NC Machine Alignment Using Monument Points and Optical QA
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Solution Overview
Problem
Current machining processes are hindered by complex tooling fixtures and part-to-fixture indexing, leading to increased costs and production time, and quality assurance processes are resource-intensive, often requiring rework or scrapping of parts due to alignment issues.
Innovation Solution
A method and system that generate monument point data, part data, and theoretical machined part data to create control data for precise machine operation, using image capture devices and computer processing to align and verify the position of parts on a machine bed, ensuring tolerance compliance and reducing rework.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If complex tooling fixtures and indexing systems are used to achieve tight tolerance requirements, then manufacturing precision is improved, but device complexity and production cost increase
Solution Approach 1:
The patent replaces complex mechanical indexing systems and tooling fixtures with an optical measurement system. Image capture devices (cameras) are used to capture images of the part and fixture, and computer processing determines the part location and orientation. This substitution of mechanical systems with optical/electronic systems directly reduces device complexity while maintaining manufacturing precision.
Solution Approach 2:
The patent creates a digital copy (image) of the physical part and fixture arrangement. By capturing images and processing them computationally, the system determines part location without requiring complex physical indexing mechanisms. This copying approach simplifies the physical system while preserving measurement accuracy.
2Measurement precision
If complex indexing systems are used to repeatably locate the part and fixture, then positioning accuracy is improved, but device complexity and production time increase
Solution Approach 1:
The patent replaces mechanical indexing systems with an optical measurement system. Image capture devices capture the position of the part and fixture, and computer algorithms determine the part location and orientation relative to the machine bed. This eliminates the need for complex mechanical indexing while achieving the same positioning accuracy.
3Measurement precision
If quality assurance is performed by physically holding the part up to a component for alignment verification, then measurement accuracy is improved, but productivity and production flow are reduced
Solution Approach 1:
The patent replaces manual physical alignment verification with an automated optical measurement system. Image capture devices automatically capture and process images to verify part alignment and machined features. This automation eliminates manual inspection time while maintaining measurement accuracy, thereby improving productivity.
Solution Approach 2:
The patent performs measurement and alignment verification during the machining process itself, rather than as a separate post-processing step. The system captures images and verifies alignment while the part is still in the fixture, allowing for immediate detection and correction of issues without interrupting the production cycle.
4Measurement precision
If manual quality assurance inspection is performed after machining, then detection accuracy is improved, but loss of time and productivity decrease
Solution Approach 1:
The patent replaces manual quality assurance inspection with an automated optical measurement system. Image capture devices and computer processing automatically detect and verify machined features, eliminating the time required for manual inspection while maintaining or improving detection accuracy.
Solution Approach 2:
The patent enables continuous measurement and verification during the machining process. The optical system captures images and performs quality checks without interrupting the machining operation, allowing useful action (production) to continue while quality assurance is performed simultaneously.
Data Source
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AI summary
A method for operating a numerical control machine including generating monument point data having a plurality of reference points representing a plurality of monument points on a machine bed, generating part data having plurality of reference points representing a part with respect to the plurality of monument points, generating theoretical machined part data having a plurality of reference points representing a theoretical machined part, generating control data by integrating the part data and the theoretical machined part data, generating machine control data by integrating the control data and the monument point data, and executing the machine control data for controlling operation of a numerical control machine to form a machined part.