Digital Twin

Abstract

The present disclosure relates to digital twins. A method for automatically adjusting at least one adjustable process parameter of a tool machining machine, which is part of a first or second manufacturing process for physically machining an input workpiece into an output workpiece, is provided. At least one geometric feature of the output workpiece is measured by a coordinate measuring machine. The measurement result is fed together with the nominal measurement data of the geometric feature into a deterministic digital simulation of at least a part of the manufacturing process, where the adjustable process parameter at least simulates the deterministic behavior of the tool machining machine related to the operation of its tool. The simulation is performed with the variation of at least one of the modeled process parameters. An adjusted value of the adjustable process parameter is obtained based on the simulation with the adjusted modeled process parameter and based on the nominal geometric data, and the adjusted value enables the adjusted operation of the tool machining machine with respect to its tool to result in a reduction in the difference between the actual geometric data and the nominal geometric data of the feature.

Description

Technical Field

[0001] The present invention relates to a method and a non - transitory computer program product for automatically adjusting at least one adjustable process parameter of a tooling machine. Background Art

[0002] Manufacturing processes, especially those provided by tooling machines, are ubiquitous in the modern world. A manufacturing process is typically configured to transform an input workpiece into an output workpiece. For example, a manufacturing process may include drilling a hole in a metal plate. The output workpiece provided by the manufacturing process may deviate from the desired target state, i.e., the manufacturing process may fail to provide the desired result, e.g., due to changing environmental influences that slowly affect the manufacturing process, where such slow changes may not be compensated for by conventional control algorithms and methods used in manufacturing.

[0003] EP3045992B1 discloses a method for controlling a production process of an object, in which a production model of the object (such as a CAD model) is adjusted based on nominal characteristic data and deviation data of the object. Thus, production errors can be compensated without changing the parameter values of the production facility, i.e., where the facility can be regarded as a "black box". This method has the drawback of being based on the production model of the object to be produced. Error compensation that is substantially independent of the production model is not possible. Summary of the Invention

[0004] Accordingly, an object of the present invention is to provide a method for improving an output workpiece provided by a manufacturing process.

[0005] The present invention relates to a fully - automatic method for adjusting parameters related to a manufacturing process, i.e., a fully - automatic method for adjusting at least one adjustable process parameter of a tooling machine having at least one material - removal tool (e.g., a milling tool and / or a turning tool), the tooling machine being part of a manufacturing process. The method comprises the steps of measuring at least one coordinate of at least one geometric feature (position and / or dimension) of an output workpiece by means of a coordinate measuring machine. The geometric feature is a direct or indirect result of machining with the tool, i.e., the measured position or dimension is caused or at least influenced by the operation of the tool.

[0006] The measurement results of the coordinate measurement (i.e., the measured coordinate data) are put together with the nominal coordinate / geometric data of the feature into a deterministic digital simulation of at least a part of the manufacturing process, which deterministic digital simulation has a digital model of the tool machining machine (preferably a digital twin) and modeled process parameters, where the modeled process parameters are adjustable process parameters of the tool machining machine. This input should not be understood as being limited to explicit input, i.e., the measured coordinate data / values and the nominal coordinate data / values will have to be directly fed into the simulation; rather, this also includes that the input can also be in the form of the difference between the measured coordinates and the nominal coordinate / geometric data, i.e., the measurement results and the nominal data are implicitly or indirectly put in in the form of their difference or in the form of the deviation of the measured coordinates from the nominal values.

[0007] Using the simulation, deterministic behaviors of the tool machining machine related to the operation of its tool can be simulated. Then, the simulation is performed with the change of the value of at least one of the modeled process parameters, and the purpose of the simulation is to simulate the measurement results. In other words, the digital representation of the manufacturing process is used to represent the manufacturing process in such a way that by virtually adjusting the process parameters, the actual results in the form of geometric features and thus the deviation from the nominal to the current can be virtually achieved or theoretically "explained". For example, this is done by virtually setting the machine behavior, which reproduces the real situation expressed or indicated by the geometric features as measured in the difference between the set value and the measured value accordingly. Therefore, the simulation of the measurement results should be understood in a broad sense: the measurement results do not have to be explicitly reproduced by the simulation (no dedicated simulated measurement results are required as the simulation output), but rather the modeled process parameters are adjusted in such a way that the digital simulation adjusted thereby conforms to the real manufacturing process expressed by the measured results. The real measurement results signal or represent the target or "destination", yet in any case do not have to reach the target or "destination", but rather in some cases, it is sufficient to adjust the simulation in such a way that knowledge is obtained about the "path" to the target or by how the measured results as the "destination" can be reached through the corresponding simulation. The simulation can be an iterative process, where as long as the digital process output related to or expressed by the geometry of the feature is different from the actual output, the modeling parameters are estimated, and a certain tolerance can be accepted thereby.

