Automatically guided tools

• US 10,078,320 B2
• Filed: 04/03/2015
• Issued: 09/18/2018
• 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:
  US14/678,752
• Publication Number:
  US 20150277421A1
• Time in Patent Office: 1,264 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 system to position a working member of a rig, the rig comprising a stage for receiving and holding the working member, and at least one motor for moving the stage, the system comprising:

a processor in combination with one or more software applications;

one or more sensors communicatively coupled to the processor, a first sensor of the one or more sensors configured to capture first information of a surface of a material; and

a memory, communicatively coupled to the processor,

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

determine, based at least in part upon the first information, a first location of the working member using a map of the surface retrieved from memory;

indicate, via a display screen of the rig, the first location of the working member relative to the map of the surface;

register a design, retrieved from memory, to the map of the surface, to identify a path for the working member;

compare the first location of the working member with the path to determine a second location for the working member corresponding to the path for the working member;

control, responsive to the second location, a first one or more motors of the at least one motor to move the stage to position the working member at the second location to align the working member with the path; and

control a second one or more motors of the at least one motor to maintain alignment of the working member with the path by moving the working member in a first direction as the rig is advanced in a second, different direction.

2. The system of claim 1, comprising:

a second sensor configured to capture second information of the surface of the material, the second information comprising a plurality of images,

wherein the one or more software applications, when executed, cause the system to use the plurality of images of the second information to build the map of the surface of the material.

3. The system of claim 2, wherein the first sensor and the second sensor are the same sensor.

4. The system of claim 1, wherein the one or more software applications, when executed, cause the system to:

analyze the first information including information corresponding to one or more markers on the surface of the material to determine the first location of the working member using the map.

5. The system of claim 4, wherein the one or more markers comprise at least one of:

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

6. The system of claim 1, wherein the one or more software applications, when executed, cause the system to:

provide the motor control information to control the at least one motor to move the stage to position the working member at a plurality of locations subsequent to the second location while the rig is advanced in a corresponding plurality of subsequent directions.

7. The system of claim 1, wherein:

the rig performs a function performed by at least one of;

a router, a drill, a nail gun, a jigsaw, a scroll saw, or a printer;

the working member comprises at least one of;

a cutting bit, a saw blade, a drill bit, a hammer, or a printer head; and

the first sensor comprises at least one of;

a camera, an ultrasonic sensor, an IR range finder, or a laser.

8. The system of claim 1, wherein:

the first sensor is configured to capture image data; and

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

receive the image data captured by the first sensor; and

use the image data to compare a previous position on the path and a preferred next position on the path to realign a position of the working member using the at least one motor.

9. The system of claim 1, wherein the one or more software applications, when executed, cause the system to:

receive the design from a computing device; and

receive an indication to manipulate the design.

10. The system of claim 1, wherein the one or more software applications, when executed, cause the system to:

indicate, via the display screen, the path relative to the first location.

11. The system of claim 1, wherein the one or more software applications, when executed, cause the system to:

indicate, via the display screen, a range of movement for the working member.

12. The system of claim 1, further comprising:

a skid pad proximate to the stage to facilitate movement of the stage,

wherein the stage further comprises an attachment point to attach the working member to the stage.

13. The system of claim 1, wherein the first one or more motors comprises a same motor as the second one or more motors.

14. The system of claim 1, wherein the first one or more motors is different from the second one or more motors.

15. The system of claim 2, wherein the one or more software applications, when executed, cause the system to build the map of the surface by stitching the plurality of images together.

16. The system of claim 2, wherein the map comprises image data.

17. The system of claim 2, wherein the first information indicates a first one or more markers, and the map indicates a second one or more markers,

wherein the system determines the first location based at least in part upon matching information corresponding to the first one or more markers from the first information to information corresponding to the second one or more markers from the map.

18. The system of claim 17, wherein the information corresponding to one or more markers from the map comprises information corresponding to one or more markers from each of two or more images from the plurality of images.

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

capturing, by a first sensor communicatively coupled to a processor, first information of a surface of a material;

determining, by a processor based at least in part upon the first information, a first location of the working member using a map of the surface retrieved from memory;

providing information, from a processor, for displaying, via a display screen of the rig, the first location of the working member relative to the map of the surface;

registering, by a processor, a design retrieved from memory to the map of the surface, to identify a path for the working member;

comparing, by a processor, the first location of the working member with the path to determine a second location for the working member corresponding to the path for the working member;

controlling, by a processor responsive to the second location, at least one motor to move a stage to position the working member at the second location to align the working member with the path; and

controlling the at least one motor to maintain alignment of the working member with the path by moving the working member in a first direction as the rig is advanced in a second, different direction.

