Servomotor Tool Path Control for Sheet Metal Trimming
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Solution Overview
Problem
Existing methods for trimming sheet metal and composite aircraft parts require exact alignment, which is inflexible and limits automation, as they reflect recesses and protrusions from the reference surface onto the trimmed shape, making it difficult to achieve desired shapes without unnecessary features.
Innovation Solution
A processing device with a servomotor-driven tool path system that uses a distance sensor to measure and generate control data for the tool's locus, allowing it to process a workpiece without exact alignment by determining step coordinate ranges and adjusting tool offsets to avoid reflecting unwanted features from the reference surface.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If a trimming is performed by tracing the shape of a reference surface, then exact alignment is not necessary, but recesses and protrusions from the reference surface are reflected onto the trimmed shape
Solution Approach 1:
The patent extracts and removes the harmful elements (recesses and protrusions) from the reference surface data through filtering processing. The control device identifies and eliminates these unwanted features from the measurement data before generating the tool path, thereby preventing them from being reflected onto the trimmed shape while maintaining the benefit of not requiring exact alignment.
Solution Approach 2:
The patent performs preliminary filtering and processing of the reference surface data before the actual trimming operation. The control device processes the measurement data in advance to remove recesses and protrusions, creating a cleaned tool path that avoids transferring unwanted surface features to the final workpiece.
2Ease of operation
If a special jig is used to provide a marking line and perform trimming along the marking line, then automation is difficult, but exact alignment is not required
Solution Approach 1:
The patent replaces the mechanical jig and marking line system with an automated measurement and control system. A measurement device captures the reference surface geometry, and a control device processes this data to generate automated tool path instructions, substituting manual mechanical guidance with automated digital control while maintaining alignment flexibility.
Solution Approach 2:
The patent creates a digital copy of the reference surface through measurement devices rather than using physical jigs and marking lines. The measurement data is processed to generate a virtual model that guides the trimming tool, replacing physical mechanical aids with digital information while enabling automation.
3Extent of automation
If an NC processing device is used to perform trimming, then automation is achieved, but exact alignment of the part is required
Solution Approach 1:
The patent introduces dynamic adaptability to the NC processing system by enabling it to measure and adapt to the actual reference surface geometry during operation. The system dynamically adjusts the tool path based on real measurement data from the workpiece, allowing the automated NC device to accommodate variations in part positioning without requiring exact pre-alignment.
Solution Approach 2:
The patent implements a feedback mechanism where the measurement device continuously monitors the reference surface and provides data to the control device, which adjusts the tool path in real-time. This closed-loop feedback system enables the automated NC processing to compensate for alignment variations by adapting to the actual workpiece geometry during the trimming operation.
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
Enables processing of workpieces into desired shapes without requiring exact alignment, improving flexibility and automation by preventing the reflection of recesses and protrusions from the reference surface onto the trimmed shape.
Implementation Method 1
a distance sensor provided to the first portion; a second servomotor configured to drive the second portion in the second direction; and a control device. The second portion supports a tool for processing a work. The distance sensor measures a distance in the second direction to a reference surface of the work and outputs a distance signal indicating the distance when the distance sensor is located at each of a plurality of positions in the first direction
Data Source
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AI summary
A first servomotor drives a first portion in a moving radius rotational direction. A second portion is supported by the first portion such that the second portion is movable in a moving radius direction. A second servomotor drives the second portion in the moving radius direction. The second portion supports a tool for processing a work. A control device generates measurement data indicating relationships between coordinates in the moving radius rotational direction of a plurality of points on a reference surface of the work and distances from the plurality of points to a distance sensor based on a distance signal from the distance sensor, determines a coordinate range in the moving radius rotational direction of a step formed on the reference surface based on the measurement data, generates control data indicating a locus of the tool based on the measurement data and the step coordinate range, and numerically controls the first and second servomotors based on the control data. The control device selectively uses a plurality of offset values based on the coordinate range of the step when generating the control data.