Integrated Machining Workstation with Photogrammetry
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Solution Overview
Problem
Current methods for machining and checking workpieces are inefficient and time-consuming, requiring trained technicians, manual intervention, and separate workstations, leading to logistical challenges, delayed quality control, and increased costs due to selective checking and potential production interruptions.
Innovation Solution
A method integrating a projector, photogrammetry device, and control unit to continuously determine the workpiece's pose and project work instructions, allowing for automated scanning and control of machining steps at a single workstation, reducing the need for manual intervention and enabling real-time error detection and correction.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If separate workstations for machining and quality control are used, then specialized equipment can be dedicated to each function, but logistical challenges and time delays occur due to transporting workpieces between locations
Solution Approach 1:
The patent combines the machining workstation and quality control measurement system into a single integrated location. The coordinate measuring machine and machining equipment are positioned at the same workstation, allowing workpieces to be measured and processed without transportation. This eliminates logistical challenges and time delays while maintaining specialized measurement precision through the dedicated CMM equipment.
2Measurement precision
If trained metrologists perform manual measurement and analysis, then measurement expertise is applied, but significant time delays and manual intervention requirements occur
Solution Approach 1:
The patent replaces manual measurement and analysis performed by trained metrologists with an automated computer-based system. The coordinate measuring machine is integrated with a control unit that automatically evaluates measurement data, compares it with CAD models, and generates quality assessments. This substitution maintains measurement precision through expert-level algorithms while dramatically improving productivity by eliminating manual intervention and reducing processing time.
Solution Approach 2:
The system implements automated feedback loops where measurement results are immediately compared with target specifications, and quality issues are identified and communicated in real-time. This automated feedback mechanism replaces the manual review process, maintaining high measurement accuracy while significantly reducing the time required for quality control decisions and enabling faster productivity improvements.
3Productivity
If selective checking is performed on only highly critical aspects, then resource consumption is reduced, but quality control coverage is insufficient and production interruptions may occur
Solution Approach 1:
The integrated workstation provides universal quality control capability that can assess all workpiece aspects, not just highly critical ones. The coordinate measuring machine and automated evaluation system are designed to handle comprehensive measurement tasks across the entire workpiece surface, enabling full coverage quality control while maintaining resource efficiency through automated operation and single-location processing.
4Measurement precision
If multiple workstations are used for different functions, then specialized equipment can be optimized for each task, but device complexity and logistical coordination increase
Solution Approach 1:
The patent merges multiple specialized functions (coordinate measuring machine, machining equipment, control unit) into a single integrated workstation. This consolidation maintains the specialized measurement precision of the CMM while reducing device complexity by eliminating the need for coordinating multiple separate workstations and their associated logistics. The integrated system manages all functions through a unified control architecture.
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 integrated approach enhances processing efficiency, reduces costs, and improves quality by allowing for immediate error correction and continuous monitoring, thereby increasing process reliability and minimizing rejects.
Implementation Method 1
a photogrammetry device, whose relative position is known, for continuously repeatable referencing to determine a pose of the workpiece relative to the projector and the photogrammetry device
Implementation Method 2
a projector for projecting a work instruction onto the workpiece... continuously achievable monitoring of the processing by scanning at least a partial area of the workpiece surface
Data Source
Figure 1a
Figure 1b
Figure 2
AI summary
A method for carrying out and checking a machining step on a workpiece, using an apparatus comprising a projector, a photogrammetry device and a control unit which knows the relative position of the projector and photogrammetry device, comprises the following steps: referencing in order to determine the positioning of the workpiece relative to the projector and the photogrammetry device in a predefined coordinate system; projection of a work instruction onto the workpiece; machining of the workpiece by a worker; and checking of the machining by scanning at least a portion of the surface of the workpiece; wherein all the steps are carried out by the apparatus at the same workstation within the context of an integrated process and with the exception of the machining by the worker.