Machine Positioning Feedback Using External Sensor Fusion
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Solution Overview
Problem
Conventional machining systems face challenges with positional accuracy over time due to drift and mechanical limitations, requiring frequent recalibration and replacement of tracking devices, which is costly and disruptive.
Innovation Solution
A real-time enhanced positioning system utilizing multiple sensors such as inertial measurement units, laser trackers, and cameras to provide continuous precision metrology data, allowing for synchronized and fused data streams to correct positional errors within a feedback loop, enabling precise positional adjustments without interrupting machine operation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If conventional tracking devices are used in machining systems, then the machine can perform positioning operations, but the precision drifts over time and requires frequent recalibration
Solution Approach 1:
The patent replaces conventional mechanical tracking devices with a laser-based optical measurement system. The laser tracker provides non-contact measurement that does not suffer from the same drift and wear issues as mechanical systems, thereby maintaining positioning precision without frequent recalibration.
Solution Approach 2:
The patent introduces a laser tracker as an intermediary measurement device that independently verifies the position of machine components. This external reference system serves as a mediator between the machine's internal positioning system and the actual physical position, enabling detection and correction of drift without interrupting machine operation.
2Measurement precision
If recalibration is performed to correct positioning drift, then precision is improved, but machine operation must be interrupted
Solution Approach 1:
The patent enables continuous measurement and correction of positioning errors while the machine remains operational. The laser tracker continuously monitors the position of measurement targets on the machine, and corrections are applied in real-time without interrupting the machining process, thereby maintaining both precision and productivity.
Solution Approach 2:
The patent implements a feedback loop where the laser tracker continuously measures actual positions, compares them with commanded positions, and provides correction data back to the machine control system. This real-time feedback enables continuous correction of positioning errors without requiring periodic recalibration interruptions.
3Measurement precision
If integrated tracking devices are used to maintain precision, then positioning accuracy is improved, but equipment replacement costs increase over time
Solution Approach 1:
The patent uses an external laser tracker as an intermediary measurement device rather than relying solely on integrated tracking devices that become obsolete. This separate, high-precision laser measurement system can be used indefinitely to verify and correct positions, eliminating the need to replace aging integrated trackers and reducing long-term equipment costs.
Data Source
AI summary
Systems and methods for machine positioning are provided herein. Exemplary embodiments include systems and methods using external positional information of an object under observation to compare to a programmed position of the object under observation. The comparison may be used in different manners including, for example, course correction, future path planning, object avoidance, etc.