Morphic Manufacturing with In-Situ Inspection Feedback
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Solution Overview
Problem
Conventional manufacturing systems face challenges in providing accurate and efficient feedback from inspection processes to manufacturing cycles, leading to human error and inefficiencies in ensuring parts meet design specifications, particularly in additive and subtractive processes.
Innovation Solution
The morphic manufacturing approach integrates in situ inspection and feedback into the manufacturing process using 3D imaging and dynamic inspection, allowing real-time adjustments to tool paths during fabrication to align parts with design specifications without removing them from the work envelope.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If manual inspection and feedback processes are used in conventional manufacturing, then human operators can perform checks and determine adjustments, but human error and inefficiencies occur leading to reduced manufacturing precision
Solution Approach 1:
The patent replaces manual inspection processes with automated 3D imaging systems and computer vision technology. The inspection system captures images of the workpiece, processes them through software to generate measurement data, and automatically compares actual dimensions against design specifications, eliminating human error in measurement and assessment
Solution Approach 2:
The patent implements a closed-loop feedback system where inspection results are automatically fed back to the manufacturing process. The system generates reports indicating deviations from design specifications and automatically adjusts machining parameters or tool paths to correct identified errors, ensuring continuous improvement of part quality
2Measurement precision
If parts are removed from the work envelope for inspection, then thorough examination can be performed, but production time increases and efficiency decreases
Solution Approach 1:
The patent merges the inspection process with the manufacturing process by integrating 3D imaging capabilities directly into the manufacturing system. The inspection system operates within the existing work envelope, allowing inspection to occur in-situ without requiring separate handling or relocation of parts to dedicated inspection equipment
Solution Approach 2:
The patent enables continuous manufacturing operations by performing inspection automatically during or immediately after machining operations. The system maintains uninterrupted production flow by eliminating idle time associated with manual inspection, handling, and repositioning of parts
3Measurement precision
If automated inspection systems are implemented, then inspection accuracy and consistency improve, but system complexity and initial investment increase
Solution Approach 1:
The patent designs the inspection system to serve multiple functions: capturing 3D images of workpieces, processing images through software algorithms, generating measurement reports, and providing feedback to control manufacturing processes. This multi-functional approach consolidates what could be separate complex systems into an integrated solution that leverages existing manufacturing infrastructure
Data Source
AI summary
A manufacturing control system for an additive, subtractive, or hybrid machining system implements a morphic manufacturing approach that integrates in situ inspection and related decision-making into the manufacturing process. After execution of a machining or deposition operation, the system performs a sensor scan to collect sensor measurement data for the resulting part while the part remains in the manufacturing work cell. The measurement data is compared with an as-designed digital model of the part to determine whether further machining or deposition is necessary to bring the finished part into tolerance with the model. If necessary, the system performs another additive and/or subtractive manufacturing operation on the part based on analysis of the measurement data to bring the part into tolerance. The measured inspection data can be stored in association with each manufactured part for auditing purposes or for creation of part-specific digital twins.