CNC Workpiece Optical Scanning for Precision Machining Alignment
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Solution Overview
Problem
CNC machine tools face inefficiencies in mechanical probing, as precision is lost when workpieces are moved between machines, requiring lengthy adjustments and increased cycle times due to high tolerances and deformation in materials like aluminum alloys.
Innovation Solution
An optical scanning method is employed to determine machining coordinates in a reference system integral with the machine frame, allowing for precise machining by adapting to workpiece and fixturing tolerances, using digital data from cameras or laser beams to generate machining coordinates for actuators, enabling accurate machining regardless of tolerance magnitude.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If mechanical probing is used to detect workpiece geometry, then machining precision can be achieved, but cycle time increases significantly and precision is lost when workpiece is moved between machines
Solution Approach 1:
The patent replaces the mechanical probing system with an optical scanning system. A camera captures images of the workpiece, and image processing algorithms automatically determine the coordinates of geometric features. This substitution eliminates the time-consuming mechanical contact probing while maintaining or improving measurement precision, and the digital coordinates can be universally applied across different machines without loss of precision.
Solution Approach 2:
The patent creates a digital copy of the workpiece geometry through optical scanning and image processing. Instead of physically probing the workpiece, the system captures visual information and processes it to generate precise coordinate data. This digital representation can be stored and reused across different machining operations and machines, eliminating the need to repeat probing each time.
2Manufacturing precision
If manual intervention is used to program machining coordinates on each workpiece, then precision can be adapted to geometry, but productivity decreases due to lengthy programming time
Solution Approach 1:
The system enables the workpiece to essentially program itself. The optical scanning system automatically captures the workpiece geometry, and the image processing software automatically extracts coordinates and generates machining data without requiring manual measurement or programming by an operator. This self-service approach maintains precision adaptation while dramatically reducing the time and labor required.
Solution Approach 2:
The patent transforms the workpiece from a passive object requiring manual programming into an active source of machining data. By changing the parameter measurement method from mechanical contact to optical imaging, and from manual recording to automated image processing, the system automatically adapts to each workpiece's unique geometry without manual intervention, thereby improving productivity while maintaining precision.
3Adaptability or versatility
If workpiece is moved to another machine or machining center, then different machining operations can be performed, but precision acquired with previous probing is lost
Solution Approach 1:
The patent creates a universal digital copy of the workpiece geometry through optical scanning. The coordinates extracted from image processing are reference-free and can be transferred to any machining center without loss of precision. This digital representation serves as a universal interface that maintains precision across different machines, eliminating the problem of precision loss when moving workpieces between machines.
Solution Approach 2:
The optical scanning system provides a universal measurement approach that works across different machine types and locations. The digital coordinates generated are machine-independent and can be used on any CNC machine or machining center, making the system universally applicable while maintaining precision. This universality allows the workpiece to be processed on different machines without sacrificing the precision established during scanning.
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 method significantly reduces cycle times and manual intervention by ensuring precise machining operations, maintaining accuracy across different machining stations and materials prone to deformation, such as aluminum alloys, by integrating scanning and machining processes within a unified reference system.
Implementation Method 1
an optical scan is made of a geometry present in a portion of the workpiece
Implementation Method 2
In step B the optical scanning is preferably done by means of a digital camera or a laser beam
Data Source
AI summary
A method is described of machining a workpiece which is clamped in a fixturing element and is processed by a tool movably mounted on a CNC machine tool.The fixturing element is integrally constrained to a frame of the CNC machine tool, then an optical scan of a geometry present in a portion of the workpiece is carried out. From digital data obtained during the optical scan, a coordinate of the geometry is determined in a reference system integral with the frame; and digital data, in particular coordinates, relating to a predetermined sequence of machining operations are processed to generate machining coordinates in the reference system integral with the frame for an actuator of the tool, said machining coordinates being such that the tool applies the pre-established sequence of machining operations on the workpiece at said coordinate.