AR Machining Overlay for Precise Tool Path Guidance
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Solution Overview
Problem
Certain disassembly and repair processes, such as those involving gas turbine engines, require precision to avoid damaging internal components, but existing methods lack effective guidance for correct tool paths and orientations, leading to potential damage and installation difficulties.
Innovation Solution
A wearable augmented reality system that provides a visual overlay using perception sensors and computing devices to guide users with correct tool paths, warnings, and internal component details, ensuring precise disassembly and repair by aligning virtual overlays with the user's field of view.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If traditional manual disassembly and repair methods are used, then operators have flexibility in performing tasks, but precision and accuracy of tool paths deteriorate leading to potential damage to internal components
Solution Approach 1:
The patent creates a virtual copy of the physical component with precise internal geometry and machining features. This digital model serves as a template to generate accurate tool paths, eliminating the need for complex physical guidance fixtures while maintaining high precision. The virtual model is overlaid on the real component through augmented reality, providing visual guidance without adding physical complexity.
Solution Approach 2:
The patent replaces traditional mechanical guidance systems (fixtures, templates, physical jigs) with a computational and visual system. Instead of using mechanical means to constrain and guide tools, the system uses augmented reality visual overlays to guide operator movements, significantly reducing device complexity while improving precision.
2Manufacturing precision
If visual guidance systems are implemented to improve precision, then tool path accuracy improves, but information overload and difficulty in interpreting guidance deteriorate
Solution Approach 1:
The patent applies visual guidance information locally at the specific location where it is needed, rather than presenting all information globally. The augmented reality overlay displays tool paths, machining features, and warnings precisely at the relevant positions on the component, allowing operators to access detailed information contextually without being overwhelmed by comprehensive data displays elsewhere.
Solution Approach 2:
The patent provides guidance information selectively based on the operator's current needs and position, rather than displaying all possible information simultaneously. The system reveals machining features, tool paths, and warnings progressively as the operator moves through the disassembly or repair process, preventing information overload while ensuring all necessary information becomes available when needed.
3Manufacturing precision
If detailed internal configuration data is displayed to improve machining accuracy, then tool path precision improves, but visual clutter and difficulty in maintaining situational awareness deteriorate
Solution Approach 1:
The patent displays internal configuration data that would normally be hidden in three-dimensional space by rendering it visible through the component structure in augmented reality. By projecting internal features, tool paths, and machining boundaries as transparent or ghosted overlays in the same visual field, the system provides precise guidance information without requiring the operator to shift attention to separate displays or mental models, maintaining situational awareness while improving precision.
Data Source
AI summary
A method of visualizing data with respect to a component includes identifying a model of the component. The method further includes accessing part data defining an internal configuration of each of a plurality of models of components. The method further includes associating the internal configuration of the model of the component with the component. The method further includes accessing process data defining a plurality of processing methods applicable to the identified model of the component, and receiving an indicator of a desired processing method out of the processing methods defined by the process data. The method further includes generating a visual overlay on a display based on the process data and the associated internal configuration of the component, wherein the visual overlay includes a guiding visualization for at least one step of the desired processing method associated with at least one feature of the internal configuration of the component.