U.S. patent application number 13/912261 was filed with the patent office on 2013-10-17 for system and method for generating instructions for customization.
The applicant listed for this patent is Jostens, Inc.. Invention is credited to Carlos D. Carbonera, Yuriy Malinin.
Application Number | 20130274907 13/912261 |
Document ID | / |
Family ID | 39410247 |
Filed Date | 2013-10-17 |
United States Patent
Application |
20130274907 |
Kind Code |
A1 |
Carbonera; Carlos D. ; et
al. |
October 17, 2013 |
SYSTEM AND METHOD FOR GENERATING INSTRUCTIONS FOR CUSTOMIZATION
Abstract
A method of creating a triangulated surfaces for generating
machine readable instructions for customization is provided. The
method comprises selecting text or symbols. The text or symbols are
spaced. The text or symbols are mapped between first and second
curves. Triangulated surfaces are generated from the mapped text or
symbols. The triangulated surfaces are converted to machine
readable instructions.
Inventors: |
Carbonera; Carlos D.; (St.
Paul, MN) ; Malinin; Yuriy; (Edina, MN) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
Jostens, Inc. |
Minneapolis |
MN |
US |
|
|
Family ID: |
39410247 |
Appl. No.: |
13/912261 |
Filed: |
June 7, 2013 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
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12958993 |
Dec 2, 2010 |
8473088 |
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13912261 |
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12016881 |
Jan 18, 2008 |
7856285 |
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12958993 |
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60885574 |
Jan 18, 2007 |
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Current U.S.
Class: |
700/98 |
Current CPC
Class: |
Y10T 409/50082 20150115;
B44B 1/006 20130101; G06F 30/00 20200101 |
Class at
Publication: |
700/98 |
International
Class: |
G06F 17/50 20060101
G06F017/50 |
Claims
1. A method of creating a triangulated surface for engraving an
item, the method comprising: selecting text or symbols; spacing the
text or symbols; mapping the text or symbols between first and
second curves; generating triangulated surfaces from the mapped
text or symbols.
2. The method of claim 1, wherein selecting text or symbols further
comprises selecting at least one divider and wherein spacing the
text further comprises placing the at least one divider and mapping
the text or symbols comprises mapping the at least one divider.
3. The method of claim 1, further comprising converting the
triangulated surfaces into machine readable instructions.
4. The method of claim 1, wherein the wherein the triangulated
surfaces are converted to machine readable instructions for the
generation of a tool path.
5. The method of claim 4, further comprising identifying areas for
clean up and generating clean-up lines.
6. The method of claim 5, wherein clean-up comprises the
elimination of sharp edges and burrs.
7. The method of claim 1, wherein spacing the text or symbols and
placing is performed on the basis of the selected text or
symbols.
8. The method of claim 1, wherein the first curve has a shape
different from the second curve.
9. The method of claim 1, wherein the first and second curves form
a bezel.
10. A method for creating a triangulated surface convertible to a
series a machine readable instructions, the method comprising:
defining a shape for placement of text and/or symbols; defining the
text and/or symbols for placement on the shape; placing the text
and/or symbols on the shape as triangulated surfaces; and
converting the triangulated surfaces to machine readable
instructions for generation of a customized item.
11. The method of claim 10, wherein the shape comprises an upper
and lower closed curve.
12. The method of claim 10, wherein the text comprises one or more
lines of text.
13. The method of claim 11, wherein placing the text and/or symbols
comprises spacing the text and/or dividers within the upper and
lower closed curves.
14. The method of claim 13, wherein the placed text and/or symbols
are mapped between the upper and lower close curves.
15. The method of claim 14, wherein triangulated surfaces are
generated from the mapped text and/or symbols.
16. The method of claim 10, wherein the triangulated surfaces are
converted to machine readable instructions for the generation of a
tool path.
17. The method of claim 16, further comprising identifying areas
for clean up and generating clean-up lines.
18. The method of claim 10, wherein the triangulated surfaces are
converted to machine readable instructions for the generation of a
photorealistic image.
19. The method of claim 10, wherein the triangulated surfaces are
converted to machine readable instructions for the generation of a
rapid prototyping model.
20. A computer-readable medium encoded with a computer program code
for creating a triangulated surface convertible to a series a
machine readable instructions, the program code causing a computer
to execute a method comprising: defining a shape for placement of
text and/or symbols; defining the text and/or symbols for placement
on the shape; placing the text and/or symbols on the shape as
triangulated surfaces; and converting the triangulated surfaces to
machine readable instructions for generation of a desired output.
Description
CROSS REFERENCE TO RELATED APPLICATIONS
[0001] This application is a continuation of U.S. patent
application Ser. No. 12/958,993, filed Dec. 2, 2010, issued as U.S.
