Systems, methods and apparatus for guided tools

• US 10,456,883 B2
• Filed: 05/12/2016
• Issued: 10/29/2019
• Est. Priority Date: 05/13/2015
• Status: Active Grant

• Current Assignee: Shaper Tools, Inc.
• Original Assignee: Shaper Tools, Inc.
• Inventors: Rivers, Alec Rothmyer, Moyer, Ilan Ellison, Martin, Matthew Wyatt, Reed, Christian
• Primary Examiner(s): Laughlin, Nathan L
• Application Number:
  US15/573,465
• Publication Number:
  US 20180126507A1
• Time in Patent Office: 1,265 Days
• CPC Class Codes: B23B 49/00 Measuring or gauging equipment on boring machines for positioning or guiding the drill; Devices for indicating failure of drills during boring; Centering devices for holes to be bored marking-out equipment B25H7/00; measuring devices, gauges G01B
• CPC Class Codes: B23Q 11/0046 by sucking
• CPC Class Codes: B23Q 11/005 by blowing
• CPC Class Codes: B23Q 11/006 by sucking and blowing simultaneously
• CPC Class Codes: B23Q 15/22 Control or regulation of position of tool or workpiece
• CPC Class Codes: B23Q 17/2233 for adjusting the tool relative to the workpiece
• CPC Class Codes: B23Q 17/2409 Arrangements for indirect observation of the working space using image recording means, e.g. a camera
• CPC Class Codes: B23Q 17/2428 for measuring existing positions of tools or workpieces
• CPC Class Codes: B23Q 3/16 controlled in conjunction with the operation of the tool
• CPC Class Codes: G05B 19/402 characterised by control arrangements for positioning, e.g. centring a tool relative to a hole in the workpiece, additional detection means to correct position G05B19/19 takes precedence
• CPC Class Codes: G05B 19/404 characterised by control arrangements for compensation, e.g. for backlash, overshoot, tool offset, tool wear, temperature, machine construction errors, load, inertia G05B19/19, G05B19/41 take precedence
• CPC Class Codes: G05B 2219/37355 Cutting, milling, machining force
• CPC Class Codes: G05B 2219/37404 Orientation of workpiece or tool, surface sensor
• CPC Class Codes: G05B 2219/37405 Contact detection between workpiece and tool, probe, feeler
• CPC Class Codes: G05B 2219/37613 Cutter axis tilt of end mill
• CPC Class Codes: G05B 2219/45127 Portable, hand drill
• CPC Class Codes: G05B 2219/45229 Woodworking
• CPC Class Codes: Y10T 409/306608 End mill [e.g., router, etc.]

Abstract

The present disclosure is directed to calibrating position detection for a tool. The tool can use a sensor to detect a first value of a parameter. The tool can use a motor to extend the working member of the tool towards a working surface. The tool can include a base. The tool can detect, with the working member in contact with the working service, a second value of the parameter. The tool can determine a z-axis position of the working member relative to the working surface.

Claims

1. A system to position a working member of a tool, comprising:

a base coupled to the tool;

a computing device comprising one or more processors;

a sensor communicatively coupled to the computing device;

a motor controlled by the computing device;

the computing device configured to;

identify, via the sensor, a first value of a parameter indicative of an amount of force exerted by a portion of the base towards a working surface;

instruct the motor to extend the working member towards the working surface;

identify, via the sensor with the working member in contact with the working surface, a second value of the parameter;

compare the first value of the parameter with the second value of the parameter to identify a difference between the first value and the second value; and

determine a z-axis position of the working member relative to the working surface based on the difference between the first value and the second value being greater than a threshold.

2. The system of claim 1, wherein

the computing device is configured to identify the first value of the parameter based on the portion of the base of the tool in contact with the working surface.

3. The system of claim 1, wherein

the computing device is configured to identify, via the sensor, the second value of the parameter based on the portion of the base of the tool not in contact with the working surface responsive to the motor causing the working member to contact the working surface.

4. The system of claim 1, wherein

the computing device is configured to determine the z-axis position responsive to the first value being greater than the second value.

5. The system of claim 1, wherein the parameter is based at least in part upon force measured by the sensor, and the second value is less than the first value.

