Machine Tool Probing With Virtual Contact Point Guidance
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Solution Overview
Problem
Existing methods for aligning a workpiece's coordinate system with a machine tool's coordinate system are time-consuming and require significant operator expertise, especially when clamping devices are involved, and often fail due to local damage or the need for extensive data generation and storage.
Innovation Solution
A method that uses 3D models of the workspace, workpiece, and probe displayed on a numerical control screen, allowing operators to intuitively align and calibrate the workpiece and clamping device by manually positioning a probe, with automated selection of contact points and quality feedback, reducing the need for special knowledge and computational effort.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If traditional probing methods are used to determine workpiece position, then measurement precision can be achieved, but the process becomes time-consuming and requires significant operator expertise
Solution Approach 1:
The system pre-calculates and stores ideal probing points and probing vectors in the workpiece model before measurement begins. During actual calibration, the control system automatically retrieves and uses these pre-defined probing parameters, eliminating the need for operators to manually select points and calculate vectors, thus reducing calibration time while maintaining precision
Solution Approach 2:
The system provides visual feedback by displaying the virtual probe, virtual workpiece, and probing vectors on the screen. This allows operators to monitor the calibration process in real-time and verify that probing is occurring at the correct locations, ensuring measurement precision without requiring extensive operator expertise
2Measurement precision
If traditional probing methods are used, then position alignment can be achieved, but operator expertise and special knowledge are required
Solution Approach 1:
The control system automatically performs the complex calculations and coordinate transformations needed for alignment. The system self-adjusts the workpiece coordinate system based on the probing results without requiring operators to manually compute transformation matrices or understand complex kinematics, making the process accessible to operators with basic training
Solution Approach 2:
A virtual workpiece model serves as an intermediary between the physical workpiece and the control system. This virtual model contains pre-defined probing parameters and facilitates automatic calculation of probing vectors, acting as a mediator that eliminates the need for operators to directly handle complex mathematical computations
3Measurement precision
If extensive probing data is collected to ensure accurate alignment, then measurement accuracy improves, but computational effort and data storage requirements increase
Solution Approach 1:
The system extracts only the essential probing parameters (ideal probing points and vectors) from the complete workpiece model before measurement begins. During calibration, only these extracted parameters are used for calculations, avoiding the need to process the entire workpiece geometry and significantly reducing computational complexity while maintaining alignment accuracy
Data Source
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AI summary
A method for measuring a workpiece in a machine tool is disclosed. This method assists an operator (B) of a machine tool (WM) in measuring a workpiece (WS) and/or a clamping device in the work area (A) of the machine tool using a probe (T) such that the model of the work area displayed on a screen (B) of a numerical control (NC) corresponds sufficiently well to reality. For this purpose, the operator (B) can move the probe (T) freely around the workpiece (WS) and, based on the distance of the virtual probe to the virtual workpiece, automatically receives planned probing points (AP) and a probing direction (AR), along with quality information. If the quality is sufficient, the operator (B) can trigger a probing operation and the measurement of the workpiece by pressing a button.