3D Profiling of Complex Composite Pipelines for On-Machine Machining
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Solution Overview
Problem
Existing machining technologies for aerospace composite pipes with complex three-dimensional features, such as variable diameters and non-coincident axes, face challenges in adaptability and accuracy, particularly in capturing the pipeline axis characteristics and spatial posture relationship between the core and covering layer.
Innovation Solution
An on-machine three-dimensional profiling machining device equipped with a linear motion module, precision lifting rod, depth vision system, six-degree-freedom motion platform, and sensors like eddy current and laser displacement sensors, enabling precise measurement and reconstruction of complex pipeline configurations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If traditional machining equipment is used for complex three-dimensional pipelines, then the equipment structure is simple, but the adaptability to complex configurations and measurement precision deteriorate
Solution Approach 1:
The patent integrates multiple functions into a single on-machine measurement and machining system. The device combines three-dimensional surface reconstruction, feature extraction, and machining operations in one integrated system, eliminating the need for separate measurement and machining equipment. This multi-functional approach enables the system to handle various complex pipeline configurations while maintaining equipment compactness.
Solution Approach 2:
The patent introduces an on-machine measurement system as an intermediary between the pipeline and the machining device. This measurement system, including depth vision systems and sensors, captures three-dimensional surface data and feeds it to the control system, which then guides the machining operations. This intermediary measurement and control layer enables precise adaptation to complex configurations without requiring complex mechanical reconfiguration.
2Adaptability or versatility
If robots or large machine tools are used for machining, then the adaptability to complex structures improves, but the space occupation and device complexity worsen
Solution Approach 1:
The patent employs a nested structure where the measurement system and machining tools are integrated within a compact on-machine setup. The depth vision system, sensors, and machining components are arranged in a space-efficient configuration that fits within the machining environment without requiring large external equipment. This nesting approach maintains high adaptability while minimizing space occupation.
Solution Approach 2:
The patent replaces traditional large mechanical machine tools with an on-machine measurement and control system that uses optical sensors, depth vision systems, and computer-controlled machining. This substitution reduces the mechanical complexity and space requirements while maintaining or improving the capability to process complex structural features through precise digital modeling and control.
3Ease of operation
If visual measurement methods are used for three-dimensional reconstruction, then the ease of operation improves, but the manufacturing precision deteriorates
Solution Approach 1:
The patent merges multiple measurement approaches by combining depth vision systems with structured light projection and sensor-based measurement. This hybrid measurement system integrates the simplicity of visual methods with the precision of structured light and tactile sensors, achieving both ease of operation and high manufacturing precision in three-dimensional reconstruction.
Solution Approach 2:
The patent employs parameter changes in the measurement process by adjusting lighting conditions, projection patterns, and sensor parameters to optimize both ease of operation and measurement precision. The system dynamically modifies measurement parameters such as light intensity, projection angle, and sensor sensitivity to achieve accurate three-dimensional reconstruction while maintaining operational simplicity.
4Measurement precision
If multiple separate measurement methods are used for pipeline features, then the measurement completeness improves, but the device complexity and time consumption worsen
Solution Approach 1:
The patent implements a universal on-machine measurement system that performs multiple measurement functions including three-dimensional surface reconstruction, feature extraction, and dimensional measurement using integrated sensors and vision systems. This multi-functional approach achieves complete feature extraction while avoiding the complexity of multiple separate measurement devices.
Solution Approach 2:
The patent combines multiple measurement functions into a single integrated system that simultaneously performs surface scanning, feature detection, and dimensional measurement. By merging these functions into one coordinated system rather than using separate devices, the patent achieves measurement completeness while reducing overall system complexity and coordination requirements.
5Reliability
If traditional multi-step machining processes are used, then the manufacturing reliability improves through multiple checks, but the productivity and time consumption worsen
Solution Approach 1:
The patent performs preliminary three-dimensional surface reconstruction and feature extraction during the initial setup phase, creating a digital model that guides subsequent machining operations. This preliminary action eliminates the need for repeated measurements and secondary clamping, maintaining machining accuracy while improving productivity by streamlining the process into fewer steps.
Solution Approach 2:
The patent implements a feedback loop where the on-machine measurement system continuously monitors the machining process and provides real-time data to the control system. This feedback mechanism ensures machining accuracy without requiring multiple separate inspection steps, thereby maintaining reliability while improving productivity through continuous process optimization.
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
The solution allows for accurate and efficient measurement and machining of large-sized complex composite material pipelines, improving adaptability and reducing secondary clamping errors, enabling high-precision reconstruction of both the pipeline core and covering layer.
Implementation Method 1
equipped with an eddy current sensor and a laser displacement sensor probe
Implementation Method 2
equipped with an eddy current sensor and a laser displacement sensor probe
Data Source
AI summary
The invention belongs to the technical field of aerospace product machinery manufacturing. Disclosed are on-machine three-dimensional profiling machining device for complex-configured composite material pipelines and an application method thereof. The on-machine three-dimensional profiling of the complex-configured composite material pipelines is In the shape machining device, a precision lifting rod is installed on the linear motion module, and a depth vision system is installed on the precision lifting rod; a precision linear motion table and a radial motion module are installed at the left end of the on-machine measurement hollow machining structure, laser displacement sensor probe, and the eddy current sensor probe is installed on the left end of the hollow machining structure for on-machine measurement through mounting bolts. The invention has the advantages of high integration, simple operation, convenience and practicality.