The Lite version of the camera-based workholding monitoring system is an optical solution designed to support workpiece setup on modern CNC machine tools. CADMatch Lite uses a high-resolution industrial camera to capture real-time images of the actual workholding environment. Based on these live images, the system accurately overlays digital CAD models of the workpieces to be machined onto the camera image. This gives the operator an immediate visual reference showing the exact position and orientation in which each workpiece must be mounted on the fixture pallet. The combination of real-time image acquisition, CAD-based referencing, and precise geometric transformation provides straightforward and reliable support during machine setup without requiring additional mechanical aids or external sensor systems.
The system helps ensure that the workpiece is positioned and clamped correctly. Incorrect setups or improper workpiece orientations are detected before machining begins, helping prevent damage to the workpiece, cutting tool, workholding equipment, and machine.
Automatic visualization of the correct workpiece position reduces manual alignment work, enabling faster and more reliable setup.
Factory-performed internal camera calibration and an integrated semi-automatic external calibration function allow the system to be installed quickly and configured without specialized expertise.
New workpieces can be added simply by placing their STL models in the designated directory. After the application is restarted, they automatically appear in the selection menu.
The system connects physical manufacturing processes with digital component data, enabling integration into modern smart manufacturing environments.
The digital reference between the CAD model and the actual workholding setup enables reproducible and traceable manufacturing processes. After the operator confirms the correct position and orientation of the workpiece by viewing the CAD model overlaid on the live camera image, the next step in the process pipeline can be initiated using the processing or save function. An image of the confirmed setup condition is then automatically saved to a defined system folder. This image can subsequently become part of the digital data flow, supporting traceability of machined components and providing clear documentation of the manufacturing process.
The operator simply selects the desired workpiece; all required CAD data and projections are processed automatically.
Incorrect clamping can pose a significant risk at high machining speeds. Visual verification reduces the likelihood of potentially critical situations.
CADMatch Lite is based on compact, industrial-grade embedded hardware with low power consumption. Built with robust industrial components, the system is specifically designed for continuous 24/7 operation in demanding production environments.
A defined and reproducible workpiece position reduces dimensional deviations, vibration, and machining errors, resulting in greater accuracy and more consistent manufacturing results.
Easily integrated software for existing systems. Space-saving embedded hardware with low power consumption. AI technologies enhance image quality, eliminating the need for external lighting.
Development and support are provided by COVISYS Computer Vision Systems GmbH, a company with more than 15 years of experience in computer vision. Our customers include AIRBUS, where we have installed three CADMatch systems that have been operating reliably since 2019.