Pat. No. 8,473,088 on Jun. 25, 2013, which is a continuation of
U.S. patent application Ser. No. 12/016,881, filed Jan. 18, 2008,
issued as U.S. Pat. No. 7,856,285 on Dec. 21, 2010, which claims
priority to U.S. Provisional Patent Application No. 60/885,574,
filed on Jan. 18, 2007, the entire contents of all of which are
incorporated herein by reference.
FIELD
[0002] The present disclosure relates to a system and method for
generating instructions for customization. More specifically, the
present disclosure relates to a system and method for creating
triangulated surfaces convertible to a series of machine readable
instructions for the generation of a tool path, photorealistic
image, or rapid prototyping model for customization of an item.
BACKGROUND
[0003] Personalized rings are popular and include, for example,
class rings, championship rings, and affiliation rings. With
particular reference to class rings, these rings have been a
popular keepsake among students for generations. Originally, class
rings were relatively uniform and provided students little
opportunity to express themselves. Over time, automated
manufacturing processes made it possible to provide students
customizing choices. Modern students are driving the class ring
market toward a level of customization that has been previously
economically impractical using present manufacturing methods.
[0004] Personalized rings include several areas that may be
customizable for a particular student or school. As shown in FIG.
1, a class ring 2 includes a shank 4 having graphics or text, a
stone or face 6, and a bezel 8 having text. The bezel 8 is the
portion of the ring 2 surrounding the gemstone or face 6. The bezel
8 comprises the groove holding the gemstone 6 in place and may
further comprise a band with text surrounding the gemstone 6. FIG.
1 illustrates a bezel 8 such as is generally provided on class
rings. As shown, the bezel 8 includes text such as the name of a
school.
[0005] Most recently, computer aided design/computer aided
manufacturing (CAD/CAM) technology has been used to provide the
text on the bezel. CAD/CAM has facilitated producing customized
rings in large quantities. The present level of customization
provides personalized features such as: student's name, school
name, graduation year, icons, academic degrees, and the like.
[0006] Traditionally, the use of CAD/CAM in the jewelry industry
has been primarily focused on the manufacture of custom molds and
engraving or otherwise machining the jewelry directly. These two
approaches have limitations. Machining molds using CAD/CAM is too
expensive for single-use custom applications. Engraving jewelry is
also expensive due to the precious metal lost to scrap,
manufacturing errors, and ordering errors.
[0007] CAD/CAM technology can be difficult to automate for the
purpose of making personalized products. In one legacy system, a
CAD/CAM operator manually manipulates a geometric model of a ring
by grabbing a surface on the blank geometric model, defining the
boundary splines, projecting the text or graphic onto the surface
and then instructing the CAD/CAM software to generate machining
instructions for the geometric model that has been created. The
machining instructions result in a desired toolpath for a computer
numerically controlled ("CNC") milling machine. Using human
operators to repeat these steps manually in order to generate the
machining instructions for thousands of individual, personalized
rings is cost prohibitive.
[0008] U.S. Pat. No. 7,069,108 for Automated Engraving of a
Customized Jewelry Item, issued Jun. 27, 2006 discloses an
automated system for personalizing a class ring and is herein
incorporated by reference in its entirety.
BRIEF SUMMARY
[0009] Systems and methods for creating triangulated surfaces
convertible to a series of machine readable instructions for the
generation of a tool path, photorealistic image, or rapid
prototyping model for customization of an item are provided. More
specifically, in one embodiment, an automated method for creating
triangulated surfaces convertible to a tool path for customization
of a bezel is provided.
[0010] In one embodiment, a method of creating a triangulated
surfaces for engraving an item is provided. The method comprises
selecting text or symbols. The text or symbols are spaced and
mapped between first and second curves. Triangulated surfaces are
generated from the mapped text or symbols.
[0011] In one embodiment, a method for creating a triangulated
surface convertible to a series a machine readable instructions is
provided. The method comprises defining a shape for placement of
text and/or symbols and defining the text and/or symbols for
placement on the shape. The text and/or symbols are placed on the
shape as triangulated surfaces. The triangulated surface is
converted to machine readable instructions for generation of a
customized item.
[0012] In one embodiment, a computer-readable medium encoded with a
computer program code for creating a triangulated surface
convertible to a series a machine readable instructions is
provided. The program code causes a computer to execute a method
which comprises defining a shape for placement of text and/or
symbols and defining the text and/or symbols for placement on the
shape. The text and/or symbols are placed on the shape as
triangulated surfaces. The triangulated surface is converted to
machine readable instructions for generation of a desired
output.
[0013] While multiple embodiments are disclosed, still other
embodiments of the present invention will become apparent to those
skilled in the art from the following detailed description. As will
be apparent, the invention is capable of modifications in various
obvious aspects, all without departing from the spirit and scope of
the present invention. Accordingly, the detailed description is to
be regarded as illustrative in nature and not restrictive.
BRIEF DESCRIPTION OF THE DRAWINGS
[0014] FIG. 1 illustrates a class ring.
[0015] FIG. 2a illustrates a workflow diagram of a process for
developing triangulated surfaces and converting such surfaces to a
set of machine readable instructions for customization of an item
in accordance with one embodiment.
