Optical Measuring Axis Layout for In-Process Tool Machining
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Solution Overview
Problem
Existing machining devices face challenges in performing high-precision, high-speed in-process measurements of workpieces without damaging sensitive or brittle materials, while also being robust against thermal effects and contamination.
Innovation Solution
A machining device with multiple translational and/or rotary machine axes, equipped with a measuring system positioned at the center of the first rotary machine axis, oriented towards the machine zero point, and configured to perform measurements along multiple axes with high accuracy and controlled force, minimizing thermal and contamination impacts.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If a touch trigger probe is used for in-process measurement, then measurement capability is provided, but measurement precision and speed are degraded due to time delay and thermal effects
Solution Approach 1:
The patent replaces the mechanical touch trigger probe with an optical measurement system that uses light beams to detect workpiece dimensions and positions. This substitution eliminates mechanical contact and associated time delays, achieving non-contact measurement that is both high-precision and high-speed.
Solution Approach 2:
The patent introduces an optical intermediary (light beam) between the measurement system and the workpiece. This intermediary enables measurement without direct mechanical contact, eliminating the time delay inherent in mechanical trigger systems while maintaining measurement accuracy.
2Measurement precision
If a touch trigger probe is used for in-process measurement, then measurement capability is provided, but measurement accuracy is degraded by thermal effects and contamination
Solution Approach 1:
The patent replaces the mechanical touch trigger probe with an optical measurement system that uses light beams to detect workpiece dimensions and positions. This substitution eliminates mechanical contact and associated time delays, achieving non-contact measurement that is both high-precision and high-speed.
Solution Approach 2:
The patent creates a protected measurement environment by positioning the optical measurement system in a thermally stable location and using optical paths that are isolated from machining debris and contamination. This inert environment approach protects the measurement process from thermal effects and contamination that would otherwise degrade accuracy.
3Measurement precision
If the measuring system is positioned close to the workpiece for high precision measurement, then measurement accuracy improves, but the system becomes more vulnerable to thermal effects and contamination
Solution Approach 1:
The patent introduces an optical intermediary (light beam) between the measurement system and the workpiece. This intermediary enables measurement without direct mechanical contact, eliminating the time delay inherent in mechanical trigger systems while maintaining measurement accuracy.
Solution Approach 2:
The patent employs a composite measurement system that combines the advantages of close positioning (for accuracy) with thermal isolation and optical protection (for contamination resistance). The system integrates optical components, protective housings, and positioning mechanisms into a unified composite structure that achieves both precision and environmental resistance.
4Adaptability or versatility
If multiple machine axes are used for machining, then machining capability and flexibility improve, but system complexity increases
Solution Approach 1:
The patent implements a universal optical measurement system that can measure workpieces across multiple machine axes and various machining operations. This multi-functional approach allows a single measurement system design to serve diverse machining capabilities, reducing overall system complexity while maintaining versatility.
Solution Approach 2:
The patent adds the optical measurement dimension to the existing mechanical machining axes, creating a multi-dimensional system that combines mechanical motion with optical detection. This dimensional addition enables comprehensive measurement capability without requiring complex mechanical modifications to the existing axis system.
Data Source
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AI summary
A machining device (1) with multiple translational and/or rotary machine axes for laser processing, grinding or electrical discharge machining of a workpiece (10) into a tool, comprising a machining unit (2), either comprising a laser system with an optical system for generating, directing and/or moving a laser beam along an optical axis, a grinding tool rotatable around a tool axis, or an electrode tool for generating electrical discharge, a workpiece support (11) on which the workpiece (10) is attached, and wherein the workpiece support (11) is arranged movable about a second rotary machine axis (4), which second rotary machine axis (4) is movable relative to a first rotary machine axis (3), perpendicular to the second rotary machine axis (4), a measuring system (20) positioned in a center (5) of the first rotary machine axis (3) and orientated towards a machine zero point (6), defined by an intersection point of the first rotary machine axis (3) and the second rotary machine axis (4), wherein the measurement system (20) is configured to perform measurements along a first measurement axis (7) and/or a second measurement axis (8) to determine measurement data further comprising a control unit (12) configured to control the machining unit (2) and/or the measuring system (20).