Instrumented Machine Tool Table Setup for Real-Time Seating Detection
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Solution Overview
Problem
Current machine tool table setups and inspections are inefficient, leading to the production of both good and bad parts due to difficulties in detecting seating failures and lack of real-time communication between designers and machinists, resulting in inaccurate part manufacturing and limited integration of CAD, CAM, and CAS systems.
Innovation Solution
A computer system and method for near real-time data sharing and feedback between designers and machinists using instrumented machine tool tables, enabling interactive access and integration of CAS data, eliminating the need for tool presetters, ballbar testers, and CMM-based final inspections, and allowing for in-situ inspections and adjustments during setup and fabrication.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If traditional separate CAD-CAM systems are used with manual setup procedures, then device complexity is reduced, but manufacturing precision deteriorates due to seating failures and lack of real-time communication
Solution Approach 1:
The patent merges CAD, CAM, and CAS systems into an integrated platform where design data flows seamlessly to manufacturing systems. The common data environment allows real-time communication between designers and machinists, eliminating the traditional siloed approach and enabling coordinated decision-making that improves part accuracy while managing system complexity through unified architecture.
Solution Approach 2:
The instrumented machine tool table serves multiple functions: it acts as both the manufacturing workspace and a data collection platform with embedded sensors that monitor positioning, temperature, and vibration. This multi-functional approach consolidates what would otherwise require separate inspection equipment, improving precision through real-time feedback while reducing overall system complexity.
2Measurement precision
If traditional manual inspection methods are used, then device complexity is reduced, but measurement precision deteriorates due to inability to detect small seating failures
Solution Approach 1:
The patent replaces manual visual inspection and traditional mechanical measurement methods with electronic sensors and digital data processing. Instrumented machine tool tables incorporate transducers, strain gauges, and position sensors that automatically detect seating failures and positioning errors, providing measurement precision far beyond human capability while the data is processed through computer systems that eliminate subjective judgment.
Solution Approach 2:
The system creates digital copies of physical measurements through sensor data and generates virtual models of the workpiece and tool positions. These digital representations allow for precise comparison against design specifications and enable detection of minute deviations that would be imperceptible in physical inspection, significantly improving measurement precision.
3Loss of time
If traditional batch inspection with CMM is used, then device complexity is reduced, but loss of time increases due to delayed detection of manufacturing errors
Solution Approach 1:
The patent implements continuous monitoring during the manufacturing process itself, rather than interrupting production for batch inspection. Sensors on the instrumented machine tool table continuously measure workpiece dimensions, tool positions, and machine health parameters in real-time, allowing immediate detection of errors and continuous correction, thereby eliminating the time loss associated with post-processing inspection while the manufacturing action continues uninterrupted.
Solution Approach 2:
The system performs preliminary inspections and measurements during the setup and machining processes themselves, before final completion. By detecting potential errors early in the process, the system allows for immediate corrective action before defective parts are fully manufactured, significantly reducing the time loss that would occur with delayed detection and enabling preventive rather than reactive manufacturing.
4Reliability
If designers work in isolation without real-time data, then ease of operation is improved, but reliability deteriorates due to inability to make informed adjustments during setup
Solution Approach 1:
The patent establishes bidirectional feedback loops between designers and machinists through the integrated CAD-CAM-CAS system. Designers receive real-time feedback from sensors on the machine tool table about actual workpiece dimensions, tool wear, and positioning accuracy, allowing them to validate designs against actual manufacturing conditions. Machinists receive feedback from designers about design intent and specifications, enabling informed adjustments during setup while maintaining design reliability.
Data Source
AI summary
A computer system and method for the assisted setup of an instrumented computer-controlled machine tool table, which in principle manufactures only good parts, is disclosed. The invention allows a plurality of users, such as machinists, designers, administrators, and showroom operators, to access and share data related to computer-assisted setup (CAS) of an instrumented computer-controlled machine tool table in a manner that is interactive in real time and internal to the CAS infrastructure architecture.