Adaptive Scan Protocol for Workpiece Geometry and Cycle Time
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Solution Overview
Problem
Current automated finishing systems face challenges in efficiently scanning and processing workpieces with varying geometries, leading to inconsistencies in surface finishes and increased scan durations due to the need for extensive data capture and high computational resources.
Innovation Solution
The system employs a method that autonomously scans workpieces using a laser line scanning sensor, generates virtual models, and adjusts scan parameters to minimize error and duration, allowing for rapid scanning and processing of similar workpieces with improved accuracy and reduced computational complexity through simulated scans and optimized scan protocols.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If extensive data capture is performed to ensure measurement precision, then manufacturing precision is improved, but scan duration increases
Solution Approach 1:
The system performs a preliminary scan at lower resolution to generate an initial virtual model, then uses this model to identify regions requiring higher resolution scanning. This preliminary action allows the system to capture extensive data only where needed, improving surface finish consistency while reducing overall scan duration compared to uniform high-resolution scanning of the entire workpiece.
Solution Approach 2:
The system applies different scan resolutions to different regions of the workpiece based on their specific requirements. High resolution is applied only to regions identified as needing detailed capture, while other regions use lower resolution. This local quality approach ensures manufacturing precision where critical while minimizing scan duration across the entire workpiece.
2Manufacturing precision
If high resolution scanning is used to improve measurement precision, then manufacturing precision is improved, but computational resources and complexity increase
Solution Approach 1:
The scanning process is segmented into multiple passes with different resolutions. The first pass captures the entire workpiece at lower resolution, and the second pass focuses only on specific regions requiring higher precision. This segmentation reduces the total computational load compared to processing a single high-resolution scan of the entire workpiece, while maintaining geometric accuracy where needed.
Solution Approach 2:
The system performs partial high-resolution scanning only on regions that require it, rather than scanning the entire workpiece at high resolution. This partial action approach maintains manufacturing precision for critical areas while significantly reducing computational complexity and resource requirements compared to comprehensive high-resolution scanning.
3Ease of operation
If uniform scan parameters are applied to all workpiece regions, then ease of operation is improved, but manufacturing precision deteriorates due to inability to adapt to varying geometries
Solution Approach 1:
The scan protocol transitions from static uniform parameters to dynamic adaptive parameters. The system automatically adjusts scan resolution and density based on the generated virtual model, adapting to varying workpiece geometries. This dynamic approach maintains ease of operation as the system self-adjusts without manual intervention, while improving surface finish consistency through region-specific optimization.
Solution Approach 2:
The system uses feedback from the initial virtual model to adjust subsequent scan parameters. The virtual model generated from the first scan provides information about workpiece geometry and identifies regions requiring higher resolution, which feeds back into the scan protocol for the second pass. This feedback mechanism maintains operational simplicity while achieving consistent surface finishes across varying geometries.
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 enables consistent surface finishes on workpieces by reducing scan duration and computational resources, improving geometric accuracy, and adapting to environmental changes, thus enhancing the efficiency and precision of automated finishing processes.
Implementation Method 1
navigating a laser line scanning sensor about a workpiece
Implementation Method 2
capturing a set of scan data representing a three-dimensional surface contour of the workpiece geometry
Data Source
AI summary
A method includes, traversing a laser line scanning sensor over a workpiece to generate a series of scan data according to a first set of scan parameters; assembling the series of scan data into a virtual model; detecting a first hole, defining absence of scan data, in a first region of the virtual model; responsive to the first hole defining a dimension less than a threshold dimension, assigning the first set of scan parameters to the first region; detecting a second hole, in a second region of the virtual model; responsive to the second hole defining a dimension greater than the threshold dimension, defining a second set of scan parameters associated with an increased resolution and assigning the second set of scan parameters to the second workpiece region; and compiling the first and second set of scan parameters into a scan protocol defining a minimum scan cycle duration.