Method for generating virtual shapes and system for data processing

Abstract

The invention relates to a method for generating a virtual geometry, in particular a computer-implemented method, a method for generating a digital twin, and a system and a computer program for data processing.SOLUTION: The method comprises obtaining machine information (12, 14) characterizing at least one machine parameter of the machine tool affecting the shape of the component, determining (230, 240, 250) at least one component factor based on the machine information (12, 14) and the target shape, and generating (260) a first virtual shape (32) as a digital geometrical image of the manufactured and / or to be manufactured component based on the component factor.SELECTED DRAWING: Figure 2

Description

[Technical Field]

[0001] The present invention relates to a method for generating a virtual shape, in particular a computer-implemented method, a method for generating a digital twin, and a system and computer program for data processing. [Background technology]

[0002] Methods for generating the virtual shape of a component having a target shape manufactured by a machine tool are known in principle, and these methods are usually based on measurement methods for measuring the manufactured component.

[0003] In general, the production of components using machine tools is subject to quality variations due to the influence of errors in the manufacturing process. The errors that occur can be divided into systematic errors and random errors. Systematic errors are caused by the system and are reproducible under the same boundary conditions. Systematic errors include, for example, wear of the tools used and thermally induced expansion of the machine tool components used. On the other hand, the remaining errors that do not originate from systematic errors are classified as random errors. Such errors generally cannot be predicted deterministically. Random errors can be caused, for example, by material properties that deviate from predetermined values ​​or by fluctuating ambient temperatures.

[0004] To take into account the many factors that affect the manufacturing process, quality assurance is carried out to ensure the quality of the components. During quality assurance, manufactured components are measured using specific measuring tools. Furthermore, components can also be measured between two manufacturing processes.

[0005] For example, dimensional, geometric, and positional tolerances are inspected as part of quality assurance. Component shape deviations can be obtained, for example, using contact coordinate measurement techniques or optical fringe projection methods. Particularly for components with complex component geometries, including freeform surfaces, available measurement methods are both time- and cost-intensive. For components with complex component geometries, downstream quality assurance can account for up to 25% of the component cost.

[0006] Furthermore, the investment costs for the measurement instruments are high and the instruments need to be regularly maintained and inspected to ensure their functionality.

[0007] WO 2016 / 065492 describes a computer-implemented method for the partial analysis of a workpiece machined by at least one NC machine, but it essentially only simulates the machining process and does not replace any measurement methods. In particular, to measure the quality of a component, additional measurement steps must be performed after the component is manufactured. For example, this document does not model technical effects and their interactions, which leads to inaccurate results. [Prior art documents] [Patent documents]

[0008] [Patent Document 1] International Publication No. 2016 / 065492 Summary of the Invention [Problem to be solved by the invention]

[0009] It is therefore an object of the present invention to provide a method, in particular a computer-implemented method, for generating a virtual shape of a component having a target shape that has been manufactured and / or is to be manufactured by a machine tool, a method for generating a digital twin, a system for data processing and a computer program, which reduce or eliminate one or more of the above-mentioned disadvantages. In particular, it is an object of the present invention to provide a solution that reduces or eliminates the burden of measurement work as part of quality assurance. [Means for solving the problem]

[0010] This problem is solved by a method, a system for data processing and a computer program having the features set forth in the independent claims. Further advantageous configurations of the method, the system for data processing and the computer program are set forth in the respective dependent claims. The features set forth individually in the claims can be combined with one another in any technically useful manner and can be supplemented by other features according to the description, resulting in further embodiments of the invention.

[0011] 1. A method for generating a virtual shape of a component having a target shape and manufactured and / or to be manufactured by a machine tool, the method comprising: acquiring machine information characterizing at least one machine parameter of the machine tool that affects the shape of the component; determining at least one component factor based on the machine information and the target shape; and generating a first virtual shape as a digital geometric image of the manufactured and / or to be manufactured component based on the component factor.

