Machine Tool Certification via Part-Specific Working Volume
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Solution Overview
Problem
Complex machine tools with multiple axes, such as 5-axis milling or mill-turn machines, face challenges in predicting and compensating for volumetric errors across their complete working envelope, making traditional certification methods inefficient and time-consuming.
Innovation Solution
A method involving a master part that replicates the geometry of the selected part, which is used to create a machine tool signature by measuring dimensional data within a part-specific working volume, allowing certification and machining within defined tolerances, and enabling real-time monitoring and proactive maintenance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If traditional certification methods are used for complex multi-axis machine tools, then complete working envelope coverage is achieved, but certification time and complexity increase significantly
Solution Approach 1:
The patent segments the complete working envelope into multiple smaller working volumes, each associated with specific parts to be produced. Instead of certifying the entire working envelope at once, the system performs certification for each segmented volume independently, significantly reducing the time and complexity required for each certification while maintaining comprehensive coverage across all working areas.
Solution Approach 2:
The patent applies partial action by certifying only the specific working volume needed for a particular part rather than the complete working envelope. This allows the system to perform minimal necessary certification for each part type, reducing overall certification time while ensuring adequate precision for the specific application.
2Reliability
If complete working envelope certification is performed for complex machine tools, then comprehensive accuracy is ensured, but measurement and prediction complexity increase
Solution Approach 1:
The patent divides the complex certification process into manageable segments by creating separate working volumes for different part types. Each segment can be measured and certified independently using simplified procedures, reducing the overall complexity while maintaining comprehensive accuracy assurance across the complete working envelope.
Solution Approach 2:
The patent applies local quality by tailoring the certification approach to each specific working volume and part type. Instead of using a uniform complex certification process for the entire working envelope, the system adapts the measurement and certification methods to the specific requirements of each local working volume, simplifying the overall process while ensuring appropriate accuracy for each application.
3Productivity
If part-specific working volume certification is used, then certification time is reduced, but measurement scope is limited
Solution Approach 1:
The patent segments the measurement scope into multiple part-specific working volumes, each certified independently. This segmentation allows the system to limit measurements to only the necessary volume for each part type, improving certification efficiency while collectively covering the complete working envelope through multiple segmented certifications.
Solution Approach 2:
The patent creates a universal certification framework that can be applied across multiple part-specific working volumes. The same certification methodology and signature creation process can be reused for different parts and working volumes, improving productivity through method standardization while adapting the measurement scope to each specific application's needs.
Data Source
AI summary
A method for machining a selected part with a machine tool, comprises obtaining a master part replicating at least a portion of a geometry of a selected part. The master part is loaded in a machine tool. A signature of the machine tool is defined by measuring at least dimensional data of the master part relative to the machine tool, the dimensional data being limited to a selected-part-specific working volume substantially smaller than a complete working volume of the machine tool. The machine tool is certified as being within tolerances to machine the selected part within the working volume, using the dimensional data of the signature. The selected part is machined from a workpiece with the machine tool.