[0016] FIG. 2b illustrates a workflow diagram of an automated
method for engraving a bezel in accordance with one embodiment.
[0017] FIG. 3 illustrates an exemplary bezel having a top text
curve and a bottom text curve created using the method of FIG.
2.
[0018] FIG. 4 illustrates an exemplary bezel having a single text
curve created using the method of FIG. 2.
[0019] FIG. 5 illustrates text mapping between two closed curves in
accordance with one embodiment.
[0020] FIG. 6 illustrates the text area, space, and tear drop for a
standard class ring.
[0021] FIG. 7 illustrates a workflow diagram of creating a ring
including the automated method for engraving a bezel of FIG. 2 in
accordance with one embodiment.
[0022] FIG. 8 illustrates a system architecture of a system for
automated engraving of a bezel in accordance with one
embodiment.
[0023] FIG. 9 illustrates detailed flow of retrieval of an order
and corresponding geometric and parameter data for the given order
in accordance with one embodiment.
[0024] FIG. 10 illustrates a flowchart of retrieval of an order and
corresponding geometric data in accordance with one embodiment.
[0025] FIG. 11 illustrates assembling a bezel in accordance with
one embodiment.
[0026] FIG. 12 illustrates a flowchart of the generation of
clean-up data in accordance with one embodiment.
[0027] FIG. 13 illustrates a flowchart of the generation of tool
path and storage of geometric data in accordance with one
embodiment.
[0028] FIG. 14 illustrates the detail of a single character M
represented as triangulated data that has been mapped between the
upper text curve, and the lower text curve in accordance with one
embodiment.
[0029] FIG. 15 illustrates text and dividers represented as
triangulated data that has been mapped between the upper text curve
and the lower text curve in accordance with one embodiment.
[0030] FIG. 16 illustrates constructing a rectangle or bounding box
containing text and dividers in accordance with one embodiment.
[0031] FIG. 17 illustrates determining minimum and maximum
expansion factors for text in accordance with one embodiment.
[0032] FIG. 18 illustrates determining the dimensions of the
bounding box of FIG. 16 in accordance with one embodiment.
[0033] FIG. 19 illustrates sample input text and resulting mapped
text in accordance with one embodiment.
[0034] FIG. 20 illustrates detail block 314 of FIG. 11 relating to
an extraction of a bezel surface and trim with mapped geometry.
DETAILED DESCRIPTION
[0035] Systems and methods for creating triangulated surfaces
convertible to a series of machine readable instructions for the
generation of a tool path, photorealistic image, or rapid
prototyping model for customization of an item are provided. While
the present disclosure describes an exemplary embodiment of the
system and method in the context of creating triangulated surfaces
convertible to a tool path for customizing a bezel, it should be
appreciated that this is for illustrative purposes only and the
system and method of the present disclosure may be used convert
triangulated surfaces to machine readable instructions for any
purpose.
[0036] FIG. 2a is a workflow diagram of a method of a process for
developing triangulated surfaces and converting the triangulated
surfaces to machine readable instructions for customizing an item.
As shown, a shape for placement of text, symbols, or other is
defined [block 1]. Additionally, the text, symbols, or other for
placement on the shape are defined [block 3]. The text, symbols, or
other, are placed on the shape, as triangulated surfaces (or
vertexes), in accordance with the method described with respect to
FIG. 2b [block 5]. Thereafter, the triangulated surfaces are
converted to machine readable instructions for creating a desired
output. For example, the triangulated surfaces of block 3 may be
converted to a tool path for creating, for example, a jewelry item,
pen, clock, or other engraveable item [block 7]. Alternatively, the
triangulated surfaces of block 3 may be converted into an image for
a photo realistic product such as a poster or printed card [block
9]. Alternatively, the triangulated surfaces may be converted into
instructions for rapid prototyping [block 11]. Generally, the
triangulated surface may be converted to machine readable
instructions or other for use in creating a customized item.
[0037] FIG. 2b is a workflow diagram illustrating an automated
method of engraving a bezel of a personalized ring in accordance
with one embodiment. Thus, FIG. 2b illustrates an exemplar
embodiment of blocks 1, 2, and 3 of FIG. 2a. Personalized rings
include a plurality of panels that may be personalized by a school
or purchaser. While the present disclosure makes specific reference
to the bezel of the ring and customizing the bezel of the ring, it
is to be understood by one skilled in the art that portions of the
disclosed method may be used to customize or personalize other
panels of a ring, other pieces of jewelry, or other non jewelry
objects such as for example, pens, clocks, keychains, automobiles,
and the like.
