Motor Vehicle Rim 3D Machining Data Generation
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Solution Overview
Problem
The manufacturing of modern car rims faces challenges in achieving precise surface finishing and burr removal due to complex residual stresses and varying rim geometries, leading to inaccurate edge position detection and incomplete burr removal, which can result in distortion, corrosion, and quality issues.
Innovation Solution
A method for creating 3D processing data of pre-processed motor vehicle rims involves measuring the 3D actual position data of spokes and surfaces using optical means, comparing it with a target geometry model, and extrapolating or interpolating to complete the input contour, allowing for precise calculation of machining data for deburring and edge rounding.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If traditional brushing or grinding methods are used to remove burrs, then burr removal is achieved, but the ridge is leveled instead of complete removal and surface quality is compromised
Solution Approach 1:
The patent applies preliminary action by performing a measurement step before the actual burr removal machining. The entry contour of the workpiece is measured to detect the precise position and geometry of burrs, allowing the subsequent machining process to target only the burr material without removing excessive base material, thus resolving the contradiction between complete burr removal and material preservation
Solution Approach 2:
The patent replaces traditional mechanical brushing or grinding methods with a more precise machining approach guided by optical or tactile measurement systems. The substitution of preliminary mechanical detection followed by controlled machining replaces the less precise direct mechanical removal methods, enabling complete burr removal while minimizing material loss
2Loss of time
If optical sensors are used to detect edge position, then detection speed is improved, but inaccurate edge position detection occurs due to undefined burr formation
Solution Approach 1:
The patent applies preliminary action by performing a first measurement to detect the entry contour including burrs, then using this information to plan a burr-removal machining path, and performing a second measurement after burr removal to verify the finished contour. This sequential measurement approach ensures accurate edge position detection at each stage while maintaining efficient measurement time
Solution Approach 2:
The patent implements feedback by comparing the measured entry contour with the target contour to identify burr locations, then using this feedback information to generate a corrected machining path that specifically targets the burrs. The process may include subsequent verification measurements to confirm burr removal accuracy, creating a closed-loop system that improves both measurement precision and efficiency
3Measurement precision
If comprehensive 3D contour data is collected from all surfaces, then measurement accuracy is improved, but measuring time increases significantly
Solution Approach 1:
The patent applies segmentation by dividing the measurement process into distinct phases: first measuring the entry contour at relevant locations to detect burrs, then generating a machining path, and optionally performing a second measurement after burr removal. This segmented approach collects comprehensive 3D contour data at critical locations without requiring simultaneous measurement of all surfaces, thus maintaining measurement precision while reducing total measuring time
Solution Approach 2:
The patent applies partial action by measuring only the necessary portions of the workpiece contour that are relevant to burr detection and machining path generation, rather than performing exhaustive measurements of all surfaces. This selective measurement approach achieves sufficient measurement precision for the intended purpose while significantly reducing data collection time
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 efficient and precise removal of burrs and edge rounding, reducing measuring time and avoiding inaccuracies, while ensuring complete data for multi-axis processing, thus enhancing the surface quality and safety of the vehicle rims.
Implementation Method 1
measuring the inside and outside at definable measuring positions at at least two, preferably three, surfaces of the respective spokes for capturing 3D actual position data using at least one optical capturing means
Data Source
Figure 1
Figure 2a~2e
Figure 3
AI summary
The invention relates to a method for generating 3D machining data (24) of a motor vehicle rim (1) which is rotationally machined and/or milled, having the steps of: providing a motor vehicle rim (1) with multiple spokes (2), an input contour (16), an outer or visible side (9), an inner or axle side (10), and a ridge (13) adhered to at least one edge (11); providing a 3D model of the target geometry (17) of the motor vehicle rim (1) to be machined in a system controller; measuring the inner and outer side (9, 10) at specified measuring positions (18) on at least two, preferably three, surfaces (14) of each spoke (2) in order to detect 3D actual position data using at least one optical capturing means (8); comparing the detected 3D actual position data with the 3D model of the target geometry (17) and completing the input contour (16) by extrapolating and/or interpolating the 3D actual position data using a computer; calculating 3D machining data (24) of the finished contour (20) using the completed input contour (16); and providing the 3D machining data (24) in the system controller.