Methods and computer program products for processing of coverings such as leather hides and fabrics for furniture and other products

• US 9,421,692 B2
• Filed: 10/23/2012
• Issued: 08/23/2016
• Est. Priority Date: 05/14/2010
• Status: Active Grant

• Current Assignee: Automated Vision LLC
• Original Assignee: Automated Vision LLC
• Inventors: Campbell, Robert L., Leonard, Charles A., Miller, Robert L.
• Primary Examiner(s): GORADIA, SHEFALI DINESH
• Application Number:
  US13/658,810
• Publication Number:
  US 20130177215A1
• Time in Patent Office: 1,400 Days
• Field of Search: 382/111, 835/20
• US Class Current: 1/1
• CPC Class Codes: B26D 2005/002 Performing a pattern matching operation
• CPC Class Codes: B26D 5/007 Control means comprising cameras, vision or image processing systems
• CPC Class Codes: B26F 1/3813 wherein the tool head is moved in a plane parallel to the work in a coordinate system fixed with respect to the work
• CPC Class Codes: B65H 2220/01 indicating an entity as a function of which control, adjustment or change is performed, i.e. input
• CPC Class Codes: B65H 2511/413 of image
• CPC Class Codes: B65H 2553/42 Cameras
• CPC Class Codes: B65H 2553/46 Illumination arrangement
• CPC Class Codes: B65H 2701/178 Hide, leather or skin
• CPC Class Codes: B65H 9/00 Registering, e.g. orientating, articles; Devices therefor
• CPC Class Codes: C14B 5/00 Clicking, perforating, or cutting leather for shoe parts, e.g. soles, A43D; apparatus not specially adapted for leather B26D

Abstract

Methods and computer program for processing coverings such as leather hides and fabrics are provided. A method for processing coverings can include placing a covering on a work surface and projecting a captured image of the covering by a projector onto the covering. Virtual markings of boundary lines and defects on the covering on the capture image can be registered using the controller. Nesting of templates can be performed on the captured image of the covering with the virtual markings and the nested templates stored as virtual markings with the captured image of the covering. The covering can then be marked, die pressed, or cut along the virtual markings.

Claims

1. A method for processing coverings comprising:

placing a covering on a work surface for processing;

projecting a captured image of the same covering by a projector onto the covering that is on the work surface;

registering virtual markings of boundary lines and defects on the covering on the captured image of the same covering using a controller; and

nesting of templates on the captured image of the covering with the virtual markings and storing the nested templates as virtual markings with the captured image of the covering.

2. The method according to claim 1, further comprising removing the covering from the work surface after the registering of the virtual markings and storing the captured image of the covering with the virtual markings thereon on the controller.

3. The method according to claim 2, wherein the nesting of templates comprises performing the nesting of templates a plurality of times on the captured image of the covering with the virtual markings while the covering is not on the work surface.

4. The method according to claim 3, further comprising placing the covering on a work surface after the nesting of templates on the captured image of the covering with the virtual markings.

5. The method according to claim 4, further comprising at least one of marking, die pressing, or cutting the covering based on the nested templates.

6. The method according to claim 2, further comprising selecting a plurality of coverings, each of which having been processed to have a corresponding captured image of the respective covering with virtual markings of boundary lines and defects, for use to form a plurality of panels for a product that requires multiple coverings and performing the nesting of templates for the panels of the product a plurality of times on all the selected coverings to increase the yield from the coverings.

7. The method according to claim 6, wherein the performing of the nesting of templates for the panels of the product a plurality of times on all the selected coverings comprises determining which combination of a covering of the selected coverings and templates being nested provides the best yield to provide a first confirmed nested covering.

8. The method according to claim 7, further comprising removing from consideration the covering and templates used in the first confirmed nested covering and performing the nesting of the remaining templates for the panels of the product a plurality of times on the remaining selected coverings to determine which combination of a remaining covering of the selected coverings and remaining templates being nested provides the best yield to provide a second nested covering.

9. The method according to claim 8, further comprising repeating the performing of the nesting of the remaining templates for the panels of the product a plurality of times on the remaining selected coverings to determine which combination of a remaining covering of the selected coverings and remaining templates being nested provides the best yield after the covering and templates used in each confirmed nested covering are removed from consideration until all the templates for the panels of the product have been nested on one of the selected coverings.

10. The method according to claim 1, further comprising rotating the image of the covering to one or more different orientations and performing the nesting of templates on the covering at each orientation using the controller.

11. The method according to claim 1, further comprising correcting the captured image projected by the projector to increase dimensionally accuracy of the protected image.