6. The system of claim 1, wherein

the extending working member contacts the working surface to tilt the base of the tool, and

determining the z-axis position of the working member relative to the working surface is responsive to the working member tilting the base of the tool responsive to the working member contacting the working surface.

7. The system of claim 1, comprising:

the computing device configured to;

instruct the motor to retract the working member in contact with the working surface away from the working surface;

identify, via the sensor when the working member is not in contact with the working surface, a third value of the parameter; and

determine a second z-axis position of the working member relative to the working surface responsive to a second difference between the first value and the third value being less than a second threshold.

8. The system of claim 1, wherein the tool comprises a frame having a cavity configured to

move, away from the working member, particles of material removed from the working surface by the working member.

9. A method of positioning of a working member of a tool, comprising:

detecting, by a sensor communicatively coupled to a computing device comprising one or more processors, a first value of a parameter for a first vertical position of a base of the tool;

extending, by a motor controlled by the computing device, the working member towards the working surface;

detecting, by the sensor with the working member in contact with the working surface, a second value of the parameter indicating a second vertical position of the base of the tool;

comparing, by the computing device, the first value of the parameter with the second value of the parameter to determine a change in vertical position of the base of the tool; and

determining, by the computing device, a z-axis position of the working member relative to the working surface based on the change in the vertical position of the base of the tool.

10. The method of claim 9, wherein

a portion of the base of the tool is in contact with the working surface when the first value of the parameter is detected.

11. The method of claim 9, wherein

a portion of the base of the tool is not in contact with the working surface when the second value of the parameter is detected, and the portion of the base of the tool is not in contact with the working surface responsive to the motor causing the working member to contact the working surface.

12. The method of claim 9, wherein the parameter is based at least in part upon force measured by the sensor,

and the z-axis position is further based on the first value being greater than the second value.

13. The method of claim 9, wherein the sensor comprises an image sensor and the parameter comprises a pixel, the method comprising:

capturing, by the image sensor, a first image comprising the first value of the parameter;

capturing, by the image sensor, a second image comprising the second value of the parameter; and

wherein comparing the first value with the second value further comprises comparing, by the computing device, the first image comprising the first value with the second image comprising the second value to identify the difference between the first value and the second value.

14. The method of claim 9, wherein the sensor comprises an accelerometer, detecting the first value further comprises determining, by the accelerometer, the first value, detecting the second value further comprises determining, by the accelerometer, the second value, and comparing the first value with the second value further comprises comparing, by the computing device, the first value with the second value to identify an acceleration of the base of the tool based on the working member contacting the working surface.

15. The method of claim 9, wherein

determining the z-axis position is responsive to the working member tilting the base responsive to the working member contacting the working surface.

16. The method of claim 9, comprising:

retracting, by the motor controlled by the computing device, the working member in contact with the working surface away from the working surface;

detecting, by the sensor upon the working member not being in contact with the working surface, a third value of the parameter, the third value of the parameter being greater than the second value of the parameter; and

determining, by the computing device, a second z-axis position of the working member relative to the working surface responsive to a second difference between the first value and the third value being less than a threshold.

17. The method of claim 9, comprising:

extending, by the motor, the working member towards a surface supporting the working surface, the base of the tool in contact with the working surface;

detecting, by the sensor responsive to the working member contacting the surface supporting the working surface, a third value of the parameter; and

determining, by the computing device, a thickness of the working surface responsive to a second difference between the first value and the third value being greater than a threshold.

18. The method of claim 9, comprising:

determining, by the computing device, a plurality of location points based on the working member of the tool contacting the working surface, each of the plurality of location points having an x-axis coordinate, a y-axis coordinate, and a z-axis coordinate; and

generating, by the computing device, a three dimensional map of the working surface using the plurality of location points.

19. The method of claim 18, comprising:

determining, by a second sensor of the tool, the x-axis coordinate and the y-axis coordinate of each of the plurality of location points using a fiducial marker placed on the working surface.

20. The method of claim 9, comprising:

moving, via a cavity of the tool, particles of material removed from the working surface by the working member; and

evacuating, by a vacuum, the particles via the cavity away from the working member.