[0008] Based on a simulation with such adjusted modeling process parameters (an adjusted simulation that explicitly or implicitly emulates the measurement results) and based on the nominal geometric data of the feature, an adjusted value of the adjustable process parameter is derived, which adjusted value enables an adjustment operation of the tool processing machine with respect to its tool to result in a reduction or minimization of the difference between the actual geometric data and the nominal geometric data of the feature. That is, considering the measured feature (and correspondingly its deviation from the nominal geometric data), the knowledge about the manufacturing process (and correspondingly the process parameters) obtained by simulating the manufacturing process (or at least a part thereof) using a digital model of the tool processing machine is then used to adjust one or more of the adjustable process parameters of the tool processing machine to counteract the measured deviation, or the tool processing machine operates according to the adjustment parameters in such a way that another output workpiece shows a smaller deviation from the nominal data or even fully meets the nominal data (within certain tolerances, of course). Here again, the simulated adjusted parameters can be adjusted iteratively until the simulated output conforms to the nominal desired output.

[0009] The invention also relates to another method for automatically adjusting at least one adjustable process parameter of a tool processing machine, which tool processing machine has at least one material removal tool, in particular a milling and / or turning tool. According to this second aspect, the tool processing machine is part of a second manufacturing process for physically processing a second input workpiece into a second output workpiece. The method comprises the steps of: coordinate-measuring at least one geometric feature of a first output workpiece, which first output workpiece is the result of a first manufacturing process, by means of a coordinate measuring machine; inputting the measurement results of the coordinate measurement and the nominal measurement data of the geometric feature into a deterministic digital simulation of at least a part of the first manufacturing process and the second manufacturing process, which deterministic digital simulation has a digital model (in particular a digital twin) of the tool processing machine and modeling process parameters, wherein the adjustable process parameters of the tool processing machine at least simulate the deterministic behavior of the tool processing machine related to the operation of its tool; running the simulation with a change in at least one of the modeling process parameters, the purpose of the simulation being to emulate the measurement results; and deriving an adjusted value of the adjustable process parameter based on the simulation with such adjusted modeling process parameters and based on the nominal geometric data of the feature, which adjusted value enables an adjustment operation of the tool processing machine with respect to its tool to result in a reduction of the difference between the actual geometric data and the nominal geometric data of the feature. Here again, the input and the simulation must be understood in the broad sense as described above.

[0010] In the best case, the digital representation of the manufacturing process (correspondingly the first and second manufacturing processes), which, when referring to the manufacturing process hereinafter, means both cases or aspects, together with its modeled tool processing machine allows for an advantageous understanding of why deviations occur in order to locate the error sources. In any case, the digital representation of the manufacturing process with modeled process parameters is fundamental to the selection and is the basis for making decisions on countermeasures in the form of adjustment operations / control of the tool processing machine (correspondingly its tools).

[0011] The digital model of the tool processing machine should be understood as a model of at least a part of the tool processing machine that is configured to physically transform the input workpiece. However, the part of the tool processing machine that is not directly involved in the physical transformation of the input workpiece can be the part that includes the digital representation of the digital model. The digital model can be embodied as a digital twin of the tool processing machine providing the manufacturing process, which is a close and accurate model of the entire tool processing machine, and using which the relevant behavior of the tool processing machine can be accurately simulated. The digital model can include model parameters that can be changed in the simulation. The digital twin of the manufacturing process offers many benefits as it allows simulating the impact of the manufacturing process applied to the input workpiece before the physical realization of the manufacturing process. For the digital twin to be useful, it must be very similar to reality. Only being extremely similar can meaningful inferences be made and thus be safely and effectively translated into reality.

[0012] The parameters related to the manufacturing process can be adjusted as follows: If the geometric measurement data is different from the corresponding data obtained from the output workpiece target, the model parameters can be adjusted, and the subsequent evaluation of the digital model with the adjusted model parameters can provide a simulated output workpiece that can be compared with the output workpiece target. For example, the adjusted model parameters can be linked to the parameters related to the manufacturing process by including the parameters related to the manufacturing process or by a mapping between the model parameters and the parameters related to the manufacturing process. The adjusted model parameters can be used to adjust the parameters related to the manufacturing process, and the manufacturing process is adjusted based on the adjusted parameters related to the manufacturing process.

[0013] The coordinate measuring machine can be embodied as a Cartesian orthogonal coordinate measuring machine or as a coordinate measuring machine using, for example, a cylindrical or spherical coordinate system provided by an articulated arm coordinate measuring machine. The coordinate measuring machine can include non-linear kinematics. The coordinate measuring machine can be embodied as a stacked turntable coordinate measuring machine or as a robotic coordinate measuring machine.

[0014] Geometric measurement data can include shape data of an output workpiece, e.g., describing surface points evaluated on the surface of the output workpiece by a coordinate measuring machine, or lengths between points, or areas, etc. The geometric measurement data can also include texture data of the output workpiece, which is related to, e.g., the roughness of the surface of the output workpiece.

