Machining Head Sensor Position Correction for Workpiece Tolerance
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Solution Overview
Problem
Existing methods for machining non-rotationally symmetrical workpieces struggle to maintain precise spatial positioning due to dimensional deviations caused by material stresses and ambient temperature effects, leading to potential collisions and poor machining quality, especially when dealing with curved workpieces that exceed tolerance limits.
Innovation Solution
A method and apparatus that utilize a machining head with sensors for contactless distance and position measurements to detect and correct the spatial position of workpieces before machining, ensuring deviations are within admissible tolerance values by aligning the machining head and workpiece relative to a virtual measuring axis, thereby preventing collisions and improving machining precision.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If workpieces are positioned using standard positioning devices, then machining can proceed with pre-programmed contours, but spatial position deviations occur due to material stresses and temperature effects, leading to collisions and poor machining quality
Solution Approach 1:
The system performs preliminary measurement of the workpiece spatial position before machining begins. Sensors mounted on the positioning device measure the actual positions of multiple workpiece points, and the control unit calculates deviation values compared to the programmed spatial position, enabling correction before machining starts
Solution Approach 2:
The system establishes a feedback loop where sensor measurements of workpiece position are continuously fed back to the control unit, which calculates deviation values and generates correction signals to adjust the machining path or workpiece position, ensuring precision throughout the machining process
2Manufacturing precision
If correction measures are implemented to maintain precision, then machining quality improves, but the process becomes more complex and time-consuming
Solution Approach 1:
The positioning device is designed with multi-functionality, serving both as the workholding device and as the mounting platform for measurement sensors. This integration eliminates the need for separate measurement equipment and reduces system complexity
Solution Approach 2:
The system uses the existing positioning device structure and sensors to perform self-measurement and self-correction of workpiece position, without requiring external measurement equipment or additional complex subsystems
3Measurement precision
If traditional sensing methods are used to detect position deviations, then measurement can be performed, but the sensing device must be arranged on holding device or machining head, increasing complexity
Solution Approach 1:
The measurement sensors are merged with the positioning device structure, with sensors mounted directly on the positioning device to measure workpiece position. This integration combines the positioning and measurement functions into a single unified system, reducing overall complexity
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This approach allows for efficient precalculation of machining paths, reduces the need for control measurements, and ensures high precision in machining non-rotationally symmetrical workpieces, preventing collisions and maintaining tolerance limits, thus enhancing the quality of the machining process.
Implementation Method 1
at least one sensor (5) for contactless distance measurement is provided in the machining head (2)
Data Source
AI summary
A method and an apparatus for detecting and correcting a spatial position of a workpiece held in a positioning device, wherein a machining head having at least one sensor and position sensor is fed into at least one measuring position. Contactless sensing of an actual position of a measuring point of the workpiece is carried out at the measuring position using the machining head and the sensed actual position is compared with an expected nominal position and deviation values between the actual position and the nominal position are ascertained. The ascertained deviation values are compared with an admissible tolerance value and the machining head is fed to a contour when the ascertained deviation is within the admissible tolerance value, or the machining head and the workpiece are oriented with respect to one another and to the contour such that a deviation of the actual position is within the admissible tolerance values following orientation.