[0038] As shown, text is entered or retrieved for placement on the
bezel [block 10] and curve and database data for a given bezel is
retrieved [block 12], discussed more fully below. A font type may
be selected for the text. Alternatively, as will be described more
fully below, the font type may be determined during ring selection
and thus automatically set for the system. In the embodiment shown,
a TrueType brand typographic font is selected for the text [block
14]. The text is spaced and placement of the dividers is set based
on the entered text [block 16]. The entered text and dividers are
mapped between curves [block 18] and triangulated surfaces are
generated from the mapped data [block 20]. Areas that will need
further tooling are identified [block 22] and clean-up geometry for
a tool path is generated [block 24]. The final step in the workflow
diagram of FIG. 2b is creating a tool path [block 26]. It is to be
appreciated that in various embodiments of generating instructions
for customization, some of the steps may not be performed and or
other steps may be performed. For example, in some embodiments,
clean-up geometry may not be generated.
[0039] Referring still to FIG. 2b, in one embodiment, a first line
of text and a second line of text are retrieved or entered [block
10]. Now referring to FIG. 3, in one embodiment, the first line of
text 30 appears over the gemstone 6 or face of the ring and the
second line of text 32 appears under the gemstone 6 or face of the
ring. As previously discussed, dividers 34 may be selected for
placement between the first and second lines of text 30, 32 [block
12 of FIG. 2b].
[0040] In embodiments having first and second lines of text 30,32,
all entered text may be facing in the same direction when the ring
is manufactured. Alternatively, a single divider 34 may be selected
for placement at the end of a single line of text 36, as shown in
FIG. 4. Thus, using only a single line of text 36, the text wraps
around the gemstone 6 and changes direction such that it appears
upright over the gemstone 6 and upside down under the gemstone
6.
[0041] Referring again to FIG. 2b, using the system and method, the
text is spaced and placement of the dividers 34 is set based on the
entered text for the first and second lines 30, 32 [block 16], for
a ring such as shown in FIG. 3, or for a single line of text 36 for
a ring such as shown in FIG. 4.
[0042] As described with reference to FIG. 2b, the entered text and
dividers are mapped between curves [block 18]. The entered text and
dividers may be mapped between two closed curves 40, 41, as shown
in FIG. 5. The shape of the curves may be any suitable shape.
Further, the two curves may have varying shapes. The shape of the
curves 40, 41 may be preselected based on the shape and size of the
ring. Thus, referring back to FIG. 2b, curve and database data for
a given bezel may be retrieved [block 12] and the text and dividers
spaced based on that data [block 16]. The entered text and dividers
are converted into surfaces. More specifically, triangulated
surfaces are generated from the mapped data[block 20].
[0043] FIG. 14 illustrates the triangulation of a single character
M 21 after being mapped. FIG. 15 illustrates the text 30, 32 and
dividers 34 mapped and triangulated between the upper and lower
closed curves 40, 41. The upper and lower closed curves 40, 41 may
alternatively be referred to as upper and lower text curves. Thus,
the system and method spaces the text 16, maps the text and
dividers between upper and lower curves 16, and generates
triangulated surfaces 20. In some embodiments, the triangulated
surfaces are used to generate a tool path, described more fully
below with reference to FIG. 6, that typically is output as curves.
While FIGS. 3-5 depict bezels having a generally annular shape, it
is to be appreciated that system and method of the present
disclosure may be used to automatically generate toolpaths for
bezels having any shape, such as for example, square, rectangular,
and polygonal. In various embodiments, the triangulated surfaces
may be converted into any machine readable instructions or other
for creating a customized item.
[0044] Referring again to FIG. 2b, areas that will need further
tooling are identified [block 22] and clean-up geometry (including
curves and/or triangulated surfaces) for a tool path are generated
[block 24]. These areas generally are along the bottom edges of
letters and/or within islands of letters. Islands of letters are
the embedded portions of letters, for example the top and bottom
circle within a capital B. The clean-up lines largely eliminate
sharp edges and buns. In the past, these areas, including the sharp
edges and burrs, have been hand-finished using tooling. Such
hand-finishing is time consuming, thus increasing manufacturing
costs, and can result in error requiring replacement of the ring.
For example, hand tooling often is done to clean up along the
bottom edge of letters or along the inner edge of the bezel. As
shown in FIG. 6, a space 43 is provided along the bottom edge 42 of
the text 44, the space 43 being provided between the text 44 and a
teardrop 46. The mapped triangulated text 44 between the upper and
lower curves is placed at a specific depth of cut 48. The space 43
is used during generation of a wax mold for the ring to create a
metallic portion that is used as a wall around the gemstone. During
hand finishing, a tooling burr may hit the tear drop and, thus, wax
is not able to flow into the space to create the metallic portion
for the wall. Thus, if the tear drop 46 is hit by the burr, a new
ring must be created. Generating clean up geometry [block 24] and
then creating a tool path over the clean-up geometry minimizes hand
tooling and gives more consistency to the creation of rings. Clean
up geometry (including lines and/or curves) may also be generated
between letters to minimize the sharp edges between letters.
Identifying areas needing clean-up [block 22] comprises estimating
where sharp edges result and generating a curve along the sharp
edge. The curve, or clean-up line, may then be converted into a
tool path.
