Autonomous Workpiece Scanning With Adaptive Resolution Protocols
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Solution Overview
Problem
Current automated finishing systems face inefficiencies in scanning and processing workpieces due to the need for extensive data capture and high computational resources, which limits their ability to quickly and accurately generate toolpaths for consistent surface finishes across similar workpieces.
Innovation Solution
The system employs a method of autonomously scanning workpieces using a laser line scanning sensor, generating virtual models, and adjusting scan parameters to minimize error, allowing for rapid data capture and toolpath generation with reduced computational resources by leveraging simulated scans and adaptive scan protocols.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If extensive data capture is performed to ensure accurate virtual model generation, then manufacturing precision is improved, but productivity deteriorates due to increased scan duration
Solution Approach 1:
The system performs a first scan with a first set of scan parameters to capture initial data, then performs a second scan with a second set of scan parameters to capture additional data. By selectively combining data from both scans rather than requiring complete data capture in a single exhaustive scan, the system achieves accurate virtual model generation while reducing total scan duration and improving productivity
Solution Approach 2:
The scanning process is divided into multiple discrete scan operations, each capturing data for specific regions of the workpiece. The system segments the data capture task into manageable portions that can be processed and combined to form the complete virtual model, reducing the time penalty associated with comprehensive data capture
2Manufacturing precision
If high computational resources are allocated to process scan data, then manufacturing precision is improved, but device complexity worsens
Solution Approach 1:
The system generates virtual models and computes toolpaths based on scan data before actual machining operations begin. By performing computational tasks in advance and storing the results, the system reduces the need for complex real-time computational resources during manufacturing operations, thereby reducing device complexity while maintaining precision
Solution Approach 2:
The system creates virtual models as digital copies of the physical workpiece, allowing all computational processing to occur on the digital representation rather than requiring complex computational resources during physical manufacturing. This copying approach maintains manufacturing precision while significantly reducing the computational complexity required during actual production
3Manufacturing precision
If comprehensive scan data is collected for all workpiece regions, then manufacturing precision is improved, but loss of time worsens due to extended scan duration
Solution Approach 1:
The system performs multiple scans with different parameters, capturing data for different regions of the workpiece. By selectively combining data from these partial scans rather than requiring complete comprehensive data capture in a single long scan, the system achieves consistent surface finish accuracy while reducing total scan cycle time
Solution Approach 2:
The scanning process is executed in periodic cycles, with each cycle capturing data for specific regions using specific parameters. The system alternates between different scan configurations across multiple cycles, efficiently collecting comprehensive data over time without requiring each individual scan to be exhaustive, thereby reducing overall scan cycle time while maintaining precision
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 efficient and accurate processing of multiple workpieces with similar geometries by reducing scan duration and computational complexity, ensuring consistent surface finishes and improved geometric accuracy.
Implementation Method 1
a laser line scanning sensor arranged on the end effector
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.