3D-Printed Metrology Features for Contact-Free Component Alignment
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Solution Overview
Problem
The complexity of automated assembly processes in manufacturing, particularly in environments with intricate shapes and high precision requirements, is hindered by the limitations of conventional measurement devices and the need for increased equipment in confined spaces.
Innovation Solution
The implementation of 3-D printed metrology features that allow for contact-free measurements using a laser detector or other light sources, enabling a measurement device to detect feature locations and determine component position or orientation without physical contact.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If conventional measurement devices are used in automated assembly, then measurement capability is provided, but device complexity and equipment quantity increase in confined spaces
Solution Approach 1:
The patent replaces conventional contact-based mechanical measurement devices with contact-free laser-based optical measurement. The laser detector measures metrology features on components without physical contact, eliminating the need for complex mechanical measurement equipment in the confined assembly space while maintaining high measurement precision.
Solution Approach 2:
The patent uses laser light to create an optical copy or representation of the metrology features on the component surface. The laser detector captures reflected light patterns that represent the spatial coordinates of the features, enabling measurement without physical contact and reducing equipment complexity.
2Extent of automation
If multiple robots are used for automated assembly, then assembly automation is improved, but coordination difficulty and space requirements increase
Solution Approach 1:
The patent introduces a centralized controller as an intermediary that coordinates multiple robots and the laser measurement system. The controller receives measurement data from the laser detector and sends positioning commands to robots, simplifying the coordination complexity by providing a single point of control for all automated operations.
Solution Approach 2:
The patent implements a feedback loop where the laser detector continuously measures the positions of metrology features on components, the controller processes this data to determine precise positioning requirements, and the robots adjust their positions accordingly. This real-time feedback enables coordinated automation without increasing system complexity.
3Measurement precision
If contact-based measurement is used during assembly, then measurement data is obtained, but interference with stabilization and positioning tasks occurs
Solution Approach 1:
The patent replaces contact-based mechanical measurement with contact-free laser measurement. The laser detector measures metrology features without touching the component, eliminating interference with robot stabilization and positioning tasks while maintaining measurement precision.
4Manufacturing precision
If traditional manufacturing methods are used for metrology features, then manufacturing capability is maintained, but production cost and time increase
Solution Approach 1:
The patent changes the manufacturing method of metrology features from traditional subtractive manufacturing or separate assembly to additive manufacturing (3-D printing). The features are printed directly into the component during the main manufacturing process, eliminating additional production steps while maintaining the precision required for laser measurement.
Solution Approach 2:
The patent merges the manufacturing of metrology features with the manufacturing of the main component structure. Both are created in a single 3-D printing process, eliminating the need for separate manufacturing operations and reducing overall production time and cost.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This approach reduces the complexity and clutter in assembly cells, enables concurrent or sequential task performance, and improves the accuracy and efficiency of the assembly process by allowing precise measurement and alignment of components.
Implementation Method 1
a contact-free metrology apparatus... through the use of unique metrology features printed-in with a 3-D printed component... allow a distant measurement device to use a laser detector or other light source to collect metrology data
Data Source
AI summary
Aspects for implementing 3-D printed metrology feature geometries and detection are disclosed. The apparatus may a measurement device for a 3-D printed component. The component may include a plurality of printed-in metrology features arranged at different feature locations on a surface of the component. The measurement device can be configured to detect the feature locations of the printed-in metrology features and to determine a position or an orientation of the component based on the detected feature locations. In various embodiments, the metrology feature may be a protruding or recessed spherical portion, with the corresponding feature location at the center of the sphere.