In-Process Digital Twin Creation Using In-Situ Part Metrology
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Solution Overview
Problem
Conventional manufacturing systems face inefficiencies in collecting as-built metrology data due to the manual and time-consuming nature of part inspections, which often require parts to be removed from the work envelope, leading to incomplete data collection and inaccuracies in aligning inspection data with the manufacturing coordinate system.
Innovation Solution
Implementing in-process inspection and digital twinning by integrating metrology sensors with the machining tool's operating arm to collect inspection data within the work envelope, allowing for the creation of part-specific digital twins that accurately model the finished part's geometry and behavior.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If manual inspection methods are used with parts removed from the work envelope, then inspection can be performed with standard equipment, but inspection time increases and data alignment accuracy deteriorates
Solution Approach 1:
The patent combines the manufacturing process and inspection process into a single integrated system. The metrology sensors are mounted on the machining tool's operating arm, allowing inspection to occur within the work envelope during or immediately after machining operations, eliminating the need to remove parts to separate inspection stations and enabling automatic coordinate system alignment
Solution Approach 2:
The patent introduces metrology sensors as an intermediary component mounted on the operating arm between the machining tool and the workpiece. These sensors capture inspection data directly at the machining location, serving as a bridge that enables in-situ measurement without requiring part removal or complex coordinate transformations
2Extent of automation
If in-process inspection with integrated sensors is implemented, then inspection automation and data accuracy improve, but system complexity increases
Solution Approach 1:
The operating arm is designed to serve multiple functions: it holds and positions the machining tool for manufacturing operations, and simultaneously serves as a mounting structure for metrology sensors to perform inspection functions. This multi-functionality reduces the need for separate inspection equipment and simplifies the overall system architecture
Solution Approach 2:
The system performs self-inspection by using its own operating arm and integrated metrology sensors to automatically measure and inspect the workpiece immediately after machining. The manufacturing system inspects itself without requiring external inspection equipment or manual intervention, enabling automated data collection and digital twin creation
3Loss of information
If complete in-process inspection data collection is implemented, then digital twin accuracy improves, but inspection cost increases
Solution Approach 1:
The patent performs inspection actions during or immediately after the machining process, before the part is removed from the work envelope. This preliminary inspection captures complete as-built metrology data while the part is still in position, eliminating the need for subsequent manual inspection operations and reducing overall inspection costs through automated in-situ measurement
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.