[0015] The measurement results or data provided by a coordinate measuring machine can be related to an already machined output workpiece. The coordinate measuring machine can be separate from the tool machining machine providing the manufacturing process, or can be integrated into the tool machining machine. If integrated into the tool machining machine, the coordinate measuring machine can be used to provide measurement data related to an intermediate state of the workpiece, i.e., measurement data related to a workpiece in a machined state between its input workpiece state and its final output workpiece state at the end of the manufacturing process.

[0016] The geometric proximity between an output workpiece target and the output workpiece can be evaluated based on the geometric measurement data and corresponding data derived from the output workpiece target, e.g., by using an error metric such as the mean squared error evaluated between points on the output workpiece measured by a coordinate measuring machine and corresponding points on the output workpiece target.

[0017] The simulation of at least deterministic behavior related to the operation of a tool of a tool machining machine includes: optionally simulating, based on a digital model, the operating posture of the tool with respect to at least one translational degree of freedom or rotational degree of freedom, e.g., the position or orientation of the tool relative to the workpiece when the tool operates on the workpiece, and the adjustment operation involves a corresponding physical or real operating posture, e.g., changing the operating posture by adjusted parameters, whereby it can be indirectly or directly linked to the operating posture. In the case of direct linkage, the parameter is, e.g., the value of the rotational position or translational position of a machine part of the tool machining machine, and in particular, the parameter can be a parameter of the tool itself.

[0018] As an additional or alternative option, the adjustable process parameters can also relate to a volumetric map of the tool machining machine, which can directly or indirectly depend on time, e.g., depending on a time stamp and / or according to the desired / nominal operating position of the tool and / or related to different or specific commands of a part-program. As a further option, the parameter relates to the position, rotational speed, travel speed, and / or acceleration of the tool machining machine, to a path along an individual axis of the tool machining machine, and / or to a trajectory of an individual axis of the tool machining machine, whereby each of the position, etc. is again at a certain time stamp and / or according to the desired / nominal operating position of the tool and / or related to different or specific commands (program positions, e.g., code lines) of the part-program used to control the manufacturing process.

[0019] The digital model optionally includes modeling of the machining forces and / or the dynamic behavior of the machining tool machine, whereby characteristics of the workpiece that act on or have an influence on the machining forces or the dynamic behavior, such as the deformability or stiffness of the workpiece, can be taken into account. As another option, the deterministic behavior relates to the deformation of the machining tool machine, which is due to machining forces, dynamics or environmental influences, in particular temperature influences.

[0020] As an optional additional result of the simulation of the process, taking into account the measured characteristics (and correspondingly their deviations), an adjustment of the deterministic digital simulation, in particular of the digital model, is derived and implemented. The digital representation including the digital model may deviate from the reality, i.e., it may not describe the manufacturing process well enough. Using the measurement results, the digital representation (specifically the digital model) can be adjusted to better match the real manufacturing process. In the case where the digital model is close to the physical description of at least one process part of the manufacturing process and in the case where, for example, some environmental factors change (the changed environmental factors can be detected by the measurement results or by additional sensors), the digital model can be changed to better match the changed environmental conditions. In the case where the digital model is initially configured to operate in a first temperature range and the first temperature range changes to a second temperature range, the digital model may need to be adjusted in order to optimally describe the process part of the manufacturing process operating in the second temperature range. The digital representation metric can measure how accurately the digital representation (specifically the digital model) describes at least one process part of the manufacturing process under changing physical conditions.

[0021] In another embodiment of the method according to the invention, the method comprises the steps of measuring, using a sensor, a measured value representing the current state of the machining tool machine, the workpiece and / or the environmental conditions, and inputting the measured value into the simulation. Thus, additional process data is measured and used in the simulation, which additionally includes a corresponding model of the machining tool machine, the workpiece or the environment related to the measured value. Examples of sensors are speed sensors, current sensors in the engine, vibration sensors (such as microphones), accelerometers and temperature sensors.

[0022] In another embodiment of the method according to the invention, the sensor is integrated in or attached to the machining tool machine, and / or process measurement data is acquired by the sensor during the machining of the at least one input workpiece by the machining tool machine. The sensor can acquire data during machining, i.e., in an intermediate state between the input workpiece state and the output workpiece state of the workpiece.

[0023] In another embodiment of the method according to the invention, the process measurement data is related to process parameters of the manufacturing process and / or workpiece parameters of the machined workpiece, where these workpiece parameters capture the changes to the machined workpiece during the machining of the manufacturing process.

[0024] In another embodiment of the method according to the invention, the adjusted parameter is a physical parameter, where the adjustment of the adjusted parameter can be directly linked to a corresponding modification of the manufacturing process.

