In-Process Digital Twin Creation From In Situ Part Inspection
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Solution Overview
Problem
Conventional manufacturing systems face challenges in efficiently collecting as-built metrology data for every manufactured part, as the process is time-consuming and costly, often resulting in incomplete inspection data and inaccuracies due to manual handling and differing coordinate systems for machining and inspection data.
Innovation Solution
Implementing an in-process inspection and digital twinning approach within manufacturing systems, where metrology sensors attached to the machining tool perform inspections in situ, allowing for the collection of part-specific data in the same coordinate system as machining, creating an as-built digital twin for each part.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If manual inspection processes are used with separate inspection stations, then inspection data can be collected, but the process becomes time-consuming and costly
Solution Approach 1:
The patent combines the inspection system with the manufacturing system by integrating sensors directly into the machining tool, allowing inspection to occur in the same work cell and coordinate system as manufacturing, eliminating separate inspection stations and manual handling
Solution Approach 2:
The machining tool is equipped with both manufacturing capability and inspection capability through integrated sensors, allowing the same tool to perform both material removal and measurement functions, reducing the need for separate specialized equipment
2Productivity
If in-process inspection is implemented with sensors attached to the machining tool, then inspection speed and accuracy improve, but device complexity increases
Solution Approach 1:
The machining tool is enhanced with integrated sensors to perform both manufacturing and inspection functions, creating a multi-functional system that improves productivity while managing complexity through consolidation rather than addition of separate systems
3Adaptability or versatility
If separate coordinate systems are used for machining and inspection data, then each system can operate independently, but data alignment and accuracy suffer
Solution Approach 1:
The patent merges the coordinate systems by performing both manufacturing and inspection operations in the same work cell using the same tool and sensors, ensuring all data is collected in a single unified coordinate system and eliminating the need for complex data alignment transformations
Data Source
AI summary
A manufacturing control system for an additive, subtractive, or hybrid machining system implements in situ part inspection to collect as-built metrology data for a manufactured part while the part remains in the work envelop, and uses the resulting measured inspection data to generate an as-built digital twin that accurately models the finished part. After execution of a subtractive and/or additive tooling operation, the system performs a sensor scan to collect three-dimensional imaging measurement data for the resulting manufactured part while the part remains in the work cell. The measurement data is then integrated with as-designed part metadata for the idealized part to yield the as-built digital twin. Since metrology measurements are integrated into the manufacturing process, customized as-built digital twins can be generated for each manufactured part without requiring manual inspections to be performed on each part.