Rotary Axis Calibration from a Single 3D Scan
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
CNC milling machines face misalignment issues due to vibrations and resistive forces, particularly in precision applications like dental prostheses, leading to product defects and increased waste, with manual alignment being time-consuming and challenging.
Innovation Solution
An automated computer-implemented method for milling machine calibration, which includes receiving a calibration alert, performing automated calibration to determine offsets, and updating production instructions, using a 3D virtual calibration block scan to determine X and Z offsets, thereby correcting axis misalignment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If manual alignment is used for calibration, then the operator can track and identify misalignment, but the process becomes time-consuming and labor-intensive
Solution Approach 1:
The system performs self-calibration by automatically detecting misalignment through sensors and computing offset values without requiring manual measurement or operator intervention, thereby eliminating time-consuming manual alignment procedures while maintaining precision
Solution Approach 2:
The patent replaces manual mechanical measurement methods with an automated sensor-based detection system that uses electronic signals and computational algorithms to identify misalignment, substituting human operators with automated electronic systems
2Productivity
If repeated milling operations are performed, then production output increases, but vibrations and resistive forces cause axis misalignment and reduce quality
Solution Approach 1:
The system continuously monitors axis alignment during milling operations using sensors, detects misalignment caused by vibrations and resistive forces, computes offset values, and applies corrections to maintain precision throughout repeated production operations
Solution Approach 2:
The system performs calibration to determine offset values before production milling begins, and can re-calibrate during operations, proactively preventing misalignment issues before they affect product quality rather than reacting after defects occur
3Extent of automation
If automated calibration is implemented, then calibration time is reduced and precision is improved, but device complexity increases
Solution Approach 1:
The calibration system is integrated into the existing CNC milling machine control architecture, allowing the same computational resources and control systems to serve both production control and calibration functions, reducing the need for separate dedicated calibration hardware
Data Source
AI summary
A computer-implemented system and method of automated milling machine calibration includes receiving a calibration alert from a milling machine; performing automated calibration on the milling machine to determine one or more offsets; and automatically updating milling production instructions with the one or more offsets. A non-transitory computer readable medium storing executable computer program instructions to provide automated milling machine calibration, the computer program instructions including instructions for: receiving a calibration alert from a milling machine; performing automated calibration on the milling machine to determine one or more offsets; and automatically updating milling production instructions with the one or more offsets. A computer-implemented method includes receiving a 3D virtual calibration block scan including a first surface region, a second surface region, and a curved surface region; determining an X-offset based on the first surface region and the second surface region; and determining a Z-offset based on the curved surface region.