[0025] The physical parameter can be a parameter that can be directly used to adjust the manufacturing process. Examples of physical parameters can be the drilling speed of a drill, and another example can be the correction of the orientation of one axis relative to other axes. Physical parameters can be contrasted with abstract parameters (e.g., the efficiency of a tool machining machine). Such abstract parameters usually may not be directly used to adjust the manufacturing process, but rather may typically require multiple nontrivial modification steps of the manufacturing process.

[0026] The adjustment operation can be enabled by modifying the volume map of the tool machining machine, i.e., the tool machining machine maps the path that it is configured to follow via the volume map onto the movement of at least one individual axis. The volume map can provide an accurate forward kinematic description of the tool machining machine. This accurate forward kinematic description can allow for compensation of non-ideal deviation behavior of the axes of the tool machining machine, in particular for deviations of individual axes and deviations between axes. The volume map can allow for a simple reaction to execution errors during movement. The volume map can allow for the execution of complex compensation without explicitly modifying the source code.

[0027] Thus, the G-code instructions as a computer numerical control (CNC) programming language can remain unchanged, and the volume map can be used at the top level of the G-code to compensate for the errors of the tool machining machine. Using the volume map can compensate for low-frequency and position-related and slow effects, while it may be more difficult to compensate for dynamic effects / force effects using the volume map because such effects usually also depend on the manufacturing process itself. To compensate for dynamic effects / force effects, it may be necessary to affect the trajectory, i.e., time may need to be included as an additional dimension during compensation.

[0028] In addition to using the volume map, the path of the machine tool can also be directly corrected; this direct correction can replace the volume map. However, the path usually may not be directly accessible and modifiable. Changing the volume map can be regarded as an indirect method for correcting the path.

[0029] Part machining programs or G-code modifications or adjustments based on the adjusted values of adjustable process parameters can in principle also be used to compensate for the deviation behavior of the tool machining machine. However, such G-code compensation may be difficult to implement because it is feature-based correction and limits the possibility of compensating for errors at individual points in the compensated machine volume. Possible G-code changes are, for example, spindle speed, tool selection, orientation of the tool relative to the workpiece, etc.

[0030] In another embodiment of the method according to the invention, the digital representation is configured to additionally use 1) the geometric model and / or material model of the at least one input workpiece, and / or 2) the model representing the at least one input workpiece relative to the fixture of the tool machining machine.

[0031] As another option, the digital representation takes into account, in addition to parameters related to internal factors such as machining forces, internal heat generation, internally generated vibrations, etc., environmental factors that affect the manufacturing process, which are preferably part of or integrated into the digital model of the tool machining machine. The term environmental factors can be understood to refer to the influencing factors that occur outside the machine tool providing the manufacturing process and affect the manufacturing process. Examples of environmental factors are external temperature changes or humidity changes.

[0032] In another embodiment of the method according to the invention, the adjustment of the parameters related to the manufacturing process is additionally based on a measurement process model that digitally represents the measurement process providing the measurement results. Thus, in addition to the manufacturing process representation, the simulation includes a measurement process model that digitally represents the coordinate measurement using the CMM. Alternatively or additionally, the measurement model models the measurements of the measurement sensors as described above. Using the measurement process model can at least partially compensate for the systematic errors of the coordinate measuring machine or sensor, and since the measurement results provided by the coordinate measuring machine may be more accurate, the overall adjustment process is improved.

[0033] In another embodiment of the method according to the invention, the digital representation is embodied as a digital analytical model or a digital numerical model, in particular a finite element model of a part of the tool machining machine, or a combined digital analytical-numerical model. The digital model is based, for example, on polynomials, machine learning, and / or finite elements. The model can describe various physical effects, such as the dynamic compliance of the tool machining machine, for example, as a result of the forces and accelerations applied to the moving joints of the machine, such as the non-uniform thermal expansion of the machine due to the environmental situation around the machine and due to the internally wasted energy.

[0034] In another embodiment of the method according to the invention, adjusting the manufacturing process comprises modifying a control program or a part program configured to control a machine tool, in particular modifying the instruction set of the control program, the modified instruction set being in particular G-code parameters. Due to the complexity of G-code, usually only individual parameters are modified.

[0035] In another embodiment of the method according to the invention, adjusting the manufacturing process comprises: modifying the volume map and adjusting the manufacturing process by mapping the path that the machine tool is configured to follow onto the movement along at least one individual axis via the volume map.

[0036] The invention also relates to a computer program product for adjusting parameters related to a manufacturing process as in the method according to the invention. BRIEF DESCRIPTION OF THE DRAWINGS

[0037] Below, by way of example only, the method of the invention is described in more detail with reference to specific exemplary embodiments schematically illustrated in the drawings, and other advantages of the invention are also examined. Identical elements are denoted by the same reference numerals in the drawings.

