In-Machine CNC and CMM Feedback for Dimensional Correction
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Solution Overview
Problem
Current CNC machining processes face dimensional variability due to positional errors and tool wear, requiring time-consuming and costly manual inspections, which are prone to human error and disrupt the manufacturing process.
Innovation Solution
A system integrating a CNC machine tool with a coordinate measuring machine (CMM) and a correction module that allows for real-time inspection and modification of components without removing them from the machine, using multi-axis coordinates and reference inspection data to determine variances and create executable correction instructions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If manual inspection processes are used to check dimensional compliance, then measurement capability is provided, but processing time increases and productivity decreases
Solution Approach 1:
The patent combines the coordinate measuring machine (CMM) and CNC machine tool into an integrated system where the CMM module is positioned within the CNC machine tool. This merging allows inspection and machining to occur in the same workspace without removing the component, eliminating transfer time and enabling continuous processing while maintaining measurement precision.
Solution Approach 2:
The system enables continuous machining operations by performing inspections during idle periods or between machining passes without removing the component from the machine tool. The controller automatically pauses machining, performs CMM inspection, analyzes dimensional compliance, and resumes machining if corrections are needed, maintaining continuous useful action throughout the process.
2Measurement precision
If manual inspection processes are used, then dimensional compliance can be determined, but the process becomes disruptive and cost increases
Solution Approach 1:
The integrated system performs self-inspection and self-correction. The CMM module automatically inspects the component, the controller analyzes the dimensional data against specifications, and the system autonomously determines whether corrective machining is needed. This eliminates the need for skilled technicians to perform manual inspections and interpret measurements, reducing human intervention while maintaining measurement capability.
Solution Approach 2:
The system implements automated feedback loops where CMM measurement results are immediately analyzed by the controller, which then determines compliance status and triggers appropriate responses. If dimensional compliance is not met, the system automatically generates corrective machining instructions and updates the machining program, creating a closed-loop feedback system that continuously ensures quality without manual intervention.
3Reliability
If corrective actions are determined by skilled operators based on experience, then correction decisions can be made, but human error potential increases and processing time extends
Solution Approach 1:
The controller automatically receives CMM measurement data, compares it against dimensional specifications, and determines compliance status without human intervention. The system provides real-time feedback on whether the component meets requirements and automatically generates corrective machining instructions if needed, eliminating subjective human judgment and extending correction identification time.
Solution Approach 2:
The system replaces the human operator's experience-based decision-making with automated computational analysis. The controller uses algorithms to analyze dimensional data, determine compliance, and generate corrective instructions, substituting mechanical human judgment with automated computational systems that eliminate human error and reduce decision time.
Data Source
AI summary
A system and method for manufacturing a component is provided that includes a CNC machine tool, a correction module, and a system controller. The CMM module is controllable to determine a set of multi-axis coordinates surface points on the component. The correction module is in communication with the CMM module and stored reference inspection data. The system controller is in communication with the CNC machine tool, the correction module, and stored instructions. The instructions when executed cause the system controller to: a) control the CNC machine tool to modify a surface of the component; b) control the CMM module to determine multi-axis coordinates for surface points; c) determine surface position variances using the reference inspection data and the multi-axis coordinates; d) determine if surface position variances exceed a threshold; and e) create correction action instructions for controlling the CNC machine if surface position variances exceed the threshold.