AR CNC Programming for Accurate Blank Alignment and Tool Selection
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Solution Overview
Problem
The manual process of creating CNC machining programs is time-consuming, error-prone, and dependent on operator experience, leading to production delays and increased costs, especially in selecting machining tools and aligning workpieces for precise CNC machining.
Innovation Solution
The implementation of Augmented-Reality (AR)/Mixed-Reality (MR) technology to create and configure CNC machining programs by rendering 3D models of machined parts, aligning them with blanks, selecting tools, and simulating machining cycles, thereby reducing human error and optimizing the machining process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If manual process is used to create CNC machining programs, then operator flexibility and decision-making are maintained, but the process becomes time-consuming and error-prone
Solution Approach 1:
The patent uses AR/MR technology to create a virtual copy of the machining process that can be visualized and validated before actual machining. The system generates a digital representation of the workpiece, tools, and machining operations, allowing operators to review and verify the program without physical execution, thereby reducing errors while maintaining productivity
Solution Approach 2:
The system provides real-time visual feedback through AR/MR displays showing the machining process overlay. Operators can see the virtual toolpaths, tool positions, and workpiece geometry during program creation and validation, enabling immediate detection and correction of errors, thus improving both reliability and efficiency
2Productivity
If manual selection of machining tools and parameters is performed, then operator expertise can be applied, but time is increased and errors are increased
Solution Approach 1:
The system enables operators to visually select and configure machining tools through AR/MR interface by simply pointing the device at the virtual workpiece. The system automatically presents relevant tool options and parameters based on the selected features, reducing manual search time while ensuring appropriate tool selection for precision machining and minimizing material waste
Solution Approach 2:
The system performs preliminary analysis and preparation of tool selection and parameter settings before the actual machining operation. By pre-configuring appropriate tools and parameters based on the 3D model and machining requirements, the system reduces on-site decision time and ensures optimal settings for precision and material efficiency
3Measurement precision
If visualization of the final machined part is attempted manually, then understanding of the design can be achieved, but trial and error is required for accuracy and positioning
Solution Approach 1:
The system creates a precise virtual copy of the final machined part and overlays it onto the physical workpiece using AR/MR technology. This digital twin allows operators to visualize the exact final geometry, dimensions, and positioning requirements without physical prototypes or trial machining, achieving high measurement precision and correct alignment immediately
Solution Approach 2:
The AR/MR display acts as an intermediary between the digital design model and the physical workpiece. It provides a visual bridge showing the superposition of the virtual final part onto the actual workpiece, enabling accurate alignment and positioning verification without physical trial and error, thus saving time while maintaining precision
4Ease of manufacture
If traditional CNC programming methods are used, then established processes are followed, but production delays and costs increase
Solution Approach 1:
The patent replaces traditional mechanical and manual programming methods with AR/MR-based visualization and programming interface. Instead of working with complex G-code syntax and manual coordinate calculations, operators interact with intuitive 3D visual representations, making the manufacturing process easier to understand and execute while dramatically improving production speed and reducing errors
Data Source
Figure 1~3
Figure 2
AI summary
Disclosed is a method (300) and a system (100) for configuring a CNC machine (106) to machine a blank (116) to a machined part involving creating a 3D model of the machined part (114) and providing the blank to the CNC machine. An AR/MR device (104) is used for rendering the 3D model as an overlay to the blank, positioning and aligning the overlay with respect to the CNC machine, and providing indication therefor. The method sets an origin point by selecting a point on the overlay, indicating where CNC machining dimensions begin. A machining program (118) is created by using the AR/MR device to select a machining tool or cutting insert, tip a surface of the blank, present a machining cycle to be approved or disapproved. The process is repeated until the machining program is ready for simulation. Finally, the CNC machine is configured with the created machining program.