[0038] Specifically:

[0039] Figure 1 A schematic depiction of a method for improving a manufacturing process according to the invention is shown;

[0040] Figure 2 Another schematic depiction of a method for improving a manufacturing process according to the invention is shown; and

[0041] Figure 3 is another example of the method according to the invention. DETAILED DESCRIPTION

[0042] Figure 1 A schematic depiction of a method for improving a manufacturing process 2 according to the invention is shown. An input workpiece 1 is provided to the manufacturing process 2, which transforms the input workpiece 1 into an output workpiece 3. The manufacturing process 2 is configured to produce the output workpiece 3, which ideally is as close as possible to the output workpiece target 6, the term as close as possible referring to the closeness in a geometric sense, for example, referring to the shape or texture. However, in practice, the actually produced output workpiece 3 mostly or usually differs from the ideal output workpiece target 6. The method according to the invention is configured to gradually improve the manufacturing process 2 using a digital representation (preferably a digital twin) of the manufacturing process 2 to reduce this difference.

[0043] The first input workpiece 1 is transformed into a first output workpiece 3 by a manufacturing process 2. The first output workpiece 3 is measured in a measurement process 4, which provides geometric measurement data related to, for example, the shape or texture of the first output workpiece 3. The measurement process 4 uses a coordinate measuring machine, which can be physically separated from the manufacturing tool providing the manufacturing process 2, or the coordinate measuring machine can be integrated into the manufacturing tool providing the manufacturing process.

[0044] The provided geometric measurement data is then used to adjust 5 the manufacturing process before transformation into a second output workpiece 3. The adjustment 5 is based on a comparison of the output workpiece target 6 with the geometric measurement data evaluated for the first output workpiece 3 provided by the measurement process 4.

[0045] The adjustment 5 of the manufacturing process and / or the second input workpiece 1 according to the invention can work as follows: A digital model (e.g., a digital twin) of at least one process part of the manufacturing process is given, and optionally a desired geometric output model, an input geometric model including material data together with G-code instructions and the machine position of the second input workpiece 1, the digital model and the geometric model including model parameters. At least a part of the transformation from the second input workpiece to the second output workpiece can be simulated based at least on the digital model and the geometric model, the simulation representing the physical effects of at least one process part of the manufacturing process and providing at least one simulated part of the second output workpiece.

[0046] By adjusting the model parameters of the digital model and / or the geometric model of the second input workpiece and performing the simulation using the adjusted model parameters, a set of model parameters can be identified that provide a simulated second output workpiece that is geometrically closer to the output workpiece target than the manufactured first output workpiece. Using the adjusted model parameters, the manufacturing process 2 and / or the second input workpiece 1 are adjusted in such a way that they conform to the adjusted parameters, and the second output workpiece 3 is manufactured. The adjustment of the manufacturing process 2 and / or the second input workpiece 1 can be carried out by adjusting the parameters related to the manufacturing process 2 using the adjusted model parameters. The parameters related to the manufacturing process 2 can also be part of the model parameters.

[0047] The adjustment of the manufacturing process can also be based on n output workpieces that have been manufactured, where n represents a natural number greater than 1, and the geometric measurement data obtained from measuring the n output workpieces is used to adjust the (n + 1)th input workpiece and / or the manufacturing process in order to improve the manufacture of the (n + 1)th output workpiece. The adjustment of the parameters related to the manufacturing process and indirectly the manufacturing process itself can be carried out based on the statistical information obtained from the n output workpieces.

[0048] The digital model and / or geometric model of the second input workpiece may include model parameters that can be directly linked to the physical parameters of the manufacturing process 2. If these physical parameters related to the manufacturing process are adjusted, it directly affects the manufacturing process 2. Therefore, the physical parameters are different from pure abstract parameters that have no clear or distinct physical counterparts in the real world. Abstract parameters may be parameters that cannot be directly mapped to changes that affect the manufacturing process 2. An example of an abstract parameter is process efficiency, while an example of a physical parameter is drill speed. In the case where the digital model and / or geometric model includes parameters related to the manufacturing process and these parameters are physical parameters, the changes in the physical parameters determined in the simulation can be directly translated into changes in the underlying physical manufacturing process and / or the second input workpiece.

[0049] Figure 2 Another schematic depiction of a method for improving a manufacturing process according to the present invention is shown. A digital model 5 of at least one process part of the manufacturing process 2 is given, and this digital model 5 is capable of accurately modeling the physical process part (e.g., the drilling step) of the manufacturing process 2. Information can flow from the physical manufacturing process 2 to the digital model 5 (especially to facilitate the establishment and alignment of the digital model 5 with respect to the actual process), and from the digital model 5 to the physical manufacturing process 2 (especially for adjusting the physical manufacturing process 2 based on the adjustment of the digital model 5).