[0012] In particular, the method is a computer-implemented method. The method is configured to generate a virtual shape. In this specification, a virtual shape refers in particular to a geometrical mapping of a manufactured and / or to-be-manufactured component. The virtual shape of the manufactured component may be equivalent to a measurement result of a three-dimensional measurement. The virtual shape may be, for example, a point cloud whose surface is a mapping of the manufactured component. Furthermore, the virtual shape may be or include a polygon mesh, a non-uniform rational B-splines, a boundary representation model, a constructive solid geometry (CSC), a dexel, a multidexel, a voxel, and / or an octree. The virtual shape of the to-be-manufactured component may also be understood as a predicted shape. In this case, a virtual shape of the to-be-manufactured component is generated.

[0013] As used herein, "shape" refers to, for example, the macro-shape of a component. The macro-shape refers to the shape and dimensions of the component. In addition, "shape" also refers to the micro-shape. The micro-shape refers to, for example, the surface topography and / or surface roughness. Preferably, "shape" refers to a measurable characteristic of a component.

[0014] The component may be manufactured on a machine tool or may be manufactured by a manufacturing machine. For example, the machine tool may be a milling machine or a lathe. Furthermore, the machine tool may be any machine for performing a manufacturing process.

[0015] The manufactured and / or to-be-manufactured component has a target shape. The target shape is a shape that is specifically assumed or predefined for the manufactured and / or to-be-manufactured component. The target shape of the component is specified, for example, in the design. The target shape can specify, for example, the shape and dimensions of the to-be-manufactured component and / or other parameters such as surface roughness and surface topography.

[0016] In a first step, machine information is acquired. Machine information may also be understood to mean machine data. Acquiring machine information is fundamentally understood to mean any method for acquiring, collecting, retrieving, obtaining, etc., machine information. The machine information characterizes at least one machine parameter of a machine tool that affects the geometry of a component during manufacturing. As will be explained in more detail below, the machine parameter may be, for example, one or more axis positions, one or more output values.

[0017] The machine information can be acquired, for example, by means of sensors. Acquiring machine information is further understood as meaning the collection of information or data. For example, the machine information can be acquired in such a way that the control device of the machine tool is read and the machine information is acquired in this way. Alternatively or additionally, the machine information can also be read from other data memories and / or data sources. Furthermore, the acquisition of the machine information can be performed in a computational manner, in particular by calculating the machine information by means of a model.

[0018] The method further includes determining at least one component factor based on the machine information and the target shape, the component factor being derived from the machine information and the target shape, the component factor thus taking into account the machine information and the target shape, and being particularly configured to generate the first virtual shape using the component factor.

[0019] The present invention is based on the finding that the shape of a manufactured component can be determined not only by measurements on the component itself, but also based on machine information. The inventors have discovered that by skillfully correlating the machine information with a target shape for the component, it is possible to estimate the actual or virtual shape of the component.

[0020] Because machine information is typically available in modern machine tools anyway, and the target geometry of the manufactured component is also available based on the CAD design, the method allows for on-the-fly determination of the component geometry, thereby eliminating the need for a subsequent inspection step using a measurement means or method. This reduces or avoids the cost of subsequent inspection, essentially eliminating the aforementioned 25% of the component cost for quality assurance. Furthermore, 100% inspection can be performed on all components, eliminating the error-prone sampling inspections common in current metrology methods. Additionally, statistical process control can be performed or supported based on the first virtual shape and the second virtual shape described below. For example, due to the high data availability of the method, process control can be performed based on the first virtual shape between two sampling inspections.

[0021] Based on the component factors, a first virtual shape is then generated as a digital geometric image of the manufactured and / or to-be-manufactured component, for example, the first virtual shape can be generated based on a target shape by determining deviations of the target shape at predefined points using the component factors.

[0022] The inventors have experimentally verified the above-described method and found that the first virtual shape essentially matches the shape generated by a complex 3D measurement method, and in some cases, the above-described method has even been shown to produce more realistic results.

