3D Abrasive Sanding With Force Feedback for Dimensional Accuracy
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Solution Overview
Problem
Current automated finishing systems lack the ability to autonomously scan, process, and model a digital twin of a workpiece with high accuracy, leading to inconsistencies in surface finish and dimensional accuracy.
Innovation Solution
A method that involves navigating a sanding head across a workpiece using a toolpath adjusted based on real-time force feedback and position data, allowing for the detection of surface contour differences and generation of secondary toolpaths to correct deviations from a target model, thereby improving 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 surface finish consistency deteriorate
Solution Approach 1:
The patent creates a digital twin (virtual copy) of the workpiece that is continuously updated with actual measurement data during machining. This digital model serves as a reference for real-time toolpath adjustments, enabling high precision without requiring complex physical measurement systems throughout the process
Solution Approach 2:
The system implements closed-loop feedback by continuously measuring the workpiece surface during machining, comparing actual dimensions against the digital twin, and automatically adjusting subsequent toolpaths to compensate for deviations, thereby maintaining high manufacturing precision
2Measurement precision
If the system performs comprehensive scanning and modeling of the workpiece, then the digital twin accuracy improves, but the processing time increases
Solution Approach 1:
The system performs an initial comprehensive scan to create the digital twin before machining begins, and also conducts preliminary identification of high-points that require material removal. This allows the machining process to focus only on critical areas rather than processing the entire workpiece surface uniformly
Solution Approach 2:
The system applies different measurement and processing densities to different regions of the workpiece. High-resolution scanning and detailed toolpaths are applied only to areas identified as high-points requiring material removal, while other areas receive minimal or no processing, reducing overall processing time while maintaining measurement precision where needed
3Manufacturing precision
If the sanding head follows a fixed toolpath, then the device complexity remains low, but the manufacturing precision deteriorates due to force variations
Solution Approach 1:
The system uses force sensors to monitor contact forces between the sanding head and workpiece in real-time. When force deviations are detected, the control system automatically adjusts the toolpath to maintain consistent contact force, ensuring uniform surface finish without requiring overly complex mechanical force control mechanisms
Solution Approach 2:
The toolpath transitions from a fixed static path to a dynamic adaptive path that adjusts in real-time based on measured workpiece geometry and force feedback. The system dynamically modifies toolpath parameters such as sanding head position, speed, and contact force to compensate for workpiece variations, achieving consistent surface finish through software-based adaptation rather than complex mechanical systems
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
The system achieves a high-resolution digital twin of the workpiece, ensuring consistent surface finish and increased accuracy by iteratively refining the virtual model through contact-based measurements and material removal, enhancing the precision of the finishing process.
Implementation Method 1
Method for modifying dimensional accuracy of a workpiece via three-dimensional abrasion
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.