In-Machine 3D Scanning for Unknown Workpiece Geometry Machining
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Solution Overview
Problem
The existing methods for machining workpieces with unknown geometry in machine tools are complex, imprecise, and require multiple data processing steps across different systems, involving re-clamping and data transfer, which increases effort and reduces precision.
Innovation Solution
A method that involves a hand-held 3D line scan with a measuring probe to create a first data set, followed by data preparation to generate a rough component geometry, which is then used for automatic 3D line scanning to obtain an exact geometry, allowing for automated processing without re-clamping or data transfer between systems.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If workpiece geometry is captured on an external 3D measuring machine and data is transferred to the machine tool, then the workpiece geometry can be measured, but the process becomes complex and requires multiple data processing steps on different systems
Solution Approach 1:
The patent combines the 3D measuring machine and machine tool into a single integrated system. The measuring probe is directly mounted on the machine tool, allowing measurement and machining to occur on the same device. This eliminates the need for external measuring machines and complex data transfer processes between different systems, directly resolving the contradiction between achieving accurate geometry measurement and avoiding process complexity.
Solution Approach 2:
The machine tool is designed to perform multiple functions: it can both measure workpiece geometry using an integrated measuring probe and execute machining operations. This multi-functionality eliminates the need for separate external measuring equipment and simplifies the overall process by consolidating measurement and machining capabilities into a single universal device.
2Ease of manufacture
If the workpiece is re-clamped for machining after measurement, then the workpiece can be processed, but the position changes and precision is reduced
Solution Approach 1:
By integrating the measuring probe directly on the machine tool, the workpiece remains clamped in the same position for both measurement and machining operations. The measuring probe accesses the workpiece from the machine tool's moving axes without requiring workpiece repositioning or re-clamping, thereby maintaining position accuracy and eliminating the precision loss associated with re-clamping.
Solution Approach 2:
The measuring probe acts as an intermediary that can access the workpiece geometry without requiring the workpiece to be moved or re-clamped. The probe is mounted on the machine tool's moving components and can reach the workpiece from various positions, enabling measurement and subsequent machining to occur on the same clamped workpiece, thus preserving position accuracy.
3Measurement precision
If manual 3D line scan is performed with a measuring probe, then the workpiece geometry can be captured, but the process requires high personnel qualification and more time
Solution Approach 1:
The system performs preliminary automated actions to prepare for the manual measurement process. The control device automatically generates scan paths based on the workpiece geometry and guides the measuring probe through the necessary measurement trajectories. This preliminary automation reduces the skill requirement for operators and accelerates the measurement process by eliminating the need for manual path planning and complex manual operations.
Solution Approach 2:
The control device provides real-time feedback during the manual 3D line scan process. It automatically processes the measured data, generates 3D CAD surfaces, and creates machining paths based on the captured geometry. This feedback mechanism automates the complex data processing steps that would otherwise require highly qualified personnel, thereby improving productivity while maintaining measurement precision.
4Adaptability or versatility
If data is transferred between different systems and software environments, then measurement data can be used for machining, but compatibility conversion is required and time is lost
Solution Approach 1:
By integrating the measuring probe and control device into a single machine tool system, the patent eliminates the need for data transfer between separate measuring machines and machine tools. The measurement data is captured and processed within the same system that performs machining, removing the compatibility conversion steps and associated time losses that occur when transferring data between different software environments.
Solution Approach 2:
The control device automatically processes the measurement data captured by the integrated measuring probe. It performs 3D CAD surface generation, creates machining paths, and prepares the data for machining operations without requiring external data transfer or compatibility conversion. This self-service capability eliminates the time-consuming data exchange processes between different systems.
Data Source
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AI summary
Provided is a method for machining workpieces with unknown workpiece geometry using a machine tool, comprising the steps of: clamping (10) the workpiece on a clamping device of the machine tool, performing (20) a hand-held 3D line scan with a touch probe inside the machine tool to capture the workpiece geometry in a first data set, processing (30) the first data set to compensate for errors of the hand-held 3D line scan in order to obtain a second data set, using the second data set for 3D CAD surface generation to create (40) a rough component geometry, using the rough component geometry to generate (60) scan paths for an automatic 3D line scan, and performing (70) an automatic 3D line scan of the workpiece with the touch probe inside the machine tool to obtain a third data set.Using the third data set for 3D CAD surface generation to generate (40) an accurate component geometry, and automated machining (80) of the workpiece by the machine tool based on the accurate component geometry and a machine tool to carry out the process.