[0050] The adjustment of the digital model 5 is based on the measurement results obtained from the measurement process 4 performed on the output workpiece of the manufacturing process 2. Thus, the results of the coordinate measurement are used as the input of the digital model 5 together with or relative to the nominal coordinate data (e.g., in the form of deviations). If the output workpiece is different from the desired and simulated target workpiece, the manufacturing process 2 and / or the input workpiece in the manufacturing process are adjusted, where the adjustment is based on adjusting the model parameters of the digital model 5. The adjustment and / or the foregoing method steps can thus be implemented as described in the principle given in the example Figure 1 presented.

[0051] Figure 3 Another schematic depiction of the method according to the present invention is shown. There is a digital representation 8 of the manufacturing process or at least its sequence, which is stored, for example, on a CPU that communicates with a tool machining machine and a CMM. The digital representation 8 includes at least a digital model of the tool machining machine, an autonomous and automatic interpretation of the measurement data of the CMM, and a data interpretation and exchange between manufacturing and measurement.

[0052] An input workpiece is manufactured or formed by a tool machining machine used in the manufacturing process, thereby producing an output workpiece with a desired geometry. Data 6 describing the desired values is stored and available for simulation 8, from which additional data, such as data describing the material properties of the workpiece, can be obtained. The tool machining machine includes an actuator, preferably including a sensor. Such a sensor can, for example, measure the position of the workpiece or the tool tip, the speed (especially the number of revolutions) of the parts of the tool machining machine, or the orientation of the tool machining machine (correspondingly its segments). The digital representation 8 simulates the manufacturing process. Among them, the digital twin of the tool machining machine is used and controlled according to the input control parameters 7 that model the control parameters used in the actual manufacturing process 2.

[0053] (Actual or physical) manufacturing process 2 produces an output workpiece, which is measured metrologically so that geometric measurement data 11 is available. The measurement can be performed according to the digital model of the workpiece.

[0054] After the measurement, considering the nominal data 6, the measurement data 11 is compared with the output parameters 9 of the digital representation 8. When starting with a "new" digital representation 8, it is expected that it does not accurately simulate the behavior of the real manufacturing process 2 or the tool machining machine. For example, input parameters 7 different from the actual parameters 10 of the tool machining machine, the workpiece, the manufacturing environment, or other conditions can be used, which results in a deviation between the actual result and the expected result.

[0055] Now, the digital representation 8 is optimized by changing the virtual process parameters 7 in the following way: the output of the digital representation matches the measurement data 11 of the real object. Thus, the goal is to locate the cause of the deviation, that is, to find out why the initial process parameters are not suitable or do not conform to the reality.

[0056] For optimization, data from the sensors or actuators of the tool machining machine, as well as data from the measurement machine and model data, historical data, etc. can be used. Neural networks, machine learning, or AI, for example, used for parameter optimization and / or error source evaluation, are used to analyze the data. The optimization is carried out or repeated until the deviation is below a certain threshold. Finally, there is an optimized digital representation 8, which includes enhanced or additional information about the actual manufacturing process 2 at the beginning.

[0057] Then, this improved knowledge about process 2 and corresponding input parameter 7 is used to adjust the adjustable input parameter 7 in such a way that the nominal data 6 can be achieved by an enhanced digital representation 8 with improved model process parameters 7. This is done by an iterative process in which the input parameter 7 representing the controllable parameter 7 related to the result (characteristics or geometry of the workpiece under consideration) is estimated until the result conforms to the nominal data 6. That is, first, the enhanced digital representation 8 (or more particularly, the digital model of the tooling machine or the process parameters used) is enhanced based on the measurement information, thereby providing an understanding of the actual manufacturing process 2 to better simulate or represent the process 2, and second, such enhanced digital representation 8 (which now optimally reproduces the actual manufacturing process as it is in reality (now) or the actual condition of the tooling machine) is used to find the working parameters 10 of the tooling machine that will cause the machined workpiece to show no deviation or at least a small deviation from the nominal geometry. In the latter case, method 100 can be repeated. In particular, this method can be a continuous support or a constant part of the manufacturing process 2, thereby providing in-situ monitoring and optimization of the manufacturing process 2.

[0058] The digital representation 2 can include: a process model of the tooling machine such as a digital twin, a process model related to the machining steps, an adjustment model using the digital twin to estimate a better fit of the input parameter, a model of the workpiece with information on geometry, material, and / or manufacturing fixation (e.g., workpiece-related data according to the information of the workpiece shown in G-code). Thus, it should be noted that the optimization is basically independent of or not focused on the workpiece, but rather uses the understanding of the manufacturing process replicated in the digital representation 2 of the manufacturing process to correct the deterministic and physical effects of the machining itself / machining machinery (especially the tooling machine).