[0023] A preferred embodiment of the method is characterized in that the machine information characterizes the axis positions of at least one machine axis and / or machine spindle of the machine tool. Preferably, the machine information characterizes the axis positions of two or more or all machine axes. The axis positions of the machine axes can typically be read out from a machine control device of the machine tool.

[0024] The machine axis may be, for example, the axis of a machine table, the axis of a build chamber of an additive manufacturing machine and / or the axis of a laser scanner. The machine spindle may be, for example, the tool spindle of a milling machine or a lathe spindle for rotating a component.

[0025] The axis position is preferably defined as the distance between a predefined point on a machine element of the machine tool and a predefined origin at a specific time. Preferably, the method includes a step of acquiring the axis positions of at least one machine axis, preferably two or more or all machine axes. This may be done by reading the machine control of the machine tool. The axis positions are in particular given as a function of time or associated with a time unit. On this basis, further velocity, acceleration and jerk can be determined by differential operations.

[0026] In another preferred embodiment of the method, it is envisaged that the machine information characterizes power values ​​of at least one machine axis, preferably two or more or all machine axes and / or machine spindles of the machine tool. The power values ​​may be expressed directly, for example, in watts or kilowatts. Furthermore, the power values ​​may be expressed indirectly, for example, in amperes or percentages. The power values ​​are in particular given as a function of time or associated with time units. The power values ​​are in particular power values ​​of drives of the machine axes.

[0027] In a further preferred embodiment of the method, the initial shape of the workpiece to be machined is taken into account.

[0028] Preferably, the method includes obtaining output values ​​of at least one machine axis, preferably two or more or all machine axes and / or machine spindles of the machine tool, which may be done by reading the machine controller and / or calculating the output values.

[0029] In the following, the terms axis position and information characterizing the axis position and output value and information characterizing the output value are used partly synonymously. Furthermore, it is preferred that the output value and the axis position are related to one another. This can be done, for example, by a time variable and / or a time correspondence.

[0030] A further preferred embodiment of the method comprises the steps of: determining a process force, in particular a plurality of process forces, using the output value and the contact area between the tool and the component used, and determining a displacement factor determined by a tool displacement and / or a component displacement based on the process force, wherein the component factor is determined based on the displacement factor.

[0031] Here, "component factors are determined based on displacement factors" particularly means that component factors are determined based on displacement factors in addition to other elements.

[0032] In particular, it is preferred to determine process forces. Process forces are generally known in manufacturing technology as forces acting on a component and / or a tool, and / or acting between a tool and a component, and / or transmitted through a medium between the tool and the component. Process forces are also defined as forces resulting from a manufacturing process and affecting the process result. Individual process forces among the plurality of process forces are preferably determined as force vectors, i.e., in three spatial directions, particularly in the machine axis X, Y, and Z directions. The process forces are determined as a function of the tool position, among other factors.

[0033] The contact area between the tool being used and the component is commonly known in manufacturing technology as the contact geometry. In practice, the contact area is determined analytically and / or discretely. The contact area is essentially determined by the geometry of the component being machined, the tool geometry, and their relative positions and orientations.

[0034] The contact area may be configured as, for example, a line contact or an area contact. In practice, the contact area is determined analytically and / or discretely. The contact area is essentially defined by the geometry of the component to be machined, the tool geometry and the engagement conditions, such as the tool angle between the tool and the component.

[0035] The tool used may be, for example, a cutting tool or a laser beam. Additionally, a tool may be any element that affects a workpiece in a manufacturing process.

[0036] The inventors have found that tool displacement and / or component displacement during the component manufacturing process often affect the deviation of the manufactured component shape from the target shape, with either tool displacement or component displacement being more important depending on the tool used and the component being manufactured.

[0037] For example, for delicate components, such as thin-walled components like one-piece axial compressor impellers or thin-walled engine blades, component displacement is often more important than tool displacement. In contrast, when machining deep-drawing tools weighing several tons, tool displacement is of greater importance than component displacement. Tool displacement and component displacement are essentially determined based on process forces. Process forces acting between the component and the tool result in tool displacement or component displacement. Tool displacement and / or component displacement can be determined, for example, based on numerical approximation tests or analytical models, such as a mechanical model of a bending beam. Tool displacement and / or component displacement can characterize misalignment and / or deformation of the component and / or tool.

