StitchAI — Industrial Vision and CNC Automation System

StitchAI is a comprehensive automation platform designed to transform manufacturing workflows by integrating real-time computer vision, segmentation, motion planning, and CNC machine control.

Rather than relying on pre-designed DXF files, StitchAI captures raw visual data directly from industrial cameras, processes it through advanced algorithms, and automates production via G-code generation and CNC communication.

Key Modules:

• Vision Processing: Real-time capture, correction, and enhancement of raw images via Basler cameras.
• Perspective Calibration: Accurate 4-point matrix calibration for real-world coordinate mapping.
• AI-Powered Segmentation: Integrated Segment Anything Model (SAM) with support for manual refinement and morphological operations.
• Path Planning: Geometrically optimized route generation with offset calculations and intelligent processing order.
• G-code Generation: High-fidelity G-code output with simulation and visual verification.
• Machine Communication: Full Modbus (RTU/TCP) support, serial/Ethernet I/O, and real-time monitoring of CNC and PLC systems.
• Workflow Automation: Batch processing, job parameter management, and recipe-driven execution.

Industrial Applications:

• Textile and Leather Processing: Automated stitching and cutting guided by computer vision.

Technology Stack:

• Frontend/UI: PyQt6 for a high-performance desktop interface
• Computer Vision: OpenCV, NumPy, pypylon
• AI & Segmentation: PyTorch, Segment Anything Model (Meta AI)
• Geometric Computation: Shapely, ezdxf
• CNC & Communication: pymodbus, pyserial

Core Features:

• Perspective & affine coordinate transformation
• SAM-based AI segmentation and manual overrides
• Edge detection and contour tracing
• Geometry-based G-code generation with toolpath compensation
• Real-time machine state monitoring and manual override support

Example Use Cases:

• Full automatic processing: From image capture to CNC execution with a single click
• Manual segmentation and route adjustment workflows
• DXF import and G-code generation from predefined vectors

Workflow Overview:

1. Calibrate camera perspective and align coordinates
2. Capture real-time material imagery
3. Segment regions of interest (automatically or manually)
4. Optimize toolpaths and configure process parameters
5. Generate and simulate G-code
6. Execute via Modbus-connected CNC machine

Troubleshooting & Diagnostics:

• Visual aids for camera alignment and lighting conditions
• SAM model error handling and contrast optimization
• Communication diagnostics for PLC and CNC integration

This solution is designed for manufacturers seeking precision, flexibility, and full-stack automation from image to execution.