20. The method of claim 19, comprising:

capturing, by a second sensor communicatively coupled to a processor, second information of the surface of the material, the second information comprising a plurality of images; and

using, by a processor, the plurality of images of the second information to build the map of the surface of the material.

21. The method of claim 20, wherein the first sensor and the second sensor are the same sensor.

22. The method of claim 19, comprising:

analyzing, by a processor, the first information including information corresponding to one or more markers on the surface of the material to determine the first location of the working member using the map.

23. The method of claim 19, comprising:

capturing, by the first sensor, image data;

receiving, by a processor, the image data captured by the first sensor; and

using, by a processor, the image data to compare a previous position on the path and a preferred next position on the path to realign a position of the working member using the at least one motor.

24. The method of claim 19, comprising:

providing information, from a processor, for displaying, via the display screen, a range of movement for the working member.

25. The method of claim 22, wherein the one or more markers comprise at least one of:

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

26. The method of claim 19, comprising:

providing, by a processor, motor control information to control the at least one motor to move the stage to position the working member at a plurality of locations subsequent to the second location while the rig is advanced in a corresponding plurality of subsequent directions.

27. The method of claim 19, wherein:

the rig performs a function performed by at least one of;

a router, a drill, a nail gun, a jigsaw, a scroll saw, or a printer;

the working member comprises at least one of;

a cutting bit, a saw blade, a drill bit, a hammer, or a printer head; and

the first sensor comprises at least one of;

a camera, an ultrasonic sensor, an IR range finder, or a laser.

28. The method of claim 19, comprising:

receiving, by a processor, the design from a computing device; and

receiving, by a processor, an indication to manipulate the design.

29. The method of claim 19, comprising:

providing information, from a processor, for displaying, via the display screen, the path relative to the first location.

30. The method of claim 20, wherein the plurality of images are stitched together to build the map of the surface.

31. The method of claim 20, wherein the map comprises image data.

32. The method of claim 20, wherein the first information indicates a first one or more markers, and the map indicates a second one or more markers,

wherein the system determines the first location based at least in part upon matching information corresponding to the first one or more markers from the first information to information corresponding to the second one or more markers from the map.

33. The method of claim 32, wherein the information corresponding to one or more markers from the map comprises information corresponding to one or more markers from each of two or more images from the plurality of images.

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

determine, based at least in part upon a first information captured by a first sensor, a first location of the working member using a map of a surface retrieved from memory;

indicate, via a display screen of the rig, the first location of the working member relative to the map of the surface;

register a design retrieved from memory to the map of the surface, to identify a path for the working member;

compare the first location of the working member with the path to determine a second location for the working member corresponding to the path for the working member; and

control, responsive to the second location, at least one motor to move a stage, for receiving and holding the working member, to position the working member at the second location to align the working member with the path; and

control the at least one motor to maintain alignment of the working member with the path by moving the working member in a first direction as the rig is advanced in a second, different direction.

35. The computer readable media of claim 34, wherein the instructions, when executed, cause the computing system to:

capture, by a second sensor, second information of the surface of the material, the second information comprising a plurality of images; and

use the plurality of images of the second information to build the map of the surface of the material.

36. The computer readable media of claim 35, wherein the first sensor and the second sensor are the same sensor.

37. The computer readable media of claim 34, wherein the instructions, when executed, cause the computing system to:

analyze the first information including information corresponding to one or more markers on the surface of the material to determine the first location of the working member using the map.

38. The computer readable media of claim 34, wherein the instructions, when executed, cause the computing system to:

provide motor control information to control the at least one motor to move the stage to position the working member at a plurality of locations subsequent to the second location while the rig is advanced in a corresponding plurality of subsequent directions.

39. The computer readable media of claim 35, wherein the instructions, when executed, cause the computing system to build the map of the surface by stitching the plurality of images together.

40. The computer readable media of claim 35, wherein the map comprises image data.

41. The computer readable media of claim 35, wherein the first information indicates a first one or more markers, and the map indicates a second one or more markers,

wherein the system determines the first location based at least in part upon matching information corresponding to the first one or more markers from the first information to information corresponding to the second one or more markers from the map.

42. The computer readable media of claim 41, wherein the information corresponding to one or more markers from the map comprises information corresponding to one or more markers from each of two or more images from the plurality of images.