3D Probe-Guided Workpiece Alignment for Complex Machine Tools
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Solution Overview
Problem
Existing methods for aligning workpieces in machine tools are often complex and require significant operator expertise, especially when dealing with unique or damaged pieces, and they can be costly to implement and maintain.
Innovation Solution
A method that uses 3D models of the workpiece, probe, and machine tool to align the workpiece by manually positioning a probe and selecting probing points based on automated calculations, with quality assessment and iterative feedback to achieve precise alignment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If traditional probing methods are used to align workpieces, then measurement capability is achieved, but operator expertise requirements and process complexity increase significantly
Solution Approach 1:
The system performs self-alignment by automatically determining workpiece position and orientation through probing and comparing with CAD data, eliminating the need for operator interpretation and manual coordinate system definition. The control system independently completes the alignment process without requiring specialized operator knowledge.
Solution Approach 2:
The patent replaces manual operator actions with automated computational methods. Instead of operators manually defining coordinate systems and interpreting measurement data, the system uses automated algorithms to compare probe measurements with CAD models and calculate alignment transformations.
2Reliability
If complex probing cycles are implemented to handle unique or damaged workpieces, then alignment capability is maintained, but implementation and maintenance costs increase
Solution Approach 1:
The system dynamically adapts to different workpiece conditions by automatically adjusting the probing strategy based on real-time measurements and CAD model comparisons. The probing cycle is not fixed but flexibly modified to accommodate unique geometries, damaged surfaces, or varying workpiece qualities without requiring pre-programmed complex cycles.
Solution Approach 2:
The patent changes the approach from fixed probing cycles to adaptive parameter-based alignment. The system modifies probing parameters, measurement points, and evaluation criteria dynamically based on the actual workpiece characteristics detected during the alignment process, allowing handling of unique or damaged pieces without complex predefined cycles.
3Ease of operation
If manual positioning and probing is performed without automated guidance, then operator flexibility is maintained, but alignment time and productivity decrease
Solution Approach 1:
The system provides continuous feedback by comparing actual probe measurements with expected CAD model positions, automatically calculating deviations and guiding the alignment process. This feedback loop enables the system to self-correct and converge on the correct alignment without requiring operator intervention, simultaneously achieving speed and flexibility.
Solution Approach 2:
The patent performs preliminary actions by pre-loading CAD model data and preparing the alignment algorithm before the actual probing begins. The system pre-calculates expected measurement points and prepares the transformation calculations, enabling rapid execution during the actual alignment process without sacrificing operator flexibility.
Data Source
AI summary
A method for aligning a workpiece in a working space of a machine tool having a numerical control system uses a probe. 3D models of the working space, probe, and workpiece are virtually displayed. The workpiece is positioned in the working space and the virtual workpiece is positioned in the virtual working space so that there is an initial coincidence between positions thereof. The probe is manually positioned relative to the workpiece, wherein a planned probing point and probing direction are selected based on a minimum distance of the virtual probe from the virtual workpiece, and are displayed. Enabling of the probing is based on quality of the planned probing point, and, when enabled, a probing operation is triggered, and coordinates of a probing point are determined. The position of the workpiece is recalculated using these coordinates, and the position of the virtual workpiece is updated.