Multi-Head Toolpath Allocation With Digital Twin Collision Avoidance
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Solution Overview
Problem
Existing part programming systems are inefficient for operating machines with multiple heads, leading to time-consuming operations and difficulties in predicting the behavior of CNC machines against programmed toolpaths.
Innovation Solution
A method and system for generating toolpaths using a digital twin model to distribute toolpaths among multiple heads, employing an auto-balancing algorithm and artificial neural networks to minimize collision risks and optimize production time.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If multiple heads are used to increase production efficiency, then productivity increases, but the risk of collision between heads increases
Solution Approach 1:
The system performs preliminary simulation of the multi-head operating process using a digital twin model before actual execution. The collision detection algorithm predicts potential collisions in advance, and the toolpath is adjusted beforehand to avoid collisions, ensuring safe high-speed operation of multiple heads
Solution Approach 2:
The digital twin model provides real-time feedback on the positions and states of multiple heads during operation. The control system continuously monitors simulated head movements and adjusts toolpaths dynamically to prevent collisions while maintaining high productivity
2Reliability
If complex toolpath distribution is performed manually for multiple heads, then collision risks can be managed, but time consumption increases
Solution Approach 1:
The system automatically generates and optimizes toolpath distribution for multiple heads without manual intervention. The collision detection algorithm and auto-balancing algorithm work autonomously to create collision-free toolpaths, significantly reducing programming time while ensuring reliable collision management
Solution Approach 2:
The patent replaces manual mechanical programming with automated digital algorithms. The digital twin model and collision detection software automatically calculate optimal toolpaths, substituting human operators with intelligent software systems that work faster and more accurately
3Productivity
If high-speed operation is implemented for multiple heads, then productivity increases, but collision detection becomes more difficult
Solution Approach 1:
The system performs preliminary simulation at high speed using the digital twin model to predict collision risks before actual high-speed operation. By pre-detecting potential collisions in the virtual model, the system can adjust toolpaths beforehand, making high-speed operation safe and effective
Solution Approach 2:
The digital twin model creates a virtual copy of the physical multi-head system. This digital replica allows collision detection and analysis to be performed in the virtual domain, making it easier to detect and resolve collision issues without affecting actual high-speed production
Data Source
AI summary
A method of assigning a set of toolpaths (SCTFP) to a plurality of operating heads of an operating machine apparatus, the operating heads being displaceable within respective operating regions via a plurality of sub-systems of the operating machine apparatus (10). The method comprises: generating (400) a global toolpath (TP) based on a computerized object model (OB) provided via a computer-aided design, CAD processing stage (CP); based on respective operating regions and on a target travel time (CF), partitioning (402) the global toolpath (TP) and assigning toolpath partitions of a set of toolpath partitions (TP1, TP4) to respective operating heads of the plurality of operating heads; providing a computerized machine model (DT) configured to emulate the dynamical behavior of the operating machine apparatus (10); emulating (402), via the computerized machine model (DT), the displacement of the operating heads according to the toolpath partitions (TP1, . . . , TP4); based on the emulated displacement, detecting (404) collisions among operating heads; in response to detecting the presence of mutual collisions, adjusting and re-assigning toolpath partitions of the set of toolpath partitions (TP1, . . . , TP4) to respective operating heads; in response to failing to detect the presence of mutual collisions, providing (406) the set of toolpath partitions (TP1, . . . , TP4) as a set of collision-free toolpaths (CFTP1, . . . , CFTP4; SCFTP) to the operating machine apparatus for driving the sub-systems to displace the plurality of operating heads accordingly.