Hole Location Correction Using Scanned Part Geometry
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Solution Overview
Problem
Current methods for drilling holes in parts prior to assembly are time-consuming and prone to inaccuracies due to variations in actual surface shapes and hole locations, leading to difficulties in assembling machined parts efficiently and consistently.
Innovation Solution
A computer-implemented method and apparatus that acquires sensor data for actual machined configurations of parts, computes offset data to adjust nominal hole locations based on actual surface shapes and hole positions, and generates a hole location file for a computer numerical control device to drill accurate holes in a third part for assembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If holes are drilled based on nominal locations without accounting for actual part variations, then the drilling process is simple and fast, but the hole location accuracy deteriorates
Solution Approach 1:
The system performs preliminary scanning and measurement of actual part geometries before hole drilling. Sensor data is collected and processed to determine actual surface shapes and existing hole locations, which are then used to calculate corrected hole locations. This preliminary action ensures accurate hole placement while maintaining process efficiency through automated computation.
Solution Approach 2:
The system uses feedback from actual part measurements to adjust hole drilling locations. The scanning device captures real-world variations in part geometries and hole positions, and this information is fed back into the hole location calculation process to compensate for manufacturing tolerances and ensure precise alignment during assembly.
2Manufacturing precision
If actual part variations are measured and accounted for, then hole location accuracy improves, but the time required for the drilling process increases
Solution Approach 1:
The system replaces manual measurement and calculation methods with automated optical scanning and computer-based processing. The scanning device rapidly captures part geometries, and software automatically processes the data to determine corrected hole locations, significantly reducing the time required compared to traditional manual methods while maintaining high accuracy.
Solution Approach 2:
The system changes the parameters used for hole location determination from fixed nominal values to dynamically calculated values based on actual part measurements. This allows the hole locations to adapt to real-world variations while the automated computation keeps the process time minimal.
3Reliability
If nominal hole locations are used without adjustment, then the assembly process is straightforward, but assembly accuracy and fit quality deteriorate
Solution Approach 1:
The system creates a digital copy or model of the actual part geometries through scanning. This virtual representation is then used to calculate corrected hole locations without requiring physical trial-and-error or complex mechanical fixtures. The digital model accurately reflects real-world variations and enables precise hole placement through computational geometry.
Data Source
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AI summary
A method and apparatus for machining a part for an assembly (100, 202, 400). First sensor data (226) is acquired for a surface (203, 506) of a first part (101, 204) from a first sensor system (222). Second sensor data (228) is acquired for a set of existing holes (232) in a second part (102, 206) from a second sensor system (224). A surface model (238) of the surface of the first part (101, 204) is generated using the first sensor data (226). First offset data (240) is computed based on a nominal model (242) of a third part (104, 208) that is nominally positioned relative to the surface model (238) within a three-dimensional virtual environment (245). Second offset data (241) is computed (708) for the set of existing holes (232) using the second sensor data (228). Overall offset data (246) is generated (710) using the first and second offset data (241), wherein the overall offset data (246) is used to drill a set of holes (214) in the third part (104, 208) for use in fastening the third part (104, 208) to the second part (102, 206).