Machine Tool Sensor Calibration for Inferred Workpiece Measurement
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Solution Overview
Problem
Current methods for obtaining calibration information for sensors monitoring machine tools and workpieces are limited in their ability to infer measurement data about a workpiece from sensor data collected during machining, especially for difficult-to-reach features and series production of nominally identical parts, leading to inefficiencies and increased production cycles.
Innovation Solution
A method that calculates sensor-to-workpiece data calibration information by correlating measurement data from a dedicated probe with sensor data collected during machining, allowing for the inference of workpiece information from subsequent machining operations without direct measurement, thereby reducing production cycles and enabling accurate measurement of hard-to-reach features.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If direct measurement of workpiece features is performed using dedicated measurement probes, then measurement accuracy is improved, but production cycle time increases
Solution Approach 1:
The patent creates a calibration model that copies the relationship between sensor data and workpiece measurement data. Instead of directly measuring each workpiece feature, the system uses sensor data collected during machining, calibrated against actual measurements from a reference workpiece, to infer measurement data for subsequent workpieces. This copying approach eliminates the need for direct measurement of each feature while maintaining accuracy.
Solution Approach 2:
The patent performs preliminary calibration by measuring a reference workpiece with a dedicated measurement probe and correlating those measurements with sensor data collected during its machining. This preliminary action creates a calibration model that can be applied to subsequent workpieces, eliminating the need for repeated direct measurements and significantly reducing production cycle time.
2Loss of information
If dedicated measurement probes are used to inspect all workpiece features, then complete workpiece information is obtained, but device complexity and measurement time increase
Solution Approach 1:
The patent makes the sensor system multi-functional by enabling it to perform both its original monitoring function and the additional function of inferring workpiece measurement data. The same sensors used during machining now provide measurement information through the calibration model, eliminating the need for separate dedicated measurement probes and reducing overall system complexity.
Solution Approach 2:
The sensor system serves itself by generating workpiece measurement information from its own data collection during machining. The calibration model enables the sensor system to infer measurement data without requiring external measurement devices, making the system self-sufficient and reducing the need for additional complex measurement equipment.
3Productivity
If sensor data is used to infer workpiece measurement data, then productivity increases, but measurement precision may be compromised
Solution Approach 1:
The patent implements feedback by using actual measurement data from a reference workpiece to calibrate and refine the relationship between sensor data and workpiece features. This feedback loop ensures that the calibration model accurately reflects the specific tool, workpiece, and sensor configuration, maintaining high measurement precision while enabling rapid inference for subsequent workpieces.
Data Source
AI summary
A method including: a) causing a tool mounted on a machine tool to work on a workpiece, and at least one sensor, which is configured to measure one or more aspects of the tool and/or machine tool, collecting sensor data during said working; b) a measurement device inspecting the part of the workpiece that was worked on at step a) to obtain measurement data; and c) calculating sensor-to-workpiece data calibration information from the sensor data and the measurement data.