[0038] Furthermore, the method preferably determines the clamping factor based on clamping means and / or clamping parameters used to clamp the component and / or tool, which may deform the component and / or tool, and further affect dynamic and static properties.

[0039] Based on the tool displacement and / or component displacement, a displacement factor is determined. The displacement factor represents a position-resolved deviation that takes into account that specific features of the component and / or tool involved in machining are not in the positions assumed in the process plan for the component and / or tool. For example, moving the center point of the tool and / or moving the component or specific features of the component produces a shape that deviates from the target shape. Additionally, a clamping factor is preferably taken into account when determining the displacement factor.

[0040] A further preferred embodiment of the method includes a step of determining a position factor based on the axis positions, and the component factor is determined based on the position factor. The position factor takes into account that the tool itself is not at the position assumed in the process plan for the tool. This occurs because the actual axis positions have deviations from the predetermined axis positions in a position-resolved manner. These deviations are due to, for example, accelerations and jerks, which may result in the machine tool not scanning the predefined points. Particularly preferably, the position factor is determined based on the contact area determined by the axis positions, along with other factors.

[0041] Furthermore, the NC path represented by the NC program may have deviations because the NC program is subject to errors. For example, these deviations may be caused by errors or inaccuracies in the CAM algorithm and human error. This method can detect these deviations with high accuracy.

[0042] Furthermore, in the NC program, points are defined at a distance from one another, and these points are interpolated for the control of the machine tool, which also results in deviations. It is particularly preferable that the acquired axis positions are used taking into account the target shape, so that the target position of the machine tool does not have to be taken into account.

[0043] Here, "component factors are determined based on position factors" particularly means that component factors are determined based on position factors in addition to other elements.

[0044] A further preferred embodiment of the method is characterized in that it includes a step of determining a tool factor based on the tool geometry, and the component factors are determined based on the tool factor, which takes into account deviations caused by the tool not having the geometry assumed in the process plan for the tool.

[0045] Here, "component factors are determined based on tool factors" particularly means that the component factors are determined based on the tool factors in addition to other elements.

[0046] Preferably, the tool shape is determined based on an initial state and / or tool wear. The initial state represents the shape of the tool before its first use. In particular, the initial state takes into account deviations of the initial state from a predetermined target shape of the tool, which deviations may be due to, for example, imprecise manufacturing of the tool. The tool shape may represent, for example, dimensions such as tool length and tool diameter, tool shape, and / or tool runout. Tool wear occurs constantly during tool use, and this tool wear typically results in a continuous change in the tool shape.

[0047] Machining a component with a tool having a tool geometry that differs from the tool's target geometry will result in a component that deviates from the target geometry. Preferably, tool wear is determined based on contact area and / or process forces. Tool wear can be determined, for example, by empirical modeling, taking into account time-varying contact area, process forces, and additional sensor information, such as from a camera system or laser measurement system.

[0048] Furthermore, the tool may deform during machining, for example in the area adjacent to the tool center point, which also results in deviations that can be taken into account by the tool factor.

[0049] A further preferred embodiment of the method comprises a step of obtaining meta-information, wherein the meta-information represents tool parameters of the tool, machine kinematics and / or program name of the machine tool, and wherein the meta-information is used for determining the displacement factor and / or for determining the contact area.

[0050] Machine kinematics give rise to individual errors which superimpose to give a total error called the volumetric error. The superposition of all systematic individual errors in the linear and rotary axes of the machine tool results, at each position in the workspace, in a position-dependent offset of the tool relative to a predefined position and a position-dependent deviation from a predefined pose.

[0051] Metadata is additional structured data, which represents further information about the component, such as identifier, material or coordinate shift, information about the tool, such as identifier, tool type, tool radius, and information about the machine tool, such as identifier, machine kinematics or machine configuration. The program name makes it possible to associate NC operations with components and to define the machining sequence.

