In-Process Digital Twinning for As-Built Part Inspection
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Solution Overview
Problem
Conventional manufacturing systems face challenges in efficiently collecting as-built metrology data for every manufactured part, as the process is time-consuming and costly, often resulting in incomplete inspection data and deviations from as-designed dimensions, which can lead to inaccuracies and laborious reconciliation of coordinate systems during inspection.
Innovation Solution
Implementing an in-process inspection and digital twinning approach within subtractive, additive, or hybrid manufacturing systems, where metrology sensors attached to the machining tool perform inspections in situ, allowing for the collection of inspection data in the same coordinate system as the machining process, thereby eliminating the need for separate reconciliation and enabling the creation of part-specific digital twins.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If manual inspection processes are used with separate inspection stations, then inspection can be performed, but the process becomes time-consuming and costly
Solution Approach 1:
The patent combines the machining process and inspection process into a single integrated system. The metrology sensors are mounted on the same operating arm or spindle as the machining tool, allowing both manufacturing and measurement to occur in the same work envelope without removing the part. This merging eliminates the need for separate inspection stations and manual handling, directly resolving the contradiction between measurement accuracy and inspection speed.
Solution Approach 2:
The operating arm or spindle is designed to perform multiple functions: both machining operations and metrology measurements. By making the same component universal for both manufacturing and inspection tasks, the system eliminates the need for dedicated inspection equipment and manual processes, thereby improving productivity while maintaining measurement precision.
2Ease of operation
If part is removed from work envelope for inspection, then inspection can be performed, but coordinate system reconciliation becomes necessary
Solution Approach 1:
The inspection process is merged with the machining process by keeping the part in the same work envelope and using the same operating arm for both operations. This ensures that the coordinate system remains consistent throughout, eliminating the need for complex coordinate system reconciliation that would be required if the part were moved to a separate inspection station.
3Loss of information
If inspection data is collected separately, then inspection can be performed, but data integration and reconciliation become laborious
Solution Approach 1:
The patent merges the data collection processes by having metrology sensors integrated on the same operating arm as the machining tool. This allows inspection data to be collected in the same coordinate system and time frame as the machining data, enabling automatic integration without manual data processing or reconciliation. The digital twin is populated directly with both manufacturing and measurement data, eliminating time-consuming data integration steps.
4Reliability
If 100% part inspection is implemented, then quality assurance improves, but inspection time and cost increase
Solution Approach 1:
The integration of machining and inspection into a single automated process enables 100% inspection of every part without sacrificing productivity. Since the inspection occurs in-line during the machining operation itself, there is no additional inspection time required. The automated data collection and digital twin population further reduce costs by eliminating manual inspection processes, thereby achieving both high quality assurance and maintained productivity.
Data Source
AI summary
A manufacturing control system for an additive, subtractive, or hybrid machining system implements in situ part inspection to collect as-built metrology data for a manufactured part while the part remains in the work envelop, and uses the resulting measured inspection data to generate an as-built digital twin that accurately models the finished part. After execution of a subtractive and/or additive tooling operation, the system performs a sensor scan to collect three-dimensional imaging measurement data for the resulting manufactured part while the part remains in the work cell. The measurement data is then integrated with as-designed part metadata for the idealized part to yield the as-built digital twin. Since metrology measurements are integrated into the manufacturing process, customized as-built digital twins can be generated for each manufactured part without requiring manual inspections to be performed on each part.