3D Sanding Head Toolpath Correction for Workpiece Accuracy
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Solution Overview
Problem
Current automated finishing systems lack the capability to autonomously scan, process, and model digital twins of workpieces with high accuracy, leading to inconsistencies in surface finish and geometric conformity.
Innovation Solution
A method that involves navigating a sanding head across a workpiece using a first toolpath, adjusting based on force values to maintain target forces, detecting surface contours, generating secondary toolpaths for correction, and refining a virtual model through contact-based measurements to create a digital twin with enhanced geometric and dimensional accuracy.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If automated finishing systems use conventional scanning and processing methods, then the system structure remains simple, but the manufacturing precision and geometric conformity of the workpiece deteriorate
Solution Approach 1:
The patent creates a digital twin (virtual model) of the workpiece that copies its geometric features. This virtual model is used to generate toolpaths and guide the physical sanding process, enabling high precision without requiring complex physical measurement systems during manufacturing. The digital copy serves as a reference for achieving geometric conformity.
Solution Approach 2:
The patent replaces conventional mechanical scanning and measurement systems with a digital modeling approach. Instead of using complex physical sensors and measurement devices to achieve precision, the system uses computational geometry and digital twins to guide the finishing process, reducing mechanical complexity while maintaining or improving precision.
2Manufacturing precision
If automated finishing systems use conventional processing methods, then the processing speed remains high, but the surface finish quality and geometric accuracy deteriorate
Solution Approach 1:
The patent performs preliminary scanning and digital twin creation before the actual sanding process. The toolpath is pre-calculated based on the digital model, allowing the physical sanding to proceed efficiently at high speed while maintaining quality. The preliminary digital preparation enables fast execution without sacrificing surface finish or geometric accuracy.
Solution Approach 2:
By using a digital twin to represent the workpiece geometry, the system can simulate and optimize the sanding process virtually before execution. This allows high-speed processing with quality assurance, as the digital model predicts the outcome and guides the physical process to achieve both speed and precision.
3Measurement precision
If automated finishing systems lack digital twin capability, then the system complexity remains low, but the measurement precision and geometric detection accuracy deteriorate
Solution Approach 1:
The patent creates a digital twin that copies the workpiece geometry with high precision. This virtual model serves as a reference for measurement and comparison, enabling accurate geometric detection without requiring complex physical measurement devices. The digital copy provides a baseline for detecting deviations and guiding corrections.
Solution Approach 2:
The patent transforms physical geometric parameters into digital representations. By converting physical dimensions and shapes into digital model parameters, the system achieves high measurement precision through computational methods rather than complex physical instrumentation. The digital parameters enable accurate detection and comparison.
Data Source
AI summary
A method includes, during a processing cycle: navigating the sanding head across a region of a workpiece according to a toolpath; and, based on a sequence of force values output by a force sensor coupled to the sanding head, deviating the sanding head from the toolpath to maintain forces of the sanding head on the workpiece region proximal a target force. The method also includes: detecting a sequence of positions of the sanding head traversing the workpiece region; interpreting a surface contour in the workpiece region based on the sequence of positions; detecting a difference between the surface contour and a corresponding target surface defined in a target model of the workpiece; generating a second toolpath for the workpiece region based on the difference; and, during a second processing cycle, navigating the sanding head across the workpiece region according to the second toolpath to reduce the difference.