[0052] In a further preferred embodiment of the method it is envisaged that it comprises a step of acquiring sensor information, wherein the sensor information characterizes force values, moment values, in particular bending moment values, vibration values ​​and / or tool displacement values, and the sensor information is used to determine the process forces.

[0053] Force values ​​can be determined, for example, by means of a tool holder with sensors, a spindle-integrated force measuring system and / or a workpiece-side force measuring platform. Force and / or moment values ​​allow the determination of process forces. Vibration values ​​allow the determination of the dynamic compliance of the tool and / or components. Furthermore, tool wear and / or tool run-out can be determined by means of laser tool measuring systems or camera systems.

[0054] The sensor information is the output signal of a sensor, in particular a force sensor, a vibration sensor and / or a tool displacement sensor. The sensor may be, for example, a discrete sensor or a time series sensor.

[0055] Furthermore, the contact area is preferably calculated based on the tool shape of the tool and the target shape and / or the first virtual shape of the component. More preferably, the positions and orientations between the tool and the component are taken into consideration. Calculating the contact area based on the tool shape and the first virtual shape is particularly important when calculating a second virtual shape, which will be described later. The contact area depends on the shape that has been manufactured or is to be manufactured, and therefore is actually different from the contact area calculated based on the target shape. Therefore, in order to calculate a more accurate virtual shape, the contact area can be calculated based on the tool shape and the first virtual shape.

[0056] A further preferred embodiment of the method includes the following steps: determining modified component factors based on machine information and the first virtual shape; and generating a second virtual shape based on the modified component factors. The calculation of the component factors can be improved because interactions exist between the displacement factors, position factors, and tool factors, which may cause deviations. For example, deviations of the actual manufactured shape from the target shape may cause changes in contact area and process forces. Other influencing factors may also change due to these deviations.

[0057] By considering the first virtual shape instead of the target shape, it is possible to obtain component factors with higher accuracy. In particular, it is preferable to obtain a third virtual shape and subsequent virtual shapes by considering previously obtained virtual shapes as their initial shapes. In this way, it is possible to iteratively obtain highly accurate corrected component factors.

[0058] Particularly preferably, a corrective displacement factor, a corrective position factor and / or a corrective tool factor is determined based on the first virtual shape and / or on the deviation between the first virtual shape and the target shape.

[0059] Preferably, a corrective process force is determined based on the output value and the corrective contact area, which takes into account, in particular, the first virtual shape, preferably not the target shape of the component, and preferably a corrective tool displacement and / or a corrective component displacement is determined based on the corrective process force.

[0060] Based on the modified tool displacement and / or modified component displacement, a modified displacement factor is determined. The modified component factor is preferably based on the modified displacement factor. The modified tool factor is also typically different from the tool factor because deviations of the first virtual shape from the target shape change the engagement conditions of the tool.

[0061] A further preferred embodiment of the method comprises the steps of: determining shape deviations by matching the first virtual shape and / or the second virtual shape with a target shape, wherein deviation vectors are preferably formed for each predefined component section of the target shape.

[0062] According to another aspect of the present invention, the problem stated at the beginning is solved by a method for generating a digital twin of a manufactured component based on machine information of the component and a target geometry of the component, in particular a method according to any of the aforementioned embodiments.

[0063] According to a further aspect of the invention, the problem stated at the beginning is solved by a system for processing data, comprising means for carrying out the steps of the method according to any of the preceding embodiments.

[0064] The system is particularly configured for generating a virtual shape of a component manufactured and / or to be manufactured by a machine tool having a target shape. The data processing system preferably includes means for acquiring machine information characterizing at least one machine parameter of the machine tool that influences the shape of the component.

[0065] Further preferably, the data processing system includes means for determining at least one component factor based on the machine information and the target shape, and preferably the data processing system has means for generating a first virtual shape as a digital geometric image of the manufactured and / or to be manufactured component based on the component factors.