[0045] The triangulated surfaces of the text and dividers and the
curves and/or triangulated geometries of the clean-up areas thus
comprise a geometry that is convertible to machining instructions
and a tool path. Accordingly, the final step in the workflow
diagram of FIG. 2b is creating a tool path [block 26]. It is to be
noted that such creation may not be done by the system and method
and may instead be done using by a further system using the
geometry created by the system and method.
[0046] Thus, FIG. 2b illustrates the mapping of text to create a
tool path. As discussed with respect to FIG. 2a, mapping of text
may alternatively be used to create machine readable instructions
or other for generating a customized item such as photo realistic
images, an item manufactured via rapid prototyping, or other.
[0047] FIG. 7 illustrates a workflow diagram of ring creation
including the mapping of text of FIG. 2b. It is to be appreciated
that all or portions of the embodiment shown in FIG. 2a may be
automated, semi-automated, or manual. The level of automation of
the method may be set based on the user, based on the desired
output, or based on other criteria. Thus, each block of FIG. 2b may
be automated such that after the initial order is read, an output
is automatically triggered. Alternatively, the system and method
may call for user interaction or involvement at any of the blocks
of FIG. 2b.
[0048] As shown in FIG. 7, capturing of orders may be done by
various channels [block 50]. For example, consumers may access a
web-based interface for submitting an order and provide order
information which may then be stored in a database. Alternatively,
as has been traditionally done, students and their parents may fill
out paper-based order forms that are turned into a sales
representative. Each sales rep may forward a set of order foams to
the manufacturer's data entry department, where a group of data
entry clerks enter the orders into a computer repository database.
There are other order channels available, such as by using an IVR
(Interactive Voice Response) system with a telephone. Generally,
order information may be stored for later use [block 51].
[0049] An interactive interface, such as a workstation, may be
provided and managed by a production operator. Form this
workstation the production operator may manually input items, map
text (for example, via dragging and dropping to text), etc.
Additionally, from this workstation, a computer software
application can retrieve data for one of the pending orders [block
52]. The order for a class ring may include all of the
personalization to be applied to the ring. For example, the order
may specify which type of ring to use, where to engrave the
student's name, what font to use, where to place school and year
information, where to apply icons representative of the student's
interests, etc. Alternatively, this type of information may be
chosen and manually entered by the operator. The personalization
elements are applied to a model of the ring [element 54]. The model
may be a 3D virtual model. With specific reference to the bezel of
the ring, the entered text for the bezel and, if included, at least
one divider, are mapped to a 3D virtual model comprising a series
of triangulated surfaces [element 56].
[0050] The triangulated surfaces may then be sent to a further
software application that translates the triangulated surfaces into
a series of instructions describing a path that a milling machine's
cutting tool follows while machining a ring [block 60]. This set of
instructions is commonly known as the "toolpath". Alternatively,
the present system and method may convert the triangulated surfaces
into the toolpath: The toolpath is downloaded to a milling machine
[block 62] and a wax blank of the ring is engraved to the
specifications ordered by the student [block 64]. The resulting wax
model is then grouped with other wax models and the set of rings
are cast and finished [block 66], resulting in the customized ring.
Generally, using the system and method, the bezel of the customized
ring should have minimal, if any, sharp edges or buns requiring
hand finishing.
[0051] Alternatively, as discussed with respect to FIG. 2a, the
triangulated surfaces may be sent to a software application that
translates the triangulated surfaces into a series of machine
readable instructions for creating a customized item or the system
and method may generate machine readable instructions for creating
a customized item. The customized item may be, for example, a photo
realistic image, an item manufactured via rapid prototyping, or
other. Thus, the translation may describe a path that a image
writer follows while producing a photo realistic image of the
surface. As a further example, the translation may describe a path
that a rapid protyping machine follows while manufacturing a model
of the surface.
[0052] FIG. 8 shows the system architecture of one embodiment of an
automated method for engraving a bezel. A NX Bezel Personalization
System 70 is a computer program that provides the production
operator with a graphical user interface. A plurality of databases
may be provided for use with the system. For example, a
configuration database 80 having information regarding data
including general parameters about strategies for clean up, depth
of cut, distance from lower rim, etc.; a geometry template database
82 having information regarding geometry of each hob (described
below); and an order database 84 having information about placed
orders such as hob number, personalization text, order number, etc.
may be provided. The personalization client 70 searches the order
database 84 for a file containing order requests, which in turn
performs calculations to generate a generic toolpath for a milling
machine that will result in a zinc (or other suitable material)
bezel insert mold to be used to create the top of a ring as
ordered. To do so, data may be retrieved from various databases,
such as the order database 84, the geometry template files 82, and
the configuration database 80.
[0053] A toolpath viewer 72 can be used to provide a preview
visualization of what will result when the toolpath is applied to
the bezel insert mold. In one embodiment, NC rendered viewer
software (developed by Jostens) is used as the toolpath viewer 72.
