Dynamic Tolerance Adjustment for Multi-Machine Manufacturing Precision
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Solution Overview
Problem
Existing manufacturing systems lack real-time adjustment capabilities for workpiece tolerances and machining times across multiple machines, leading to variations in part dimensions and extended manufacturing times, which increase costs and cannot account for machine wear or actual machining accuracy.
Innovation Solution
A manufacturing adjustment system that includes machines with measuring instruments and a controller capable of real-time measurement and calculation of workpiece dimensions and machining times, allowing for dynamic tolerance setting and operation command adjustments to maintain predetermined ranges, and an administrative computer that learns optimal tolerances based on production data.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If close tolerances are set for all workpieces to reduce part dimension variations, then manufacturing precision is improved, but machining time increases and productivity decreases
Solution Approach 1:
The patent applies local quality by differentiating tolerance requirements among workpieces based on their actual impact on part quality. Instead of uniformly applying close tolerances to all workpieces, the system identifies and applies strict tolerances only to those workpieces that significantly affect part dimensional variations, while allowing looser tolerances for others. This selective approach reduces overall machining time while maintaining part quality within acceptable ranges.
Solution Approach 2:
The patent implements dynamics by enabling real-time adjustment of workpiece tolerances during manufacturing operations. The system continuously monitors actual machining results and dynamically modifies tolerance parameters for subsequent workpieces based on accumulated data and machine status changes such as tool wear. This dynamic tolerance adjustment allows the system to optimize the balance between precision and productivity throughout the manufacturing process rather than relying on static pre-set tolerances.
2Productivity
If tolerances are increased for non-critical workpieces to reduce machining time, then productivity is improved, but part quality control becomes more difficult
Solution Approach 1:
The patent applies feedback by continuously monitoring the dimensional variations of finished parts and using this information to adjust workpiece tolerances in real time. The system collects measurement data from completed parts, analyzes the impact of each workpiece's dimensional variations on the final assembly, and feeds this information back to modify tolerance settings for subsequent workpieces. This closed-loop control ensures that productivity gains from relaxed tolerances do not compromise part quality, as the system automatically compensates by tightening tolerances on critical workpieces when quality drift is detected.
3Manufacturing precision
If predetermined tolerances are set before manufacturing to ensure part quality, then manufacturing precision is maintained, but the system cannot adapt to machine wear or actual machining status
Solution Approach 1:
The patent implements dynamics by transitioning from static pre-set tolerances to dynamic real-time tolerance adjustment. The system continuously adapts tolerance parameters based on actual machining conditions, including machine wear, tool condition, and measured workpiece dimensions. This allows the manufacturing system to maintain precision despite changing conditions, as tolerance settings are automatically updated during production rather than remaining fixed from the beginning.
Solution Approach 2:
The patent applies self-service by enabling the manufacturing system to automatically adjust its own tolerance parameters without external intervention. The system monitors its own performance through measurement data and machine status sensors, then autonomously modifies tolerance settings to compensate for wear and maintain quality standards. This self-adjusting capability eliminates the need for manual tolerance reconfiguration when machine conditions change, improving both adaptability and operational efficiency.
Data Source
AI summary
A manufacturing adjustment system includes a decision part and a tolerance setting part. The decision part decides whether part dimensions calculated by a part dimension calculation part fall within a predetermined range of dimensions and a total machining time calculated by a total machining-time calculation part falls within a predetermined time. The tolerance setting part sets a workpiece tolerance for each machine based on the decision result of the decision part when the workpieces are produced by the machines.