at least one of:

a sticker, a projected feature, an ink marking, a pencil marking, or a marker marking.

12. The method of claim 1, wherein the one or more markers comprise a tape with a pattern, and the pattern relates to marker identification information for at least one of the one or more markers in the first set of markers.

13. The method of claim 1, wherein the marked surface is a surface of a material, and the working member is positioned on the marked surface.

14. A system to position a working member of a rig, the rig comprising a stage for receiving and holding the working member, and one or more motors for moving the stage, the system comprising:

a processor in combination with one or more software applications;

a camera, communicatively coupled to the processor; and

a memory, communicatively coupled to the processor,

wherein the one or more software applications, when executed, cause the system to;

capture, using the camera, a first set of captured images, wherein the first set of captured images includes one or more images of one or more markers on a marked surface;

determine a first set of marker data based at least in part upon the first set of captured images, wherein the first set of marker data includes marker identification information and marker position information for each marker in a first set of markers, and each of the markers in the first set of markers appears in at least one of the images in the first set of captured images;

register a design to marker identification information and marker position information in the first set of marker data for at least one marker in the first set of markers;

determine an intended path for the working member based at least in part upon the design;

capture, using the camera, a first image of at least one of the one or more markers on the marked surface after registering the design;

determine a second set of marker data based at least in part upon the first image, wherein the second set of marker data includes marker identification information and marker position information for each marker in a second set of markers, each of the markers in the second set of markers appears in the first image, and at least one marker in the second set of markers is in the first set of markers;

provide motor control information that controls the one or more motors to position the working member at a first target point on the intended path based at least in part upon a position of the camera, wherein the position of the camera is based at least in part upon the first set of marker data and the second set of marker data;

capture, using the camera, a second image of at least one of the one or more markers on the marked surface after capturing the first image, wherein the rig is located at a first location when capturing the first image, the rig is located at a second location when capturing the second image, and the first location is different from the second location;

determine a third set of marker data based at least in part upon the second image, wherein the third set of marker data includes marker identification information and marker position information for each marker in a third set of markers, each of the markers in the third set of markers appears in the second image, and at least one marker in the third set of markers is in the first set of markers; and

provide additional motor control information that controls the one or more motors to position the working member at a second target point on the intended path based at least in part upon a second position of the camera, wherein the first target point and the second target point are different points on the intended path, and the second position of the camera is based at least in part upon the first set of marker data and the third set of marker data.

15. The system of claim 14, further comprising:

a display, communicatively coupled to the processor,

wherein the one or more software applications, when executed, cause the system to;

provide first information for displaying, via the display, a representation of at least a portion of the intended path.

16. The system of claim 15, wherein the one or more software applications, when executed, cause the system to:

provide second information for displaying, via the display, a representation of a target range within which the working member may be positioned by the one or more motors.

17. The system of claim 16, wherein the one or more software applications, when executed, cause the system to:

provide third information for displaying, via the display, a representation of a position of the working member.

18. The system of claim 14, further comprising:

a display, communicatively coupled to the processor,

wherein the one or more software applications, when executed, cause the system to;

stitch a second set of captured images together to generate a photo mosaic, wherein each image in the second set of captured images is in the first set of captured images;

provide first information for displaying, via the display, a representation of at least a portion of the photo mosaic; and

provide second information for displaying, via the display, a representation of a position of the working member.

19. The system of claim 14, wherein the one or more software applications, when executed, cause the system to:

obtain the design from a remote computer system.

20. The system of claim 14, wherein the one or more markers comprise a tape with a pattern, and the pattern relates to marker identification information for at least one of the one or more markers in the first set of markers.

21. The system of claim 14, wherein the motor control information and the additional motor control information cause the working member to engage a material along the intended path to remove some of the material.

22. Non-transitory computer readable media storing instructions for positioning a working member of a rig, wherein the instructions, when executed by a computer system, cause the computer system to:

capture, using a camera, a first set of captured images, wherein the first set of captured images includes one or more images of one or more markers on a marked surface;

determine a first set of marker data based at least in part upon the first set of captured images, wherein the first set of marker data includes marker identification information and marker position information for each marker in a first set of markers, and each of the markers in the first set of markers appears in at least one of the images in the first set of captured images;

register a design to marker identification information and marker position information in the first set of marker data for at least one marker in the first set of markers;

determine an intended path for the working member based at least in part upon the design;

capture, using the camera, a first image of at least one of the one or more markers on the marked surface after registering the design;

determine a second set of marker data based at least in part upon the first image, wherein the second set of marker data includes marker identification information and marker position information for each marker in a second set of markers, each of the markers in the second set of markers appears in the first image, and at least one marker in the second set of markers is in the first set of markers;

provide motor control information that controls one or more motors to position the working member at a first target point on the intended path based at least in part upon a position of the camera, wherein the position of the camera is based at least in part upon the first set of marker data and the second set of marker data;

capture, using the camera, a second image of at least one of the one or more markers on the marked surface after capturing the first image, wherein the rig is located at a first location when capturing the first image, the rig is located at a second location when capturing the second image, and the first location is different from the second location;

determine a third set of marker data based at least in part upon the second image, wherein the third set of marker data includes marker identification information and marker position information for each marker in a third set of markers, each of the markers in the third set of markers appears in the second image, and at least one marker in the third set of markers is in the first set of markers; and

provide additional motor control information that controls the one or more motors to position the working member at a second target point on the intended path based at least in part upon a second position of the camera, wherein the first target point and the second target point are different points on the intended path, and the second position of the camera is based at least in part upon the first set of marker data and the third set of marker data.

23. The computer readable media of claim 22, wherein the instructions, when executed by the computer system, cause the computer system to:

provide first information for displaying, via a display, a representation of at least a portion of the intended path.

24. The computer readable media of claim 23, wherein the instructions, when executed by the computer system, cause the computer system to:

provide second information for displaying, via the display, a representation of a target range within which the working member may be positioned by the one or more motors.

25. The computer readable media of claim 24, wherein the instructions, when executed by the computer system, cause the computer system to:

provide third information for displaying, via the display, a representation of a position of the working member.

26. The computer readable media of claim 22, wherein the instructions, when executed by the computer system, cause the computer system to:

stitch a second set of captured images together to generate a photo mosaic, wherein each image in the second set of captured images is in the first set of captured images;

provide first information for displaying, via a display, a representation of at least a portion of the photo mosaic; and

provide second information for displaying, via the display, a representation of a position of the working member.

27. The computer readable media of claim 22, wherein the instructions, when executed by the computer system, cause the computer system to:

obtain the design from a remote computer system.

28. The computer readable media of claim 22, wherein the one or more markers comprise a tape with a pattern, and the pattern relates to marker identification information for at least one of the one or more markers in the first set of markers.

29. The computer readable media of claim 22, wherein the motor control information and the additional motor control information cause the working member to engage a material along the intended path to remove some of the material.