The toolpath viewer 72 may be used in troubleshooting, validations,
setup, or to preview the appearance of the bezel insert mold. The
preview may help to determine if the cutter has been broken during
the NC Milling processing or if the mill is properly zeroed.
[0054] Once the NX Bezel Personalization System 70 assembles the
generic toolpath (for example, Jostens's generic ascii GA) format
file a post-processor (such as downloader 74) can be used to
translate the generic toolpath to the mill-specific toolpath, which
may be downloaded to the milling machine 76.
[0055] FIG. 9 provides additional details for an automated method
for engraving a bezel in accordance with one embodiment. As shown
in FIG. 9, bezel information for the order to be processed is read
or retrieved [block 100]. This information may include information
about the text or dividers to be engraved on the bezel of the
finished ring. From the order data, personalization information for
the bezel is processed, the basic geometry for the bezel is
generated [block 110, 112]. Personalization information may include
triangulated surfaces for text and dividers and geometries for
clean-up areas, as discussed in reference to FIG. 2b. The toolpath
for the bezel is then created [block 114]. Once the geometric model
(if used) shows desired personalization, a toolpath (set of
machining instructions) is generated to create a ring to match the
geometric model. Through this process flow, a high level of
customization flexibility, such as the ability to project text and
icons onto the bezel, is provided. After the tool path is generated
and sent to a milling machine or stored [block 114], the system
proceeds to look for more order data [block 116]. If more order
data is retrieved, the process restarts. If no further order data
is available, the process ends.
[0056] FIG. 10 shows more detail of retrieval of templates and
reading of orders (block 100 of FIG. 9). The order is read [block
200]. In block 200, information pertaining to the hob number for
the particular bezel, the text to be engraved, the desired font of
the text, and the desired dividers may be extracted from the order
file. This information may be extracted as a single line. The
information is parsed, and each of the different entries is
extracted [block 202]. From this parsed information, it is
determined if the panel contains one divider or two dividers [block
204]. FIG. 3 illustrates the result of two dividers and FIG. 4
illustrates the result of one divider. The hob number specifies the
product being personalized. For example, the hob number specifies
which configuration parameters to use (i.e., boundary curves,
fonts, machining strategies, different parameters that control the
look of the text, the manner in which the specialized cleanout will
be done, etc.). Based on the hob number information extracted, the
bezel database is read [block 206]. Bezel information on the files
that contain the different template geometries for the upper and
lower text curves, and the surface of the bezel are stored in the
bezel database. This information, as well as different strategies
(or operations) to machine the bezel insert, may be retrieved
[block 208]. Specifically, the Bezel database may be read to
determine the font for the divider, the font for the text, and the
name of the Bezel curve files.
[0057] FIG. 11 shows more detail of creating the geometric model
(block 110 of FIG. 9). FIG. 11 thus illustrates assembling the
bezel geometry. The model for each type of ring includes a specific
bezel. That bezel is retrieved from a repository including specific
data for each bezel. Assembling the text geometry is preceded by
retrieving the text requested by the customer as well as a hob
number. The order data includes an indicator for the desired font
to use in personalizing the text. In one embodiment, this is
retrieved and the operating system is queried for the appropriate
font geometry. Thus, in the embodiment shown, curve data for a
TrueType brand typographic font that corresponds to the text is
extracted [block 300]. Similarly, curve data for the dividers is
extracted [block 302]. In a further embodiment, each character may
be mapped independently between two portions of a curve, for
example, using CORE software available from Jostens.
[0058] A 2-dimensional rectangle to contain the text and dividers
is constructed [block 304]. FIG. 16 illustrates the construction of
block 304 in further detail. The characters of the text are
extracted from the corresponding font file [block 600]. In the
embodiment shown, the font file is a true type font format file
(TTF file). Character extraction may include extracting glyph
parameters from the input text including width, height, and curves.
These parameters define each character in an order based on the
font file. A maximum height of the characters may also be
extracted. As shown, the height may be extracted from the TTF file.
The characters are placed in a native box having dimensions of
height equal to height of the characters by total width [block
602]. A box (or rectangle) is constructed having a height and a
length [block 604]. The length is approximately equal to the sum of
the widths associated to the natural glyph of each character in the
input order. The height is approximately equal to the total height
of the characters in the alphabet.
[0059] Reference is now made to FIGS. 18 and 19 to illustrate
construction of the box [block 604 of FIG. 16]. An example of input
text 44 and a corresponding bounding box 45 with the input text are
shown in FIG. 19. As shown in FIG. 18, the box 45 is constructed
with dimensions of length equal to the arc length 43 of the lower
text curve 41 and height equal to the distance 47 between the lower
text curve and upper text curve.
