In-Machine CNC Surface Correction Using Integrated CMM Feedback
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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 adjustment of components without removing them from the machine, using multi-axis coordinates and reference inspection data to create executable correction instructions for maintaining tolerancing thresholds.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If manual inspection processes are used to ensure dimensional compliance, then measurement precision is improved, but productivity deteriorates due to time-consuming inspections and process disruptions
Solution Approach 1:
The patent replaces manual mechanical inspection methods with an automated optical measurement system integrated into the CNC machine. The system uses optical sensors and cameras to capture images of the workpiece, automatically measures dimensional parameters, and compares them against tolerances without requiring manual intervention or process interruption.
Solution Approach 2:
The inspection system performs self-verification by automatically capturing workpiece images, measuring dimensional parameters, comparing results against predefined tolerances, and generating compliance determinations without external human intervention. The system serves its own inspection needs, eliminating the requirement for separate manual inspection processes.
2Measurement precision
If skilled technicians perform manual inspections, then measurement precision is improved, but device complexity deteriorates due to the need for specialized human expertise and intervention
Solution Approach 1:
The patent replaces the complex human expertise requirement with an automated optical measurement system that uses image processing algorithms and computer vision technology. The system automatically performs measurements, compares results against tolerances, and determines compliance without requiring skilled technicians or manual interpretation.
Solution Approach 2:
The system creates digital copies of the workpiece through optical imaging and uses these digital representations for measurement and analysis. This eliminates the need for physical manual measurement and complex human expertise by working with replicated digital data that can be automatically processed.
3Manufacturing precision
If corrective actions are implemented based on manual inspection results, then manufacturing precision is improved, but loss of time deteriorates due to the entire inspection and correction cycle
Solution Approach 1:
The patent enables continuous machining operations by integrating the optical measurement system directly into the CNC machine. The system performs inspections without requiring workpiece removal or process interruption, allowing machining operations to continue uninterrupted while dimensional compliance is verified in real-time.
Solution Approach 2:
The system implements real-time feedback by continuously monitoring workpiece dimensional parameters during machining, automatically comparing measurements against tolerances, and providing immediate compliance determinations. This enables rapid corrective actions if deviations are detected, maintaining manufacturing precision without time-consuming inspection cycles.
4Measurement precision
If independent CMM inspection is used, then measurement precision is improved, but productivity deteriorates due to the need to remove the component from the machine tool
Solution Approach 1:
The patent merges the optical measurement system directly into the CNC machine tool, combining machining and inspection capabilities in a single integrated system. This eliminates the need for separate independent CMM equipment and workpiece removal, allowing both machining and measurement to occur in the same location without interrupting production flow.
Solution Approach 2:
The CNC machine tool is designed with multi-functionality, serving both as a machining device and an inspection system. The integrated optical measurement system allows the machine to perform both manufacturing and verification functions, eliminating the need for separate specialized inspection equipment and maintaining machining continuity.
Data Source
AI summary
A system and method for manufacturing a component is provided that includes a CNC machine tool (36), a correction module (44), and a system controller (42). The CMM module (40) is controllable to determine a set of multi-axis coordinates surface points on the component. The correction module (44) is in communication with the CMM module (40) and stored reference inspection data. The system controller (42) is in communication with the CNC machine tool (36), the correction module (44), and stored instructions. The instructions when executed cause the system controller (42) to: a) control the CNC machine tool (36) to modify a surface of the component; b) control the CMM module (40) 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 (36) if surface position variances exceed the threshold.