3D Scan-Based Toolpath Adjustment for Robotic Part Finishing
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Solution Overview
Problem
Current CAD and CAM systems face challenges in accurately simulating finishing operations for physically manufactured parts due to manufacturing variances and imperfections, leading to inefficient robotic programming and manual intervention for correcting toolpaths.
Innovation Solution
A computing system that utilizes 3D scan data of physically manufactured parts to extract as-manufactured geometries, compare them to CAD models, and generate adjusted toolpaths for robotic finishing operations, enabling automated and flexible CAD/CAM processes that are part-agnostic and increase finishing operation accuracy.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If traditional CAD/CAM systems are used to simulate finishing operations, then the process follows standard design procedures, but the simulation accuracy deteriorates due to manufacturing variances and imperfections
Solution Approach 1:
The system performs 3D scanning of the physical part before generating the toolpath, capturing the actual as-manufactured geometry in advance. This preliminary action allows the toolpath to be adjusted based on real measurements rather than idealized CAD models, directly addressing the simulation accuracy issue caused by manufacturing variances
Solution Approach 2:
The system establishes a feedback loop where 3D scan data from the physical part is compared against the CAD model, and the toolpath is automatically adjusted based on the detected deviations. This closed-loop approach ensures that finishing operations account for actual manufacturing imperfections, improving both simulation accuracy and finishing precision
2Manufacturing precision
If manual intervention is used to correct toolpaths for manufacturing defects, then customization is possible, but productivity decreases due to tedious robotic programming
Solution Approach 1:
The system enables self-service by automatically generating adjusted toolpaths through comparison of 3D scan data with CAD models. The robotic programming system independently identifies manufacturing defects and computes corrected toolpaths without requiring manual intervention, thereby maintaining high toolpath accuracy while significantly improving productivity
Solution Approach 2:
The system replaces manual robotic programming with an automated computational process that uses 3D scan data to generate adjusted toolpaths. This substitution of mechanical/manual operations with automated algorithms eliminates the trade-off between precision and productivity, as the system can process multiple parts rapidly without sacrificing accuracy
3Productivity
If virtual toolpath simulations are used, then the process is efficient, but the accuracy deteriorates due to inability to represent physical variances
Solution Approach 1:
The system creates an accurate digital copy of the physical part through 3D scanning, capturing the actual as-manufactured geometry including all imperfections. This copy is then used to generate adjusted toolpaths, combining the efficiency of virtual simulation with the accuracy of physical measurements. The copied geometry serves as the basis for precise finishing operations while maintaining automated processing speed
Data Source
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AI summary
A computing system (100) may include a data access engine (108) and a toolpath adjustment engine (110). The data access engine (108) may be configured to access a computer-aided design (CAD) model of a part design and a computer-aided manufacturing (CAM) setup for the part design. The CAM setup (220) may include a nominal toolpath (222) specified through the CAD model (212) for performing a finishing operation for the part design. The data access engine (108) may also be configured to obtain 3-dimensional (3D) scan data for a physical part (230) manufactured from the part design. The toolpath adjustment engine (110) may be configured to extract, from the 3D scan data (250), a manufactured geometry (330) of the physical part (230) manufactured from the part design and generate an adjusted toolpath for the physical part (230) to account for the manufactured geometry (330) extracted from the 3D scan data (250).