12. The method according to claim 1, further comprising capturing an image of the covering on the work surface using an imaging device and correcting the captured image projected by the projector to increase dimensionally accuracy of the protected image.

13. The method according to claim 12, further comprising correcting the captured image using a first coordinate transformation table to increase dimensionally accuracy of the corrected captured image.

14. A non-transitory computer readable medium comprising computer executable instructions embodied in a computer readable medium that when executed by a processor of a computer control the computer to perform steps comprising:

projecting onto a covering residing on a work surface a captured image of the same covering by a projector;

registering virtual markings of boundary lines and defects on the covering on the captured image of the same covering using a controller; and

nesting of templates on the captured image of the covering with the virtual markings and storing the nested templates as virtual markings with the captured image of the covering.

15. The non-transitory computer readable medium according to claim 14, further comprising selecting a plurality of coverings, each of which having been processed to have a corresponding captured image of the respective covering with virtual markings of boundary lines and defects, for use to form a plurality of panels for a product that requires multiple coverings and performing the nesting of templates for the panels of the product a plurality of times on all the selected coverings to increase the yield from the coverings.

16. The non-transitory computer readable medium according to claim 15, wherein the performing of the nesting of templates for the panels of the product a plurality of times on all the selected coverings comprises determining which combination of a covering of the selected coverings and templates being nested provides the best yield to provide a first confirmed nested covering.

17. The non-transitory computer readable medium according to claim 16, further comprising removing from consideration the covering and templates used in the first confirmed nested covering and performing the nesting of the remaining templates for the panels of the product a plurality of times on the remaining selected coverings to determine which combination of a remaining covering of the selected coverings and remaining templates being nested provides the best yield to provide a second nested covering.

18. The non-transitory computer readable medium according to claim 17, further comprising repeating the performing of the nesting of the remaining templates for the panels of the product a plurality of times on the remaining selected coverings to determine which combination of a remaining covering of the selected coverings and remaining templates being nested provides the best yield after the covering and templates used in each confirmed nested covering are removed from consideration until all the templates for the panels of the product have been nested on one of the selected coverings.

19. The non-transitory computer readable medium according to claim 14, further comprising rotating the image of the covering to one or more different orientations and performing the nesting of templates on the covering at each orientation using the controller.

20. The non-transitory computer readable medium according to claim 14, further comprising correcting the captured image projected by the projector to increase dimensionally accuracy of the protected image.

21. The non-transitory computer readable medium according to claim 14, further comprising grading the covering in the captured image after the registering of the virtual markings of the boundaries lines and defects.

22. The non-transitory computer readable medium according to claim 21, wherein the grading of the covering in the captured image comprises fitting one or more virtual grading squares on the captured image of the covering with the virtual markings of the boundaries lines and defects so that the virtual grading squares do not overlap the virtual markings of the boundaries lines and defects to determine the grade.

23. A method for processing coverings comprising:

selecting a plurality of coverings, each of which having been processed to have a corresponding captured image of the respective covering with virtual markings of boundary lines and defects, for use to form a plurality of panels for a single product that requires multiple coverings; and

performing at least one nesting of templates for the panels of the single product a plurality of times on all the selected coverings to increase the yield from the coverings.

24. The method according to claim 23, wherein the performing of the nesting of templates for the panels of the product a plurality of times on all the selected coverings comprises determining which combination of a covering of the selected coverings and templates being nested provides the best yield to provide a first confirmed nested covering.

25. The method according to claim 24, further comprising removing from consideration the covering and templates used in the first confirmed nested covering and performing the nesting of the remaining templates for the panels of the product a plurality of times on the remaining selected coverings to determine which combination of a remaining covering of the selected coverings and remaining templates being nested provides the best yield to provide a second nested covering.

26. The method according to claim 25, further comprising repeating the performing of the nesting of the remaining templates for the panels of the product a plurality of times on the remaining selected coverings to determine which combination of a remaining covering of the selected coverings and remaining templates being nested provides the best yield after the covering and templates used in each confirmed nested covering are removed from consideration until all the templates for the panels of the product have been nested on one of the selected coverings.

27. The method according to claim 23, further comprising rotating the image of the covering to one or more different orientations and performing the nesting of templates on the covering at each orientation using the controller.

28. A non-transitory computer readable medium comprising computer executable instructions embodied in a computer readable medium that when executed by a processor of a computer control the computer to perform steps comprising:

selecting a plurality of coverings, each of which having been processed to have a corresponding captured image of the respective covering with virtual markings of boundary lines and defects, for use to form a plurality of panels for a single product that requires multiple coverings; and

performing at least one nesting of templates for the panels of the single product a plurality of times on all the selected coverings to increase the yield from the coverings.