[0060] Returning now to FIG. 11, the character curves or text
curves extracted in blocks 300, 302 are mapped to the 2D rectangle
(or box) constructed in block 304 (see, for example, FIGS. 18 and
19) to determine maximum and minimum expansion factors for text
characters. Generally the dividers are not stretched. As discussed
previously, FIG. 19 illustrates a sample input text 44 with
resulting mapped text 45. For mapping, the maximum and minimum
expansion factors for text characters are determined 306. FIG. 17
illustrates further detail of mapping the character curves to the
box, and, more specifically, of determining minimum and maximum
expansion factors. As shown, the characters are mapped from the
native box to the box induced by the upper and lower text curves
[block 700]. The aspect ratio between the width and the height of
each of the characters is calculated before and after the mapping
[block 702]. The aspect ratio is used to determine the expansion or
stretching of each character. An inquiry is performed to determine
if the aspect ratio is smaller than the original aspect ratio, and
thus whether the characters have been shrunk [block 704]. If the
aspect ratio is smaller than the original aspect ratio, the order
is rejected [block 706]. If the aspect ratio is not smaller than
the original aspect ratio, an inquiry is performed to determine
whether the characters were stretched beyond a given threshold
[block 708]. If the aspect ratio is larger than the given
threshold, the characters are padded with spaces, thus reducing the
stretch factor, until the threshold is met [block 710].
[0061] Thus, returning FIG. 11, geometry for text characters and
dividers are extracted [blocks 300, 302], a box is constructed to
contain the text and dividers [block 304], and the maximum and
minimum expansion factors of the characters is determined [block
306]. When the aspect ratio described above is within a given
threshold, the text and divider geometry curves are laid on the
constructed box [block 308]. The upper and lower curves for
placement of the text are read [block 310] and the geometry curves
from the text and dividers are mapped between the upper and lower
curves [block 312]. The upper and lower curves define the bezel
shape in two dimensions. The text may be mapped using first and
second lines of text, one over the gemstone and one below the
gemstone, or a single line of text wrapping around the gemstone.
The text and dividers thus follow the shape of the two boundaries:
the upper and lower curves. Bezel surface and trim are extracted
with mapped geometry curves [block 314] and the mapped data is
converted into triangulated three dimensional surfaces [block
316].
[0062] FIG. 20 illustrates more detail of an extraction of a bezel
surface and trim with mapped geometry (block 314 of FIG. 11). As
shown, ruled surfaces are constructed from upper and lower bexel
curves using perpendicular to base paramterization [block 800]. The
two-dimensional domains are constructed from the closed curves that
result from mapping the curves from each character between the
upper and lower curves of the bezel [block 802]. An inquiry is
performed to determine if all of the two-dimensional domains have
been constructed [block 804]. If all of the domains have not been
constructed, an interior point of a domain is determined [block
806]. A UG NX face is constructed from the bezel surface and trim
using curves and the interior point using UGOPEN function calls
[block 808]. Alternatively, an interior point of a domain is
determined [block 806] and a UG NX face is constructed from the
bezel surface and trim using curves and the interior point using
UGOPEN function calls [block 808] prior to the inquiry to determine
if all of the two-dimensional domains have been constructed [block
804].
[0063] FIG. 12 shows more detail of generation of clean-up data
(block 112 of FIG. 9). Each character is looped through each
character [block 400]. Clean-up curves for the lower rim are
generated [block 420]. A determination is made of whether the
character has inner islands [block 402]. If the character has inner
islands, clean-up closed curves are generated for the inner islands
[block 410]. The clean-up curves for the lower rim and the clean-up
closed curves for the inner island (when the character has an inner
island) are mapped between closed curves [block 422]. This process
is done for each character. When clean-up curves for each character
have been mapped, the bezel surface is trimmed using the mapped
curves [block 424]. Triangulated surfaces are then generated from
the trimmed surfaces [block 426].
[0064] FIG. 13 shows more detail of generation of the tool path,
storage of the geometry file, and sending of the tool path to the
milling machine (block 114 of FIG. 9). As shown, a recipe, or set
of machining strategies or operations to be used, is read from the
configuration database for a given HOB (or style) [block 500]. The
type of operation (or strategy) to be performed is determined
[block 502]. The type of operation may be, for example, clean out
the inner island, clean out the lower rim, or cut the text.
Different cutters or tools may be used for each operation. Depths
of cut are determined for the selected operation [block 504]. A
tool path is generated and a number of passes of the cutter is
determined. A determination is made about whether another strategy
or type of operation (referring back to block 502) is to be
performed [block 506]. After all types of operations (or all types
of selected operations) have been reviewed, a tool path including
all types of operations is generated [block 508].
[0065] In one embodiment, mapping of the text is accomplished with
the font geometry information. The splines are tessellated to
generate a polyline set for each character of the text. The text
characters are mapped into a 2D rectangular domain using the
kerning information provided with the TrueType font. Because kerned
type is often more pleasant looking than fixed-spaced type, each of
the polyline sets are spaced based on kerning data supplied with
the font geometry. The spacing is adjusted to meet the minimum
spacing requirements associated with the bezel. Once this
modification of the text is finished, the polyline sets are mapped
between the boundary curves so that the characters or icon curves
follow the shape of the two boundaries. To do this, a ruled surface
is defined between the two curves, as at block 310 of FIG. 11. This
ruled surface comprises the bezel. Such a process is discussed in
"The NURBS Book" by Les Piegl and Wayne Tiller (pages 337-339).
