Milling Gap Optical Feedback for Antenna Geometry Control
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Solution Overview
Problem
The existing milling process for producing antenna structures often results in faulty products due to the spatial distance between the milling tool and the monitoring of the antenna shape, making it difficult to identify and correct errors in real-time, leading to an increased reject rate.
Innovation Solution
A device and method that utilize a light transmitter/receiver to monitor the width of the milling gap between the milling cutter and the cliché, allowing for real-time adjustment and correction of the milling process to maintain the desired geometry of the antenna structure, using actuators to adjust the position of the milling cutter or cliché based on feedback from the light receiver.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If sensors monitor the antenna shape after milling, then the finished product quality can be checked, but the spatial distance between milling tool and monitoring point causes delayed detection making corrective reworking impossible
Solution Approach 1:
The light transmitter/receiver system is positioned to monitor the milling gap width before the milling operation completes, detecting deviations in real-time during the process rather than after. This preliminary detection allows the control system to adjust milling parameters proactively, preventing defective antenna structures from being produced in the first place.
Solution Approach 2:
A closed-loop feedback system is implemented where the light transmitter/receiver continuously measures the milling gap width, feeds this information back to the controller, which then automatically adjusts the milling tool position or speed. This real-time feedback eliminates detection delays and enables immediate corrective action during the milling process.
2Manufacturing precision
If the milling gap width is not monitored in real-time, then the device complexity is reduced, but the antenna structure geometry cannot be maintained within target specifications
Solution Approach 1:
The complex mechanical measurement systems are replaced with an optical monitoring system using light transmitters and receivers. This optical system provides precise non-contact measurement of the milling gap width, maintaining manufacturing precision while reducing mechanical complexity compared to traditional mechanical gauges or sensors.
Solution Approach 2:
The light transmitter/receiver system serves multiple functions: it monitors milling gap width, detects thermal drift of the milling tool, and provides data for real-time control adjustments. This multi-functionality reduces the need for separate monitoring devices, thereby reducing overall device complexity while maintaining precision.
3Stability of the object's composition
If thermal drift of the milling cutter is not compensated, then the device complexity is reduced, but the antenna structure dimensions vary during continuous operation
Solution Approach 1:
The light transmitter/receiver system automatically detects thermal drift of the milling tool during continuous operation and feeds this information to the controller, which self-adjusts the milling parameters to compensate for thermal effects. This self-service approach maintains dimensional stability without requiring external intervention or complex thermal management systems.
Solution Approach 2:
The system dynamically changes milling parameters (such as tool position, speed, or feed rate) based on real-time detection of thermal drift through the optical monitoring system. By continuously adjusting these parameters, the system compensates for thermal expansion or contraction of the milling tool, maintaining consistent antenna structure dimensions throughout operation.
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 solution enables precise control and correction of the milling process close to the location of antenna structure formation, reducing faulty products and maintaining the target geometry, thereby minimizing reject rates and ensuring consistent antenna structure production.
Implementation Method 1
The light stripe is thus characteristic of the width of the milling gap between the milling cutter and the cliché in one of its transverse dimensions arriving at the light receiver
Data Source
Figure 1~3
AI summary
The invention relates to the monitoring and control of a milling operation of a milling cutter interacting with a die, having the steps of: milling at least one antenna structure out of the metal layer of a flexible product having a backing and a metal layer, while the product is being passed through a milling gap between the milling cutter and the die, using a light emitter to output a light strip that crosses through the milling gap in or transversely to a running direction of the product, wherein the light strip is dimensioned, and the milling cutter and the die are intended to be arranged, such that the milling cutter and the die shadow the light strip at least at one of the two longitudinal edges thereof, before a light receiver receives the light strip, wherein the transverse dimension thereof is characteristic of the width of the milling gap, and using the light receiver to output a signal that reproduces the width of the milling gap to a controller, and outputting an adjusting signal at least to an adjusting drive that influences the width of the milling gap between the milling cutter and the die.