Flexible Part Path Generation Using Inspection Regions
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Solution Overview
Problem
The precise processing of flexible parts, such as aircraft wings, is challenging due to their shape changes under different loads, making conventional CAD models inaccurate and conventional inspection techniques insufficiently accurate and time-intensive.
Innovation Solution
A method and system for generating a processing path by identifying processing locations within inspection regions geometrically associated with the physical profile of the part, allowing for more precise inspection and processing by adapting inspection-region locations based on previous processing locations and using trending functions to account for curvature.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If conventional inspection techniques are used to measure flexible parts, then measurement coverage is achieved, but measurement precision is insufficient and time consumption increases
Solution Approach 1:
The inspection process is segmented into multiple passes, with each pass focusing on a specific inspection region. The system divides the part into discrete inspection regions and processes them sequentially, identifying processing locations within each region to build up the complete physical profile through multiple targeted measurements rather than attempting to measure the entire part at once.
Solution Approach 2:
The system performs preliminary actions by generating a preliminary physical profile from initial inspection data before final processing. It identifies processing locations in advance and generates a preliminary representation of the physical profile, which then guides subsequent inspection and processing operations to achieve the final accurate profile.
2Loss of information
If CAD models are used to represent flexible parts, then design information is available, but the models do not represent the actual flexed shape of the part
Solution Approach 1:
The system creates an accurate copy of the actual physical profile by measuring the part in its flexed state during inspection and processing. Instead of using the idealized CAD model, the system generates a physical profile that copies the real shape of the part as it exists during manufacturing, including all deformations and flexing that occur under operational loads.
Solution Approach 2:
The system changes the reference parameter from the idealized CAD model geometry to the actual measured physical profile. By transitioning from design specifications to measured reality, the system accounts for material properties, support conditions, and load effects that cause the part to deviate from its nominal CAD shape.
3Manufacturing precision
If multiple processing locations are identified to capture physical profile accuracy, then path precision improves, but processing complexity increases
Solution Approach 1:
The system segments the path generation process into discrete steps corresponding to inspection regions and processing locations. By dividing the complex task of generating an accurate path into manageable segments tied to specific inspection regions, the system reduces overall complexity while maintaining precision through systematic accumulation of measurement data.
Solution Approach 2:
The system performs preliminary path generation based on initial inspection data before final processing. It identifies processing locations in advance and generates a preliminary path that can be refined and adjusted based on actual measurements, reducing the complexity of real-time path calculation during processing.
Data Source
AI summary
A method of generating a path for processing a physical profile of a part with a tool is provided. The physical profile has a shape. The method comprises identifying a processing location on the physical profile of the part. The processing location is within an inspection region. The method also comprises identifying an inspection-region location based on the processing location. An inspection region is geometrically associated with the inspection-region location. The method additionally comprises identifying a processing location on the physical profile of the part. The processing location is within the inspection region. The method also comprises generating at least a portion of the path based on the processing location and the processing location.