[0066] The system preferably comprises an interface configured to connect the system to an external system, for example the system may be connectable via an interface to a CAQ system for quality assurance.

[0067] According to yet another aspect of the present invention, the problem stated at the beginning is solved by a computer program comprising instructions which, when the computer program is executed by a computer, cause the computer to carry out a method according to any of the preceding embodiments.

[0068] For further advantages, details of embodiments and implementations, as well as further aspects and possible improvements thereof, please refer to the above description of the corresponding features and improvements of the method for generating a virtual shape of a component manufactured and / or to be manufactured by a machine tool having a target shape. [Brief explanation of the drawings]

[0069] Preferred embodiments will now be described, by way of example only, with reference to the accompanying drawings, in which:

[0070] [Figure 1] 1A-1C are schematic diagrams illustrating exemplary embodiments of a method for generating a virtual shape; [Figure 2] FIG. 1 is a schematic diagram illustrating an exemplary embodiment of a system for processing data. [Figure 3] FIG. 1 is a diagram illustrating a flow of information in a data processing system. [Figure 4] FIG. 2 is a diagram further illustrating the flow of information in a data processing system. [Figure 5] FIG. 1 is a schematic diagram illustrating an exemplary embodiment of a manufacturing system. DETAILED DESCRIPTION OF THE INVENTION

[0071] In the drawings, identical or substantially functionally identical or similar elements are designated by the same reference numerals.

[0072] A schematic method is shown in Figure 1. In step 100, machine information 12, 14 is obtained that characterizes at least one machine parameter of a machine tool 3 that affects the shape of a component 8. The machine information may, for example, characterize axis positions 12 and / or output values ​​14 of at least one machine axis x, y, z, a, b, c.

[0073] In step 102, at least one component factor 30 is determined based on the target shape 10 of the component 8 that has been manufactured and / or is to be manufactured and on the machine information 12, 14. Step 102 is divided into steps 102a, 102b, and 102c. In step 102a, a displacement factor 26 is determined. For this purpose, first, a process force 22 is determined using the output value 14 and the contact area 20 between the tool 6 used and the component 8. Subsequently, a displacement factor 26 is determined based on a tool displacement 28a and / or a component displacement 26b, where the tool displacement 28a and / or the component displacement 26b are determined based on the process force 22.

[0074] In step 102b, a position factor 28 is determined based on the axis positions 12. In step 102c, a tool factor 24 is determined based on the tool geometry. Steps 102a, 102b, and 102c may be performed in any order, for example, in parallel. Furthermore, step 102 may be performed using only one or two of steps 102a-102c. A component factor 30 is determined based on the displacement factor 28, the position factor 28, and the tool factor 24.

[0075] In step 104, a first virtual shape 32 is generated as a digital geometric image of the manufactured and / or to be manufactured component 8 based on the component factors 30. In step 106, modified component factors are determined based on the machine information 12, 14 and the first virtual shape 32. In step 108, a second virtual shape is generated based on the modified component factors. For this purpose, preferably, modified displacement factors 28' and / or modified tool factors 24' are determined based on the first virtual shape 32, and essentially the same procedure as in steps 102a to 102c is applied.

[0076] 2 uses as input information information 10 characterizing a target shape, information 12 characterizing axis positions, information 14 characterizing output values, meta-information 16, and sensor information 18. System 1 includes means 210 for determining a contact area 20 based on target shape 10, axis positions 12, and meta-information 16. System 1 further includes means 220 for determining a process force 22 based on contact area 20, information 14, and sensor information 18. The system 1 also includes a means 230 for determining a tool factor 24 based on the process force 22 and the contact area 20 .

[0077] Furthermore, the system 1 includes means 240 for determining the displacement factor 26 based on the tool displacement and / or the component displacement 28a, 28b. The tool displacements and / or component displacements 28 a, 28 b are determined based on the meta-information 16 , the target shape 10 and the process forces 22 .

