Machining Process Visualization Using Reconstituted Tool Images
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Solution Overview
Problem
Operators face difficulties in observing the machining process due to projections of materials like cooling fluids and chips, which hinder the visibility of the real tool and blank during machining, making it challenging to detect potential machining faults in real-time.
Innovation Solution
A machining system that generates and displays reconstituted and simulated images of the machining process, using real-time positioning data and tool geometry correction data to provide the operator with a clear representation of the tool and blank positions, allowing for the detection of potential faults before they occur.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of information
If a camera is used to monitor machining, then the operator can observe the machining process, but the video image is distorted by material projections making observation difficult
Solution Approach 1:
The patent creates a virtual copy of the machining process through software simulation. Instead of capturing the physical machining scene with a camera (which suffers from material projections), the system generates a virtual image that replicates the machining process digitally, eliminating the harmful effects of chips and cooling fluids on visibility.
Solution Approach 2:
The patent replaces the mechanical/optical monitoring system (camera) with a computational system. Instead of using physical cameras to capture images that get obscured by material projections, the system uses software to generate virtual images based on machining parameters, substituting mechanical observation with digital simulation.
2Loss of information
If real-time positioning data is processed to generate reconstituted images, then operator visibility is improved, but system complexity increases
Solution Approach 1:
The control system performs multiple functions: it controls the actuators for machining, processes positioning data, generates virtual images, and provides monitoring all through a single integrated system. This multi-functionality reduces the need for separate dedicated components for each function.
Solution Approach 2:
The system uses its own existing data infrastructure (positioning data already being collected for control purposes) to generate the virtual images for monitoring. Instead of requiring separate sensors and cameras, the system repurposes its own operational data for the monitoring function.
Data Source
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Figure 3a~3b
AI summary
Machining system (10) comprising a facility comprising: - a real tool (12);- actuators (14) for displacing the real tool (12); - sensors (15) for generating positioning data (16) for the real tool (12); - a memory (17) for storing correction data in respect of the geometry (20) of the real tool (12); - a physical controller (18) for executing a machining program (19) and commanding the actuators (14), as a function of the data for correction of geometry (20), to displace the real tool (12) with respect to the real blank (13). On the basis of said data (22) representative of the positions of the real tool (12) and of the real blank (13), means for displaying images (24) generate a reconstituted image (25) representative: of the shape of the real blank (13); and of the position of the real tool (12) at a given instant.