Digital Twin Sanding Path Correction Using Force Feedback
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Solution Overview
Problem
Current automated finishing systems face challenges in achieving high dimensional accuracy and consistency in processing workpieces due to limitations in initial scan data resolution and compliance prediction, leading to defects and inconsistent material removal rates.
Innovation Solution
The system autonomously captures low-resolution scan data, generates a virtual model, and adjusts the sanding head's toolpath in real-time based on force feedback to maintain target forces and correct positional deviations, transforming the model to align with actual contact points for improved accuracy and compliance handling.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If low-resolution scan data is used to generate a virtual model, then scanning speed and productivity are improved, but measurement precision and manufacturing precision deteriorate
Solution Approach 1:
The system uses force feedback from force sensors during sanding to detect actual contact points and measures the deviation between expected and actual sanding head positions. This feedback is used to update the virtual model and correct the toolpath in real-time, compensating for the low resolution of initial scan data while maintaining high scanning speed
Solution Approach 2:
The system performs preliminary scanning at low resolution to quickly generate an initial virtual model for toolpath generation, then performs preliminary sanding operations to collect force feedback data that will be used to refine the model and correct deviations before final high-precision processing
2Manufacturing precision
If compliance prediction is used to adjust toolpath, then manufacturing precision is improved, but device complexity increases
Solution Approach 1:
Force sensors provide real-time feedback on contact forces between the sanding head and workpiece. This force feedback is used to predict compliance effects and adjust the toolpath accordingly, improving dimensional accuracy without requiring complex predictive models or additional hardware
Solution Approach 2:
The system replaces complex mechanical compliance compensation mechanisms with sensor-based force feedback and computational adjustments to the toolpath, achieving compliance prediction and compensation through software-based solutions rather than mechanical means
3Manufacturing precision
If real-time force feedback is implemented, then manufacturing precision is improved, but use of energy and device complexity increase
Solution Approach 1:
Force sensors provide real-time feedback on contact forces during sanding operations. This feedback enables dynamic adjustment of the toolpath and sanding head position to maintain consistent material removal rates and surface finish quality, improving manufacturing precision through energy-efficient sensor-based control rather than high-power actuation systems
Data Source
AI summary
A method includes: compiling images, captured by an end effector traversing a scan path over a workpiece, into a virtual model of the workpiece; generating a toolpath based on a geometry of the workpiece represented in the virtual model; and assigning a target force to the workpiece. The method also includes, during a processing cycle: navigating a sanding head, arranged on the end effector, across the workpiece according to the toolpath; based on force values output by a force sensor coupled to the sanding head, deviating the sanding head from the toolpath to maintain forces of the sanding head on the workpiece proximal the target force; and tracking a sequence of positions of a reference point on the sanding head, traversing the workpiece, in contact with the workpiece. The method also includes transforming the virtual model into alignment with the sequence of positions of the reference point.