On-Machine Point Cloud Inspection for Complex Surface Error Compensation
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Solution Overview
Problem
Current methods for detecting and compensating errors in complex surface machining, such as those on aircraft engine blades, are inefficient and require manual adjustments, leading to reduced processing efficiency and increased costs due to the need for separate detection and machining processes, and existing on-machine detection systems face challenges with accuracy and precision, especially with freeform surfaces.
Innovation Solution
An on-machine point cloud detection and compensation method using a detecting and scanning actuator with laser scanners to obtain and process point cloud data, applying noise removal and simplification techniques to accurately determine shape errors, and employing force feedback and trajectory adjustments for error compensation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If conventional detection equipments (coordinate measuring machine, automatic drawing measuring instrument) are used to measure complex surfaces, then measurement accuracy can be improved, but processing efficiency deteriorates due to separate detection and machining processes requiring manual adjustment
Solution Approach 1:
The patent combines the detection system and machining system into an integrated on-machine detection platform. The coordinate measuring machine is merged with the machining center, allowing detection and machining to occur in the same coordinate system without workpiece removal. This eliminates manual measurement-machining transfer and enables automatic error compensation, simultaneously improving measurement accuracy and processing efficiency.
Solution Approach 2:
The patent performs detection before machining in the same setup, obtaining the actual workpiece geometry data in advance. This preliminary detection allows the machining path to be automatically adjusted based on measured deviations, eliminating the need for manual measurement and adjustment after machining, thereby improving both accuracy and efficiency.
2Manufacturing precision
If manual adjustment of compensation parameters is performed during actual processing, then machining errors can be corrected, but processing efficiency deteriorates due to equipment suspension and high skill requirements
Solution Approach 1:
The patent implements an automatic feedback loop where the detection system measures the workpiece geometry, compares it with the theoretical model, calculates deviation data, and automatically generates compensation parameters. This closed-loop feedback system eliminates manual intervention, allowing continuous processing without equipment suspension while maintaining high machining precision.
Solution Approach 2:
The system performs self-measurement and self-compensation. The machining center automatically detects its own workpiece geometry, calculates errors, and adjusts its own machining path without external manual intervention. This self-service capability eliminates the need for skilled operators to suspend equipment for manual adjustments, improving both precision and efficiency.
3Ease of operation
If optical projection measuring method is used for qualitative detection, then operation simplicity is improved, but measurement accuracy deteriorates due to surface reflection effects and limited measurement range
Solution Approach 1:
The patent replaces the optical projection method with a contactless mechanical scanning system (touch probe or laser scanner) integrated into the machining center. This substitution eliminates the limitations of optical methods (surface reflection, limited range) while maintaining ease of operation through automated scanning. The mechanical/scanning system provides accurate 3D coordinate data for complex surfaces without being affected by optical interference.
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 method enables rapid and accurate detection and compensation of complex surface errors during machining, improving processing efficiency and precision by integrating detection and machining, reducing manual intervention and costs, and maintaining high accuracy even with thin-walled blades.
Implementation Method 1
The advanced complex surface shape detection equipments, such as metal surface defect detector; 3D scanners (including laser 3D scanners and structured light 3D scanners) can be used to realize the accurate detection and error evaluation of the surfaces of workpieces.
Data Source
AI summary
The present application provides an on-machine point cloud detection and compensation method for processing complex surfaces, which comprises: step S1, installing a detecting and scanning actuator on an ultrasonic rolling machine tool; step S2, installing a processed workpiece on the chuck which is scanned by the detecting and scanning actuator to obtain the point cloud data of the workpiece in a coordinate system of detecting and scanning actuator, which is converted into the point cloud data of the workpiece in a coordinate system of machine tool; step S3, processing the point cloud data of the workpiece in the coordinate system of machine tool; step S4, obtaining and compensating the shape error feature of the workpiece according to theoretical design data of the processed workpiece and processed point cloud data of the workpiece in the coordinate system of machine tool. The accuracy and efficiency of complex surface strengthening is improved in the present application.