3D Machining Visualization for Coolant-Obscured Machine Tools
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Solution Overview
Problem
Existing methods for displaying machining sequences in machine tools are inadequate for real-time monitoring and control, especially in environments with cooling lubricants, which hinder visual control and can lead to processing errors due to the inability to adapt real images to position changes during machining.
Innovation Solution
A method involving a scanning unit that creates a three-dimensional data model of the workpiece and tool before machining, continuously updating this model with position information during processing, allowing for real-time visualization and monitoring on a display unit, even in the presence of coolant, enabling comprehensive and clear monitoring and quick intervention.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of information
If real images are captured during machining, then visual monitoring is enabled, but the images cannot be adapted to position changes during processing
Solution Approach 1:
The patent creates a virtual copy of the workpiece and tool based on scanning data, then updates this virtual model's position according to control commands. This virtual image replaces the need for complex real-time adaptation of actual camera images, as the virtual model can be freely transformed without distortion issues.
Solution Approach 2:
The patent introduces a virtual image as an intermediary between the actual machining process and the display. Instead of directly processing and adapting real camera images, the system uses the virtual model as a mediator that represents the machining state without requiring complex real-time image transformation.
2Manufacturing precision
If cooling lubricants are used during machining, then processing quality is improved, but visual control becomes impossible
Solution Approach 1:
The patent creates a virtual representation of the machining process that can be displayed without being affected by cooling lubricants. This virtual copy provides the visual information that would otherwise be blocked by the lubricants, allowing operators to monitor the process clearly despite their presence.
Solution Approach 2:
The virtual image acts as an intermediary that conveys machining information to the operator without being interfered with by cooling lubricants. While the lubricants remain in contact with the actual work area, the virtual representation provides clear visual feedback through alternative means.
3Device complexity
If a 2D camera is used to image the workpiece, then simple imaging is achieved, but the images cannot be adapted to three-dimensional position changes
Solution Approach 1:
The patent transitions from 2D camera imaging to a 3D virtual model that can represent position changes in three dimensions. By creating a volumetric digital twin of the workpiece and tool, the system gains the ability to adapt to spatial transformations while maintaining relatively simple implementation through software-based model updating.
Data Source
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AI summary
The invention relates to a method for displaying the machining processes in the machining area of a machine tool, wherein a tool or workpiece is scanned and the machining process is visualized. The invention further relates to an associated machine tool and an associated system.