CNC Metrology Sensor Synchronization for Continuous Workpiece Mapping
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Solution Overview
Problem
Current CNC machines face challenges in achieving high-fidelity, continuous measurements of workpieces due to the limitations of touch probe technology, which is time-consuming and limited in feature size resolution, and struggles with synchronizing metrology instruments with the position and motion of precision production equipment, leading to inaccuracies and inefficiencies in characterizing complex shapes and verifying workpiece dimensions.
Innovation Solution
Implementing a system that converts metrology device measurements into formats readable by CNC machines, synchronizing these measurements with machine tool axes, and applying spatial corrections to account for temporal delays, enabling continuous data logging and post-processing to ensure accurate workpiece characterization and verification.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If touch probe technology is used for measurement, then discrete point measurements can be obtained, but the measurement process is time-consuming and productivity is reduced
Solution Approach 1:
The patent replaces mechanical touch probe measurement systems with optical measurement systems. The optical sensor captures workpiece surface information non-contactly at high speed without requiring physical contact or machine pausing, thereby maintaining measurement precision while dramatically improving productivity by eliminating the time-consuming discrete point-by-point measurement process.
Solution Approach 2:
The patent enables continuous measurement during machine operation by using optical sensors that can capture workpiece data without interrupting the machining process. The measurement system operates continuously alongside production, allowing simultaneous machining and measurement, thus eliminating the productivity loss associated with pausing for discrete measurements.
2Measurement precision
If touch probe measurements are taken at discrete points, then dimensional verification is possible, but the minimum feature size resolution is limited
Solution Approach 1:
The patent replaces the mechanical touch probe with an optical measurement system that uses light to detect workpiece features. This optical approach eliminates the physical limitations of probe tip size, enabling detection of much smaller features and finer surface details while maintaining dimensional verification capability through non-contact optical sensing.
3Measurement precision
If metrology instruments are synchronized with CNC machine position and motion, then accurate workpiece characterization is achieved, but system complexity increases
Solution Approach 1:
The patent merges the metrology measurement system with the CNC machine control system by integrating the optical sensor into the machine tool and synchronizing their operations. This combination allows the measurement system to automatically correlate optical data with precise machine position and motion information, achieving accurate workpiece characterization while managing complexity through integrated design rather than separate synchronized systems.
4Measurement precision
If continuous measurement data logging is implemented, then complete workpiece surface characterization is achieved, but data processing complexity increases
Solution Approach 1:
The patent applies preliminary spatial corrections to the continuous measurement data based on known temporal delays in the measurement system. By pre-compensating for these delays using the recorded CNC machine position and motion data, the system achieves complete surface characterization while simplifying subsequent data processing, as the corrections are applied automatically during data acquisition rather than requiring complex post-processing algorithms.
Data Source
AI summary
Systems, apparatuses and methods are described for integrating an electronic metrology sensor with precision production equipment such as computer numerically controlled (CNC) machines. For example, a laser distance measuring sensor is used. Measurements are taken at a relatively high sample rate and converted into a format compatible with other data generated or accepted by the CNC machine. Measurements from the sensor are synchronized with the position of the arm of the machine such as through the use of offsets. Processing yields a detailed and highly accurate three-dimensional map of a workpiece in the machine. Applicable metrology instruments include other near continuously reading non-destructive characterization instruments such as contact and non-contact dimensional, eddy current, ultra-sound, and X-Ray Fluorescence (XRF) sensors.