Method of forming a carved sign using an axially rotating carving tool

• US 5,197,013 A
• Filed: 01/09/1991
• Issued: 03/23/1993
• Est. Priority Date: 07/28/1987
• Status: Expired due to Term

• Current Assignee: David M. Dundorf
• Original Assignee: David M. Dundorf
• Inventors: Dundorf, David M.
• Primary Examiner(s): Smith, Jerry
• Assistant Examiner(s): MUIR, PATRICK
• Application Number:
  US07/639,258
• Time in Patent Office: 804 Days
• Field of Search: 364/474.05, 364/474.24, 364/474.03, 364/474.04, 364/474.06, 364/474.08, 364/474.26, 364/474.29, 364/474.16, 219/121.68, 219/121.69
• US Class Current: 700/182
• CPC Class Codes: G05B 19/02 electric
• CPC Class Codes: G05B 19/4069 Simulating machining process on screen G05B19/4068 takes precedence
• CPC Class Codes: G05B 19/4097 characterised by using design data to control NC machines, e.g. CAD/CAM G05B19/4093 takes precedence
• CPC Class Codes: G05B 2219/35287 Verify, check program by drawing, display part, testpiece
• CPC Class Codes: G05B 2219/36323 Shape is alphabetical character
• CPC Class Codes: G05B 2219/45212 Etching, engraving, sculpturing, carving
• CPC Class Codes: Y02P 90/02 Total factory control, e.g. smart factories, flexible manufacturing systems [FMS] or integrated manufacturing systems [IMS]

Abstract

A computer-produced carved sign having three-dimensional surfaces, is produced by a method which comprises designing on a computer-aided design system, a three-dimensional graphical model of the signage work having three-dimensional surfaces to be carved in a signboard. On the computer-aided design system, a desired mathematical representation of the three-dimensional graphical model of the signage work to be carved in the signboard, is determined, and the desired mathematical representation is provided to a computer-aided machining system having a carving tool. Material constituting the signboard is removed using the carving tool moving under the controlled guidance of the computer-aided machining system. The CAD system allows the user to input an alpha-numeric character. The CAD system automatically creates the machining path by developing similar outlines of the alpha-numeric character and projects these outlines into the 3D graphical model. In another embodiment of the invention, the CAD system displays a model of the machine tool removing material from the workpiece to allow the user to change the CAD program before actual machining.

Claims

1. A method of forming a carved sign embodying a signage work having three-dimensional surfaces, comprising:

(a) designing on a computer-aided design system, a three-dimensional graphical model of said signage work including an alphanumerical character having three-dimensional surfaces to be carved in a signboard, said three-dimensional graphical model comprising a three-dimensional graphical representation of said alphanumerical character having three-dimensional surfaces;

(b) determining on said computer-aided design system, a desired mathematical representation of said three-dimensional graphical model of said signage work to be carved in said signboard;

(c) providing said desired mathematical representation to a computer-aided machining system having a carving tool; and

(d) removing constituting material of said signboard using said carving tool moving under the controlled guidance of said computer-aided machining system, to leave in said signboard, a three-dimensional carved pattern corresponding to said three-dimensional graphical model of said signage work, wherein said three-dimensional carved pattern in said signboard has three-dimensional surfaces corresponding to said three-dimensional surfaces of said three-dimensional graphical model of said signage work,

wherein said three-dimensional graphical representation of said alphanumerical character is generated from a corresponding two-dimensional graphical representation having a characteristic outline by;

(a) projecting in two dimensions on said computer-aided design system, said two-dimensional graphical representation of said character having a characteristic outline;

(b) generating from said characteristic outline of said two-dimensional graphical representation of said character, at a predetermined offset towards the inside of said two-dimensional graphical representation of said character, a plurality of substantially similar outlines of said two-dimensional graphical representation and displaying said plurality of similar outlines on said computer-aided design system;

(c) projecting each of said similar outlines a predetermined distance along the third dimension of the coordinate system of said computer-aided design system;

(d) introducing in said three-dimensional coordinate system, a plurality of points at locations corresponding to points along a three-dimensional tool path of an axially rotating carving tool of predetermined carving dimensions which, when moved along said three-dimensional tool path, forms in said signboard a desired three-dimensional carved pattern having three-dimensional surfaces corresponding to said three-dimensional surfaces of said three-dimensional graphical surfaces of said alphanumerical character, and

(e) interpolating said plurality of points to render the coordinates of said three-dimensional tool path.

2. The carved sign of claim 1 wherein said desired mathematical representation comprises a numerical coordinate data file corresponding to a three-dimensional carving tool path for carving said signage work.

3. The carved sign according to claim 1 wherein said method further comprises,

applying a light reflective coating to said three-dimensional carved pattern.

4. The method according to claim 3, wherein said light reflective coating is one of gold leaf and gold paint.

5. The method according to claim 1 including the step of rotating said carving tool about an axis.

6. A method of carving a signboard, comprising:

(a) displaying in two dimensions on a computer-aided design system, a two-dimensional graphical representation of a character having an outline;

(b) generating from said outline of said two-dimensional character, at a predetermined offset towards the inside of said two dimensional character, a plurality of substantially similar outlines of said two-dimensional character and displaying said plurality of similar outlines on said computer-aided design system;

(c) projecting each of said similar outlines a predetermined distance along a third dimension of a coordinate system of said computer-aided design system, thereby providing a three-dimensional graphical model of said character;

(d) introducing in said three-dimensional coordinate system, a plurality of points at locations corresponding to points along a three-dimensional tool path of an axially rotatable carving tool of predetermined dimensions;

(e) interpolating said plurality of points to render the coordinates of said three-dimensional tool path;

(f) causing said rotatable carving tool to engage a signboard;

(g) causing said rotatable carving tool to rotate about an axis, and

(h) causing said rotatable carving tool to move along said three-dimensional tool path, thereby carving a three-dimensional v-shaped pattern within said signboard having a center line and smooth three-dimensional surfaces corresponding to the surfaces of said three-dimensional graphical model.

7. The method of claim 6 wherein said axially rotating carving tool provides a carving angle of about between 60°

to 120°

within said signboard.

8. A method of carving a signage work in a signboard, comprising:

(a) graphically representing a signboard using solid geometry to provide a solid graphical model thereof;

(b) graphically representing a carving tool using solid geometry to provide a solid graphical model thereof;

(c) moving said solid graphical model of said carving tool through said solid graphical model of said signboard;

(d) mathematically subtracting those parts of said solid graphical model of said signboard that are in mathematical union with said solid graphical model of said carving tool during said movement thereof in step (c), as to form a three-dimensional graphical model of a signage work in said solid graphical model of said signboard;

(e) displaying said three-dimensional graphical model of said signboard resulting from step (d);

(f) generating a three-dimensional carving tool path corresponding to the generation of said three-dimensional graphical model of said signage work using said solid graphical model of said carving tool;

(g) generating a three-dimensional numerical coordinate data file corresponding to said three-dimensional carving tool path;

(h) causing an axially rotatable carving tool to engage a signboard, and

(i) causing said rotatable carving tool to move along a path corresponding to said three-dimensional carving tool path while rotating said carving tool about an axis, thereby removing material from said signboard to provide a signage work corresponding to said three-dimensional graphical model, such that said signage work includes substantially v-shaped grooves having smooth, opposing side walls which adjoin each other along center lines within said grooves.