Flexible Part Processing Using 3D Shape Compensation
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Solution Overview
Problem
The manufacturing of flexible parts is challenging due to their inherent deformation and the need for precise shaping, which requires custom jigs for constraining them, leading to time-consuming and error-prone processing.
Innovation Solution
A system and method for processing flexible parts by holding them securely in an unconstrained position using a holder and an end effector, with a controller guiding the positioner to move relative to the holder based on comparisons between the part's unconstrained shape and design specifications, allowing for accurate processing without the need for custom jigs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If custom jigs are used to constrain flexible parts during processing, then manufacturing precision is improved, but device complexity and preparation time increase
Solution Approach 1:
The system creates a digital copy (3D scan) of the flexible part's actual geometry and uses this virtual model to generate compensated toolpaths. This eliminates the need for physical custom jigs while maintaining processing precision, as the controller adjusts tool positions based on the scanned geometry rather than mechanical constraints.
Solution Approach 2:
The patent replaces the mechanical constraint system (custom jigs and holders) with a computational compensation system. Instead of physically constraining the part to a specific shape, the system scans the part's actual shape and compensates for deviations through software-controlled toolpath adjustments, eliminating complex mechanical fixtures.
2Manufacturing precision
If custom jigs are constructed for each flexible part, then manufacturing precision is improved, but productivity decreases
Solution Approach 1:
The system performs a 3D scan of the flexible part before processing to capture its actual geometry. This preliminary action allows the controller to pre-calculate compensated toolpaths that account for shape deviations, enabling accurate processing without time-consuming jig construction and setup for each part.
Solution Approach 2:
The system dynamically adapts to each part's actual geometry by scanning it and generating customized toolpaths in real-time. This dynamic approach replaces static custom jigs with flexible software-based compensation, allowing the system to efficiently handle part variations without requiring physical reconfiguration for each component.
3Manufacturing precision
If flexible parts are mounted in jigs to maintain specific shape, then manufacturing precision is improved, but time consumption increases
Solution Approach 1:
The system creates a digital representation of the part's actual shape through 3D scanning and uses this copy to calculate compensated toolpaths. This eliminates the time-consuming mounting process required to physically constrain the part, as the controller compensates for shape variations through computational methods rather than mechanical fixation.
4Manufacturing precision
If custom jigs are used for each part, then manufacturing precision is improved, but ease of manufacture worsens
Solution Approach 1:
The patent implements a universal processing system that can handle various flexible parts without requiring custom jigs for each one. The 3D scanning capability and adaptive toolpath generation create a multi-functional system that accommodates different part geometries through software configuration rather than physical retooling, significantly simplifying setup and improving ease of manufacture.
Data Source
AI summary
A system and method for processing a flexible part comprising holding the flexible part securely in an unconstrained position using a holder; and controlling a positioner to process the flexible part based on a comparison of a shape and/or position of the flexible part in the unconstrained position with design specifications of the part not in the unconstrained position.