3D Probe Path Generation for Faster Part Alignment Inspection
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Solution Overview
Problem
Current subtractive and additive manufacturing systems face inefficiencies in surface inspection and part alignment due to the need for extensive measurement points, which increases processing time and reduces accuracy.
Innovation Solution
The method involves generating an optimal set of probe points from a 3D model, filtering out unnecessary points based on reachability and coverage, and ensuring a minimum number of points to maintain accuracy and lock degrees of freedom, using a mesh model and probe tool geometry to determine the final set of probing points for alignment or inspection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If extensive measurement points are used for surface inspection and part alignment, then measurement accuracy is improved, but processing time increases
Solution Approach 1:
The system extracts only the essential probe points from the complete surface model that are necessary for achieving accurate part alignment and surface inspection. By identifying and removing redundant measurement points, the system maintains measurement accuracy while significantly reducing the number of points that need to be physically measured, thus decreasing processing time.
Solution Approach 2:
Instead of measuring the entire surface uniformly, the system applies partial action by concentrating measurement efforts on critical probe points that provide maximum alignment and inspection value. This selective approach avoids excessive measurement at non-critical locations, optimizing the balance between accuracy and time efficiency.
2Area of stationary object
If more probe points are selected for surface inspection, then measurement coverage is improved, but the number of measurements and time required increases
Solution Approach 1:
The system extracts a minimal sufficient set of probe points from the complete surface geometry that provides adequate measurement coverage for alignment and inspection purposes. By removing unnecessary points while preserving coverage of critical features, the system maintains comprehensive measurement capability with fewer actual measurement operations.
Solution Approach 2:
The system applies different measurement densities to different regions of the part based on local importance. Critical features and surfaces that require high precision alignment receive concentrated probe point coverage, while less critical areas use fewer points, optimizing overall inspection efficiency while maintaining necessary coverage.
3Manufacturing precision
If a minimum number of probe points is used to lock degrees of freedom, then alignment accuracy is maintained, but the complexity of point selection increases
Solution Approach 1:
The system automatically performs the complex task of selecting the minimum necessary probe points to lock all six degrees of freedom for accurate part alignment. The software independently analyzes the part geometry, probe tool characteristics, and alignment requirements to autonomously determine the optimal probe point locations, eliminating the need for manual point selection and reducing operational complexity.
Solution Approach 2:
The system performs preliminary analysis and calculation to pre-determine the optimal set of probe points that will successfully lock all degrees of freedom before actual measurement begins. This advance preparation ensures alignment accuracy is achieved with the minimum necessary points, avoiding the need for complex real-time decision-making during the measurement process.
Data Source
AI summary
Methods, systems, and apparatus, including medium-encoded computer program products, for automatic generation of probe path for surface inspection and part alignment. A mesh model is obtained of at least a portion of a three dimensional model of a part to be manufactured using a computer-controlled manufacturing system. Vertex points from the mesh model are collected to be an initial set of probing points in a three dimensional space of a working coordinate system of the computer-controlled manufacturing system, and filtering out points are filtered out from the initial set of probing points based on coverage of the least a portion of the three dimensional model to produce a final set of probing points. The final set of probing points is provided for use in alignment or surface inspection of the part by the computer-controlled manufacturing system.