[0078] Furthermore, the system 1 includes a means 250 for determining a position factor 28 based on the contact area 20 and the target shape 10. The means 280 is configured for generating a first virtual shape 32, where the first virtual shape 32 is generated based on the tool factor 24, the displacement factor 26, and the position factor 28. Furthermore, the system 1 includes a means 270 for determining a shape deviation 34 based on the first virtual shape 32 and the target shape 10.

[0079] The first virtual shape 32 can also be used as an input for the system 1. This in particular constitutes an iterative loop as will be explained below. Based on the virtual shape 32, the information 20-34 can be determined with greater accuracy by the means 210-270, and the resulting second virtual shape 36 reproduces with greater accuracy the component 8 that has been or is to be manufactured.

[0080] The sensor information 18 can additionally be used by the means 220, 230, 240, 250 to allow various values ​​to be determined with greater precision.

[0081] 3 shows these relationships at an information level. In particular, it is shown that the displacement factor 26 is determined based on the tool displacement 28a and the component displacement 26b. Additionally, the initial shape 19 of the workpiece can be taken into account. Particularly preferably, the initial shape 19 is taken into account in the calculation of the contact area 20 and the calculation of the displacement factor 26.

[0082] 4 illustrates a method for generating a second virtual shape 38, where the first virtual shape 32 is used as an input instead of the target shape 10. Based on the information 10, 12, 14, 16, and 32, a modified contact area 20', a modified process force 22', a modified tool factor 24', and a modified displacement factor 28' are determined.

[0083] A modified component factor 30' is calculated based on the modified tool factor 24', the modified displacement factor 28', and the position factor 28. A second virtual shape 38 is calculated based on the modified component factor 30'. A modified shape deviation 34' is calculated based on the second virtual shape 38 and the target shape 10.

[0084] 5 shows a manufacturing system 3 comprising a machine tool 2 and a data processing system 1. The machine tool 2 comprises a machine spindle 4 for rotating a tool 6. With the tool 6, a component 8 is manufactured, which is clamped by a clamping means 9. The machine tool 2 has three linear axes x, y and z. Furthermore, the machine tool 2 has a first swivel axis a, a second swivel axis b and a third swivel axis c. The machine tool 2 is connected to the data processing system 1 by signal transmission.

[0085] This connection allows a first virtual shape 32 to be generated in situ as a digital geometric image of the manufactured component 8. For this purpose, component factors 30 are determined on the basis of machine information, in particular axis positions 12 and output values ​​14 of the machine tool 2, and the target shape. The machine information 12, 14 is obtained, for example, by reading it out from the machine control of the machine tool 2. The difference between the manufactured component and the virtual shape, i.e., the reproduction accuracy, can be improved by an iterative loop. For this purpose, for example, a second virtual shape 36 and / or a third virtual shape and / or further virtual shapes are generated.

[0086] The above-described method and the above-described system 1 allow the elimination of metrology methods from the manufacturing process chain, on the premise that the shape of the manufactured component 8 is determined not on the basis of a metrology method but on the basis of machine information 12, 14 and a predetermined target shape 10. This allows 100% inspection of the manufactured component 8, reducing rejects.

[0087] Furthermore, the process chain costs for complex components are reduced by eliminating 25% of the component costs for the measurement method mentioned at the beginning. Furthermore, the method can also be performed completely virtually, so that: The NC code can be adjusted based on the first virtual shape or the second virtual shape, on the basis that the process force 22 can also be calculated.

[0088] Thus, a robust method is provided by which the quality of the component 8 can be predicted on the one hand and controlled on the other hand. [Explanation of symbols]