Reference is made to FIG. 17 for further discussion of mapping
characters into a bezel.
[0066] The parameterization of the boundary curves will determine
the type of mapping. Two basic maps are used in one embodiment:
"parallel to ends" and "perpendicular to base." Using a "parallel
to ends" technique, the vertical legs of each text character are
defined by an interpolation of the slopes of the left and right
edges of the boundary shape. Using a "perpendicular to base"
technique, the vertical legs of the characters are defined as being
perpendicular to the base curve of the boundary shape.
[0067] In some embodiments, configuration parameters are retrieved
from a repository. The configuration parameters vary for each ring
design. Thus, for each ring, the repository may store such data as
the font name, character spacing, character thickness, character
type (such as raised, incised, etc.), boundary curves, cutter type,
and machining pattern.
[0068] One exemplary method of building the toolpath is as follows.
A set of machining patterns and information for the associated
cutting tools are retrieved. There are several machining patterns
(a.k.a. strategies) available. While other strategies may be used,
reference is made particularly to vornoi, or profile, patterns and
raster patterns. A profile pattern is where Voronoi diagram
techniques are used to generate 2D offsets defined by text
geometry, cutting tool shape, and cutting depth. Generally, a
profile pattern is a nested loop. A raster pattern is where Voronoi
diagram techniques are used to generate 2D offsets defined by text
geometry, cutting tool shape, and cutting depth. A raster pattern
may alternatively be referred to as a parallel lines pattern.
(Other machining patterns can be implemented in various embodiments
of the invention. For instance a 3D curve machining pattern may be
used in certain embodiments such as for cleaning up the rim of the
bezel.
[0069] In one embodiment, the geometry being machined is
approximated by 21/2-dimensional geometry. That is, it is assumed
that the objects are two dimensional with a nearly constant
z-height. This assumption is valid for many of the ring
manufacturing designs. Thus, once the machining patterns are
retrieved, the 21/2-dimensional toolpath is generated by retrieving
the type of pattern specified. If the pattern requested is
"profile", the 21/2-dimensional toolpath for the profile pattern is
generated. If the pattern requested is "raster", the
21/2-dimensional toolpath for the raster pattern is generated.
Otherwise, a full or light skeleton toolpath is generated. The
toolpath generated for the personalization element is (in one
embodiment) either a simultaneous 4-axis toolpath or a positional
4-axis toolpath. In the simultaneous version, the rotational axis
is moving from one tool location to another continuously while in
the positional version, the tool will remain at a constant
rotational axis position, changing only from one panel to the
other.
[0070] At the next step of the process, the toolpath is projected
onto the surface of the ring. This generates the corresponding
three-dimensional toolpath. Once the projection is accomplished,
the toolpath is rotated by a specified angle to achieve the final
toolpath for that particular personalization panel.
[0071] For the skeleton strategy pattern, the present invention
gets a point in the remaining set of edges from the Voronoi
diagram. The distance from that point to the text or icon curves is
determined. Next, the depth that corresponds to an effective radius
equal to the calculated distance is assigned as a z-value. The
point with z-value is added to the toolpath. This repeats for
additional points.
[0072] For profile and raster strategy patterns, the present
invention first gets a point in the remaining set of edges in the
Voronoi diagram. Then the depth of cut is assigned as a z-value,
and the point is added with that z-value to the toolpath. This
repeats for additional points.
[0073] While the present disclosure describes the system and method
in the context of creating triangulated surfaces convertible to a
tool path for a bezel, alternatively, the system and method may
create triangulated surfaces convertible to machine readable
instructions for any desired output. In one embodiment, the system
and method may create triangulated surfaces convertible to machine
readable instructions for creation of a rapid prototyping model.
For example, the triangulated surfaces may be sent to a software
application that translates the triangulated surfaces into a series
of instructions describing a path that a rapid protyping machine
follows while manufacturing a model of the surface. Generally,
rapid prototyping refers to the transformation of virtual designs
into thin, virtual, horizontal cross-sections and then creating
each cross-section in physical space, one after the next to create
a model of the virtual design.
[0074] Additionally, in an alternative embodiment, the system and
method may create triangulated surfaces convertible to machine
readable instructions for creation of a photorealistic image, such
as a poster. For example, the triangulated surfaces may be sent to
a software application that translates the triangulated surfaces
into a series of instructions describing a path that a image writer
follows while producing an image of the surface.
[0075] Although the invention has been described with reference to
preferred embodiments, persons skilled in the art will recognize
that changes may be made in form and detail without departing from
the spirit and scope of the invention.
* * * * *