Robotic Hole Machining Paths Under Clamp-Up Force Constraints
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Solution Overview
Problem
Current techniques for controlling robotic devices in machining holes lack efficiency and cost-effectiveness, particularly in optimizing path length considering clamp-up forces and tool changes, making it challenging to create optimal paths for machining operations in complex workpieces like aircraft components.
Innovation Solution
A method and system that identify a set of pre-existing hole locations for temporary fasteners to create an optimal path for machining operations, reducing the distance and time required by determining an ordered sequence that takes into account clamp-up force specifications, thereby minimizing the number of tool changes and positioning stations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a programmer manually creates a program to machine holes in a workpiece, then the manufacturing operations can be performed, but the path optimization becomes increasingly difficult and time-consuming as the number of holes increases
Solution Approach 1:
The patent replaces manual programming with an automated computer-based system that uses algorithms to generate optimal machining paths. The system automatically processes workpiece data, identifies hole locations, calculates optimal sequences considering clamp-up force requirements, and generates robotic control programs without human intervention, thereby eliminating the time-consuming manual path optimization process.
Solution Approach 2:
The system enables self-service by allowing the computer to autonomously determine the optimal machining path based on workpiece specifications and constraints. The automated path optimization system independently analyzes the workpiece geometry, identifies clamp-up force requirements, and generates the machining sequence without requiring programmer expertise or manual intervention.
2Manufacturing precision
If temporary fasteners are installed to provide clamp-up force for machining, then hole quality improves with less deflection, but the complexity of identifying the optimal path increases
Solution Approach 1:
The patent replaces complex manual path planning with an automated computer-based optimization system. The system automatically determines the optimal sequence of machining operations that incorporates temporary fastener installation and clamp-up force requirements, calculating the most efficient path that ensures hole quality while minimizing processing time and complexity.
Solution Approach 2:
The system performs preliminary analysis of clamp-up force requirements before generating the machining path. It identifies locations where temporary fasteners need to be installed and determines the optimal sequence that establishes necessary clamp-up forces before machining each hole, ensuring manufacturing precision is maintained throughout the process.
3Productivity
If the number of holes to be machined increases, then more manufacturing operations are performed, but creating an optimal path becomes increasingly challenging
Solution Approach 1:
The patent replaces manual path optimization with an automated computer-based system capable of handling large numbers of holes efficiently. The system uses algorithms to process workpiece data, identify all hole locations, and generate optimal machining sequences that consider clamp-up force requirements, regardless of the total number of holes, thereby maintaining productivity while eliminating the increasing difficulty of manual optimization.
Solution Approach 2:
The system dynamically adapts the machining path optimization to accommodate varying numbers of holes and changing workpiece configurations. The automated algorithm can efficiently recalculate optimal paths as hole locations or clamp-up force requirements change, providing flexible and scalable solutions for workpieces with different complexities and sizes.
Data Source
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AI summary
A method for implementing machining operations (114) for a workpiece (110). Pre-existing hole locations (132) for temporary fasteners (134) in the workpiece (110) requiring a clamp-up force (136) for performing the machining operations (114) to form holes (126) in the workpiece (110) is identified. A set of the pre-existing hole locations (132) is determined from the pre-existing hole locations (132) that results in an optimal path (128) for performing the machining operations (114) on the workpiece (110) taking into account clamp-up force specifications (130) for the workpiece (110). The optimal path (128) has a near-minimum distance (138). An ordered sequence (140) for performing the machining operations (114) to form the holes (126) at hole locations (124) is determined that has the optimal path (128). Robotic control files (122) that causes robotic devices (106) to perform the machining operations (114) using the optimal path (128) is created. The robotic devices (106) are operated using the robotic control files (122) to form the holes (126) in the ordered sequence (140) using the optimal path (128) that takes into account the clamp-up force specifications (130).