[0089] The list of corresponding reference numbers is as follows: 1. Data processing system 2 Machine tools 3 Manufacturing System 4 Machine Spindle 6 Tools 8 Components 9. Clamping means 10 Information characterizing the target shape 12 Information characterizing axis position 14 Information characterizing the output value 16 Meta information 18 Sensor Information 19 Initial shape 20 Information characterizing the contact area 20' Information characterizing the corrected contact area 22 Information characterizing process power 22' Information characterizing the correction process force 24 Information characterizing tool factors 24' Information characterizing the modified tool factor 26 Information characterizing the displacement factor 26' Information characterizing the modified displacement factor 26a Tool Displacement 26b Component Displacement 28 Information characterizing the location factor 30 Information characterizing component factors 30' Information characterizing the modified component factors 32 Information characterizing the first virtual shape 34 Information characterizing form deviations 34' Information characterizing the corrected shape deviation 36 Information characterizing the second virtual shape 100~108 method steps 210 Means for determining contact area 220 Methods for determining process power 230 Methods for determining tool factors 240 Methods for determining displacement factors 250 Methods for determining the location factor 260 means for generating a first virtual shape 270 Means for determining shape deviation a Machine axis b Machine axis c Machine axis x machine axis y machine axis z machine axis

Claims

1. A method for generating a virtual shape of a component (8) manufactured and / or to be manufactured by a machine tool (2) having a target shape, in particular a computer-implemented method, comprising: obtaining machine information (12, 14) characterizing at least one machine parameter of said machine tool (2) that influences the shape of a component (8); determining at least one component factor (30) based on the machine information (12, 14) and the target shape (10); generating a first virtual shape (32) as a digital geometric image of the manufactured and / or to-be-manufactured component (8) based on the component factors (30); A method comprising:

2. the machine information characterizing the axis position (12) of at least one machine axis (x, y, z, a, b, c), preferably two or more or all machine axes, and / or the axis position of a machine spindle (4) of the machine tool (2); The method of claim 1.

3. the machine information characterizing at least one machine axis (x, y, z, a, b, c), preferably two or more or all machine axes, and / or an output value (14) of the machine spindle (4) of the machine tool (2); 10. A method according to any one of the preceding claims.

4. determining a process force (22) using the output value (14) and / or a contact area (20) between the tool (6) used and the component (8); determining a displacement factor (26) based on a tool displacement (26a) and / or a component displacement (26b) based on the process force (22); the component factors (30) are determined based on the displacement factors (26); 10. A method according to any one of the preceding claims.

5. determining a position factor (28) based on the axis position (12); The component factors (30) are determined based on the position factors (28).

10. A method according to any one of the preceding claims.

6. determining a tool factor (24) based on the tool shape; The component factors (30) are determined based on the tool factors (24).

10. A method according to any one of the preceding claims.

7. the tool shape is determined based on an initial state and / or tool wear; Preferably, the tool wear is determined based on a contact area and / or the process force.

10. A method according to any one of the preceding claims.

8. obtaining meta-information (16), wherein the meta-information represents tool parameters of the tool, machine kinematics and / or program name of the machine tool, and the meta-information is used to determine a displacement factor and / or to determine a contact area.

10. A method according to any one of the preceding claims.

9. acquiring sensor information (18), wherein the sensor information characterizes force values, vibration values ​​and / or tool displacement values, and the sensor information is used to determine a process force.

10. A method according to any one of the preceding claims.

10. the contact area is determined based on the tool shape of the tool and the target shape and / or the first virtual shape of the component; 10. A method according to any one of the preceding claims.

11. determining modified component factors based on the machine information (12, 14) and the first virtual shape; generating a second virtual shape based on the modified component factors; Preferably, a corrective displacement factor, a corrective position factor and / or a corrective tool factor is determined based on the first virtual shape and / or a deviation between the first virtual shape and the target shape.

10. A method according to any one of the preceding claims.

12. a step of finding a shape deviation by comparing the first virtual shape and / or the second virtual shape with the target shape, Preferably, a deviation vector is formed for each specific portion of a predefined component of the target shape.

10. A method according to any one of the preceding claims.

13. 10. A method for generating a digital twin of a manufactured component based on the machine information and the target shape of the component according to the method of any one of the preceding claims.

14. A data processing system (1), A data processing system comprising means (210-270) for carrying out the method according to any one of claims 1 to 13.

15. A computer program comprising: A computer program comprising instructions which, when executed by a computer, cause the computer to carry out the method according to any one of claims 1 to 13.

Images