[0059] The digital twin 2 can be an analytical model, such as describing the deformation of the tooling machine caused by physical forces, temperature, kinetics (acceleration), or load in the continuous mechanics of certain simplified geometries. It can be a numerical model, such as a polynomial description of the behavior (deformation) with certain constants and varying input parameters (e.g., temperature); a machine learning-based model (based on classical regression or neural network, deep learning) or a discrete geometric description, where the body is divided into finite small sub-bodies, and thereby, any effects caused by physical loads are estimated on each sub-body, and finally, the superposition of all sub-body effects describes the system effect. It can also be, for example, both an analytical sub-model and a numerical sub-model.

[0060] Although the present invention has been illustrated above, with reference to some preferred embodiments in part, it must be understood that many modifications and combinations of different features of these embodiments can be made. All of these modifications fall within the scope of the appended claims.

Claims

1. A method for automatically adjusting at least one adjustable process parameter of a tool machining machine, the tool machining machine having at least one material removal tool, the tool machining machine being part of a manufacturing process for physically machining an input workpiece into an output workpiece, the method comprising the steps of: coordinate measuring at least one geometric feature of the output workpiece by a coordinate measuring machine, the geometric feature being a direct or indirect result of the machining using the at least one material removal tool; inputting the measurement results of the coordinate measurement and the nominal measurement data of the geometric feature into a deterministic digital simulation of at least a part of the manufacturing process, the deterministic digital simulation having a digital model of the tool machining machine and modeled process parameters, wherein the adjustable process parameters of the tool machining machine at least simulate the deterministic behavior of the tool machining machine related to the operation of the tools of the tool machining machine; running the simulation with a change in at least one of the modeled process parameters, the purpose of the simulation being to simulate the measurement results; deriving an adjustment value of the adjustable process parameter based on the simulation with the so-adjusted modeled process parameters and based on the nominal geometric data of the feature, the adjustment value being such that the adjustment operation of the tool machining machine with respect to the tools of the tool machining machine can result in a reduction in the difference between the actual geometric data and the nominal geometric data of the feature.

2. The method according to claim 1, Among them, wherein the at least one material removal tool is a milling tool and / or a turning tool.

3. The method according to claim 1, Among them, wherein the digital model is a digital twin.

4. The method according to claim 1, Among them, the step of at least simulating the deterministic behavior of the tool machining machine related to the operation of the tools of the tool machining machine includes: simulating the operation postures of the at least one material removal tool involving at least one translational degree of freedom or rotational degree of freedom based on the digital model, and wherein the adjustment operation involves corresponding actual operation postures.

5. The method according to claim 4, Among them, wherein the adjustable process parameter is directly linked to the operation posture.

6. The method according to claim 1, Among them, the adjustable process parameter: is a parameter of the at least one material removal tool; and / or relates to the volume map of the tool machining machine.

7. The method according to claim 6, Among them, wherein the volume map directly or indirectly depends on time.

8. The method according to claim 1, Among them, the adjustable process parameter: relates to the position, rotational speed, travel speed and / or acceleration of the tool machining machine; relates to the path along an individual axis of the tool machining machine; and / or relates to the trajectory of the individual axis of the tool machining machine; each of the position, rotational speed, travel speed and / or acceleration of the tool machining machine, the path along an individual axis of the tool machining machine, the trajectory of the individual axis of the tool machining machine is at a specific timestamp and / or according to a desired operation position and / or related to different commands of a part machining program.

9. The method according to claim 1, Among them, The digital model includes modeling of the machining force and / or dynamic behavior of the tool machining machine.

10. The method according to claim 1, Among them, The deterministic behavior involves deformation of the tool machining machine.

11. The method according to claim 1, Among them, The digital model is implemented as a digital analysis model and / or a digital numerical model.

12. The method according to claim 11, Among them, The digital model is implemented as a digital analysis model and / or a digital numerical model based on polynomials, machine learning, and / or finite elements.

13. The method according to claim 1, Among them, The method includes the steps of: measuring values of the tool machining machine, the workpiece, and / or the environmental conditions using sensors, and inputting the measured values into the simulation, wherein the digital model includes modeling related to the measured values.

14. The method according to claim 13, Among them, The measuring step is performed during machining of the input workpiece by the tool machining machine.

15. The method according to claim 1, Among them, The simulation includes a measurement process model that digitally represents the coordinate measurement and / or the measurement using sensors.

16. The method according to claim 1, Among them, An adjustment of the deterministic digital simulation is derived and implemented based on the simulation.

17. The method according to claim 16, Among them, An adjustment of the digital model is derived and implemented based on the simulation.

18. The method according to claim 1, Among them, The adjustment operation is enabled by modifying the part machining program configured to control the tool machining machine according to the adjustment value of the adjustable process parameter.

19. The method according to claim 18, Among them, The adjustment operation is enabled by modifying the G-code according to the adjustment value of the adjustable process parameter.

