Poloidal Segment Groove Machining via 3D Point Cloud Reverse Engineering
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Solution Overview
Problem
The existing manufacturing process of poloidal segments for nuclear fusion reactors faces challenges with large forming and assembly errors, leading to inaccurate determination of machining allowances, which results in low machining precision of welding grooves.
Innovation Solution
A method involving 3D point cloud data collection, reverse model reconstruction, and calculation of target machining allowances for each poloidal segment, allowing for precise machining strategy generation and implementation to improve groove welding precision.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If traditional manufacturing process is used for poloidal segments, then fabrication and assembly can be completed, but forming and assembly errors are large leading to inaccurate machining allowance determination
Solution Approach 1:
The patent applies preliminary action by performing reverse engineering to obtain the actual 3D model before machining operations. The actual 3D model is reconstructed from point cloud data of the fabricated poloidal segments, allowing the machining allowance to be calculated in advance based on the real geometry rather than ideal dimensions. This preliminary modeling step enables accurate determination of machining allowances before the actual groove machining begins.
Solution Approach 2:
The patent replaces traditional mechanical measurement and inspection methods with 3D point cloud scanning and digital reverse engineering. By using optical scanning to capture the actual geometry and computational methods to reconstruct the 3D model, the system substitutes physical measurement processes with digital modeling, enabling more precise and comprehensive analysis of the poloidal segment geometry and its deviations.
2Manufacturing precision
If machining allowance is not accurately determined, then fabrication can proceed, but machining precision of welding grooves is greatly lowered
Solution Approach 1:
The patent implements feedback by using the actual 3D model obtained from reverse engineering to calculate the real machining allowance, which is then fed back into the machining process planning. The system compares the actual geometry with the ideal design, determines the precise amount of material to be removed, and adjusts the machining parameters accordingly. This feedback loop ensures that the machining process compensates for previous forming and assembly errors.
Solution Approach 2:
The patent performs preliminary reverse engineering and 3D modeling before the machining operation to determine the exact machining allowance required. By reconstructing the actual 3D model from point cloud data and calculating the precise deviations from the ideal geometry in advance, the system prepares accurate machining parameters before the actual groove cutting begins, ensuring high welding precision.
3Manufacturing precision
If 3D point cloud data collection and reverse model reconstruction are performed, then actual 3D model can be obtained for accurate machining allowance calculation, but process complexity increases
Solution Approach 1:
The patent uses copying by creating a digital 3D copy of the actual poloidal segment geometry through point cloud scanning. Instead of physically measuring every dimension manually or disassembling components, the system creates a complete digital replica of the actual geometry, including all surface features and dimensional characteristics. This digital copy serves as the basis for calculating machining allowances and planning the machining process.
Solution Approach 2:
The patent performs the reverse engineering and 3D model reconstruction as a preliminary step before the actual machining operations. By completing the digital modeling and machining allowance calculation in advance, the system prepares all necessary machining parameters and tooling requirements before the physical machining begins, streamlining the overall manufacturing process despite the added initial complexity.
Data Source
AI summary
This application relates to manufacturing of vacuum chambers of nuclear fusion reactors, and more particularly to a method, device and apparatus for machining grooves of poloidal segments of a vacuum chamber of a nuclear fusion reactor, and a computer-readable storage medium. The method includes: collecting three-dimensional (3D) point cloud data of surfaces of individual poloidal segments of the vacuum chamber; performing reverse model reconstruction, based on the three-dimensional point cloud data, to generate an actual 3D model to acquire a sectional view of the vacuum chamber; extracting a cross-reconstruction region between two adjacent poloidal segments; and calculating a target machining allowance of individual poloidal segments according to the cross-reconstruction region and a preset segment boundary to generate a machining strategy for the groove of individual poloidal segments.