Machine Path Correction for Tight-Tolerance Large-Structure Assembly
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Solution Overview
Problem
Conventional systems for manufacturing large structures, such as wind turbine blades, face challenges in achieving precise tolerances due to the need for expensive and complex CNC machines, leading to high operational costs and skilled labor requirements, as well as inefficiencies in adhesive usage and bond control.
Innovation Solution
A control system comprising a target path correction unit and a position correction unit that modifies and corrects the real-time operating position of machines based on sensed parameters, eliminating the need for highly skilled operators and reducing costs by semi-automating the correction process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If CNC machines are used for high precision finishing operations, then manufacturing precision is improved, but device complexity and operational cost increase
Solution Approach 1:
The system continuously measures the actual position of the operating tool using sensors (laser trackers, encoders) and compares it with the target path, then automatically calculates and applies corrections in real-time to maintain precision without requiring complex CNC machinery
Solution Approach 2:
The patent replaces complex mechanical CNC control systems with a combination of sensors, processors, and actuators that use electronic feedback loops to achieve the same positioning precision, thereby reducing mechanical complexity while maintaining manufacturing accuracy
2Manufacturing precision
If CNC machines are used for high precision finishing operations, then manufacturing precision is improved, but operational cost increases
Solution Approach 1:
By implementing real-time feedback control with sensors and processors, the system achieves high precision finishing operations using simpler, less expensive equipment, thereby reducing operational costs while maintaining manufacturing quality standards
Solution Approach 2:
The system performs automatic self-correction of positioning errors through its feedback mechanism, eliminating the need for highly skilled operators and reducing labor costs associated with complex CNC machine operation and monitoring
3Manufacturing precision
If adhesive thickness is reduced to achieve tight tolerances, then manufacturing precision is improved, but adhesive strength decreases
Solution Approach 1:
The real-time position correction system ensures that components are positioned with high precision during assembly, allowing for consistent, optimal adhesive thickness control that maximizes bond strength while meeting tolerance requirements, eliminating the trade-off between thickness and precision
4Manufacturing precision
If expensive high-performance adhesives are used to achieve tight tolerances, then manufacturing precision is improved, but operational cost increases
Solution Approach 1:
The precision positioning and correction system enables the use of standard, cost-effective adhesives by ensuring that bond line thickness and alignment are tightly controlled through automated feedback control, eliminating the need for expensive specialty adhesives
Data Source
AI summary
Embodiments of present disclosure relates to efficient control system and method for controlling operation of at least one machine in an industrial environment. The control system comprises a target path correction unit and a position correction unit. The target path correction unit is configured to modify a target path fed to the at least one machine, based on real-time spatial position of the at least one machine. The position correction unit is configured to correct real-time operating position of the at least one machine. The position correction unit corrects the real-time operating position by sensing one or more parameters related to the at least one machine and displacing operating tool of the at least one machine, based on the one or more parameters. The control system achieves tight tolerance in manufacturing of large structures inexpensively and eliminates the need of high skilled operator to operate the machine.