Machining Controller With In-Situ 3D Defect Detection and Rework
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional machining systems require unloading workpieces for dimension measurement, leading to inefficiencies and limited capacity ratios, as they cannot automatically detect or correct machining defects in real-time.
Innovation Solution
A control system with a controller and photographing device that generates three-dimensional models of workpieces during machining, compares them to simulation models, and performs automatic corrections by modifying settings and executing additional machining based on defect analysis.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If a workpiece is unloaded from the machine for dimension measurement, then measurement can be performed, but the capacity ratio deteriorates due to interruption of machining operation
Solution Approach 1:
The patent implements continuous machining operation by performing dimension measurement in-situ within the machine tool without unloading the workpiece. The photographing device captures images during machining, and the controller continuously monitors dimensions, eliminating interruptions and maintaining continuous productive action throughout the machining process.
Solution Approach 2:
The patent introduces a photographing device as an intermediary tool that enables dimension measurement without physical contact or removal of the workpiece. This intermediary device captures optical images that are then processed by the controller to extract dimensional information, allowing measurement to occur within the machining environment without disrupting the machining operation.
2Reliability
If a photographing device is used to capture workpiece images during machining, then real-time monitoring is enabled, but device complexity increases
Solution Approach 1:
The controller serves multiple functions: it controls the machining operation, processes images from the photographing device, performs three-dimensional reconstruction, compares measured dimensions with design specifications, and executes automatic correction. This multi-functionality reduces the need for separate dedicated systems and minimizes overall device complexity while enabling real-time monitoring.
Solution Approach 2:
The system performs self-monitoring and self-correction. The photographing device captures images, the controller automatically processes these images to measure dimensions, compares them with target values, and executes corrective machining actions without external intervention. This self-service capability reduces the need for additional monitoring equipment and simplifies the overall system architecture.
3Manufacturing precision
If automatic correction is implemented by modifying settings and executing additional machining, then manufacturing precision improves, but device complexity increases
Solution Approach 1:
The system implements a closed-loop feedback mechanism where the photographing device continuously measures workpiece dimensions, the controller compares these measurements with design specifications, and automatically executes corrective machining when deviations are detected. This feedback loop enables automatic correction of machining errors, improving manufacturing precision through real-time adjustment without requiring complex external intervention systems.
Data Source
AI summary
A control system includes a controller that controls machining of a workpiece, and a photographing device that photographs an image of the workpiece under machining operation. The controller generates a three-dimensional model of the workpiece under machining operation based on the acquired image, compares the generated three-dimensional model and a three-dimensional model generated by a machining simulation with each other, and determines a presence or absence of a machining defect based on a result of the comparison. When the machining defect is present and re-machining is possible, a setting is modified depending on a cause of the machining defect and additional machining is executed based on the modified setting.