20. The method according to claim 1, Among them, The adjustment operation is enabled by modifying the volume map of the tool machining machine, and the tool machining machine maps the path it is configured to follow to the movement of at least one individual axis via the volume map.

21. A non-transitory computer program product, the non-transitory computer program product includes program code, the program code is stored on a machine-readable medium and has computer-executable instructions, and the computer-executable instructions, when executed, cause a computer to execute the method according to any one of claims 1 to 20.

22. A method for automatically adjusting at least one adjustable process parameter of a tool machining machine, the tool machining machine having at least one material removal tool, the tool machining machine being part of a second manufacturing process for physically machining a second input workpiece into a second output workpiece, the method includes the following steps: Performing coordinate measurement of at least one geometric feature of a first output workpiece by a coordinate measuring machine, the first output workpiece being the result of a first manufacturing process; Input the measurement results of the coordinate measurement and the nominal measurement data of the geometric feature into the deterministic digital simulation of at least a part of the first manufacturing process and the second manufacturing process. The deterministic digital simulation has a digital model of the tool processing machine and modeled process parameters, wherein the adjustable process parameters of the tool processing machine simulate at least the deterministic behavior of the tool processing machine related to the operation of the tool of the tool processing machine; Run the simulation with the change of at least one of the modeled process parameters. The purpose of the simulation is to simulate the measurement results; Derive the adjustment value of the adjustable process parameter according to the simulation with the so-adjusted modeled process parameter and based on the nominal geometric data of the feature. The adjustment value enables the adjustment operation of the tool processing machine regarding the tool of the tool processing machine to cause the difference between the true geometric data and the nominal geometric data of the feature to decrease.

23. The method according to claim 22, Among them, The at least one material removal tool is a milling tool and / or a turning tool.

24. The method according to claim 22, Among them, The digital model is a digital twin.

25. The method according to claim 22, Among them, The step of simulating at least the deterministic behavior of the tool processing machine related to the operation of the tool of the tool processing machine includes: simulating the operation posture of the at least one material removal tool involving at least one translational degree of freedom or rotational degree of freedom based on the digital model, and wherein the adjustment operation involves the corresponding true operation posture.

26. The method according to claim 24, Among them, The adjustable process parameter is directly linked to the operation posture.

27. The method according to claim 22, Among them, The adjustable process parameter: is a parameter of the at least one material removal tool; and / or relates to the volume map of the tool processing machine.

28. The method according to claim 27, Among them, The volume map directly or indirectly depends on time.

29. The method according to claim 22, Among them, The adjustable process parameter: relates to the position, rotational speed, traveling speed, and / or acceleration of the tool processing machine; relates to the path along the individual axis of the tool processing machine; and / or relates to the trajectory of the individual axis of the tool processing machine; Each of the position, rotational speed, traveling speed, and / or acceleration of the tool processing machine, the path along the individual axis of the tool processing machine, and the trajectory of the individual axis of the tool processing machine is at a specific timestamp and / or is related to the desired operation position and / or different commands of the part processing program.

30. The method according to claim 22, Among them, The digital model includes the modeling of the machining force and / or dynamic behavior of the tool processing machine.

31. The method according to claim 22, Among them, The deterministic behavior relates to the deformation of the tool processing machine.

32. The method according to claim 22, Among them, The digital model is implemented as a digital analysis model and / or a digital numerical model.

33. The method according to claim 32, Among them, The digital model is implemented as a digital analysis model and / or a digital numerical model based on polynomials, machine learning, and / or finite elements.

34. The method according to claim 22, Among them, The method includes the steps of: measuring, using a sensor, measured values of the tool machining machine, the workpiece, and / or the environmental conditions, and inputting the measured values into the simulation, wherein the digital model includes modeling related to the measured values.

35. The method according to claim 34, Among them, The step of measuring is performed during the machining of the input workpiece by the tool machining machine.

36. The method according to claim 22, Among them, The simulation includes a measurement process model that digitally represents the coordinate measurement and / or the measurement using a sensor.

37. The method according to claim 22, Among them, An adjustment of the deterministic digital simulation is derived and implemented based on the simulation.

38. The method according to claim 37, Among them, An adjustment of the digital model is derived and implemented based on the simulation.

39. The method according to claim 22, Among them, The adjustment operation is enabled by modifying a part machining program configured to control the tool machining machine according to the adjustment value of the adjustable process parameter.

40. The method according to claim 39, Among them, The adjustment operation is enabled by modifying the G-code according to the adjustment value of the adjustable process parameter.

41. The method according to claim 22, Among them, The adjustment operation is enabled by modifying the volume map of the tool machining machine, and the tool machining machine maps the path configured to be followed by the tool machining machine to the movement of at least one individual axis via the volume map.

42. A non-transitory computer program product, the non-transitory computer program product includes program code stored on a machine-readable medium and having computer-executable instructions that, when executed, cause a computer to perform the method according to any one of claims 22 to 41.

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