Digital Twin Parameter Adaptation for Tooling Machine Accuracy
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Solution Overview
Problem
Manufacturing processes often deviate from desired outcomes due to environmental influences that conventional control algorithms cannot compensate, limiting the ability to independently compensate errors without relying on production models.
Innovation Solution
A fully automatic method that uses a digital twin of a tooling machine to simulate and adapt process parameters by measuring geometric features of output work pieces, allowing for the emulation of measurement results to minimize deviations from nominal data, thereby improving manufacturing process accuracy.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional control algorithms are used to manage manufacturing processes, then the control system remains simple and easy to operate, but the system cannot compensate for slow environmental changes and deviations from target state
Solution Approach 1:
The patent creates a digital twin (virtual copy) of the physical manufacturing system including the tooling machine, workpiece, and measurement system. This digital replica allows for simulation and analysis of manufacturing processes without modifying the physical system, enabling complex error compensation while keeping the physical control system relatively simple. The digital model captures geometric data, process parameters, and measurement results to simulate and predict manufacturing outcomes.
Solution Approach 2:
The patent performs preliminary digital simulation and error analysis before actual manufacturing operations. By using the digital twin to predict deviations and test compensation strategies in advance, the system can pre-calculate correction values and adjust process parameters before production, avoiding the need for complex real-time control algorithms during manufacturing.
2Manufacturing precision
If production models are used for error compensation as disclosed in EP 3 045 992 B1, then error compensation is achieved, but the approach is limited by dependence on the production model and cannot provide model-independent compensation
Solution Approach 1:
The patent implements a closed-loop feedback system where measurement results from the coordinate measuring machine are fed back into the digital twin. The system compares measured geometric data with nominal values, identifies deviations, and automatically adjusts process parameters in the digital model. This feedback mechanism enables the system to adapt to actual manufacturing variations without being constrained by the initial production model assumptions.
Solution Approach 2:
The patent transforms the static production model into a dynamic digital twin that can be continuously updated and adapted. The system allows for modification of process parameters, material properties, and geometric data in the digital model based on actual measurement results. This dynamic approach enables the system to evolve and adapt to changing conditions, providing versatility beyond the limitations of a fixed production model.
3Productivity
If manual parameter adjustment is used to correct manufacturing deviations, then the process remains simple to understand, but the method is time-consuming and not fully automatic
Solution Approach 1:
The patent implements a self-service system where the digital twin automatically performs parameter adaptation without requiring manual intervention. The system autonomously imports measurement results, executes simulations, analyzes deviations, calculates correction values, and generates adapted process parameters. This automated workflow eliminates the need for manual parameter adjustment while maintaining system intelligibility through the structured digital model.
4Manufacturing precision
If environmental influences are not compensated, then the manufacturing process remains stable and simple to control, but output work pieces deviate from desired target state
Solution Approach 1:
The patent introduces the digital twin as an intermediary between the physical manufacturing process and the control system. This virtual model acts as a mediator that captures environmental influences and their effects on the manufacturing process, allowing for analysis and compensation without directly interfering with the physical system's stability. The digital twin simulates environmental effects and enables prediction of deviations, facilitating corrective actions while maintaining process stability.
Data Source
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AI summary
Method for automatically adapting at least one adaptable process parameter of a tooling machine such as a milling and/or turning tool, the tooling machine being part of a first or second manufacturing process for physically processing input work pieces into output work pieces. According to the method, at least one geometric feature of an output work piece is measured by a coordinate measuring machine, the geometric feature being a direct or indirect result of the processing with the tool. The measurement result is together with nominal measurement data of the geometric feature fed into a deterministic digital simulation of at least a part of the manufacturing process with a digital model such as a digital twin of the tooling machine and modelled process parameters, therein the adaptable process parameter of the tooling machine, simulating at least a deterministic behavior of the tooling machine relevant for an operation of its tool. The simulation is executed with varying of at least one of the modelled process parameters with the objective to emulate the measurement result. From the simulation with thus adapted modelled process parameters and based on nominal geometric data of the feature an adapted value for the adaptable process parameter is derived which enables an adapted operation of the tooling machine with respect to its tool resulting in a reduced difference between real and nominal geometric data of the feature.