Watertight Spline Morphing for CAD-to-Inspection Deviation Mapping
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Solution Overview
Problem
Current CAD software relies on restrictive mathematical assumptions, leading to incomplete modeling of critical information, which necessitates iterative and labor-intensive processes to repair and convert CAD models for downstream applications, resulting in productivity losses and increased time to market.
Innovation Solution
The method involves determining a warp function based on the difference between an as-designed watertight spline model and an as-inspected watertight spline model, constructed from measurement points and metadata, to characterize discrepancies and maintain semantic PMI data throughout the design-through-inspection lifecycle.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If restrictive mathematical assumptions are used in CAD software, then the software can operate with simplified models, but critical information is not explicitly modeled requiring iterative repairs
Solution Approach 1:
The patent segments the CAD model into multiple hierarchical levels: the original restrictive mathematical model, intermediate representations with additional information, and final detailed models with all critical information. This allows the system to maintain simplified models for general operations while automatically generating detailed versions when needed, preventing information loss without compromising ease of manufacture.
Solution Approach 2:
The system performs preliminary actions by pre-computing and storing multiple levels of model detail and critical information alongside the base CAD model. When downstream applications require specific information, the system can immediately provide it without iterative repairs, as the information was prepared in advance.
2Adaptability or versatility
If iterative repair and conversion processes are used, then CAD models can be converted to acceptable formats, but substantial work is wasted and productivity is reduced
Solution Approach 1:
The patent creates a universal intermediate representation that can serve multiple downstream applications simultaneously. Instead of performing separate iterative conversions for each application (FEA, CFD, additive manufacturing, inspection), the system generates one comprehensive model that adapts to all needs, eliminating redundant work and improving productivity while maintaining versatility.
Solution Approach 2:
The system creates accurate digital copies of the CAD model at different levels of detail and in different formats as needed, rather than repeatedly modifying the original model. These copies preserve all critical information while being optimized for specific applications, eliminating wasteful iterative repair cycles.
3Reliability
If manual repair of CAD model gaps is performed, then models can be made watertight, but countless hours are wasted causing time to market increases
Solution Approach 1:
The system implements self-service by automatically detecting gaps and errors in CAD models and performing repairs without human intervention. The computational system analyzes the model structure, identifies watertightness issues, and applies appropriate fixes automatically, eliminating the need for manual repair while ensuring model reliability.
Solution Approach 2:
The patent replaces the manual mechanical process of model repair with an automated computational system. Instead of designers and engineers manually identifying and fixing gaps, software algorithms automatically analyze the model geometry, detect watertightness violations, and apply repairs, dramatically reducing time loss while maintaining or improving model reliability.
4Adaptability or versatility
If one-way file conversion operations are used, then models can be converted between formats, but redundant operations occur causing productivity losses
Solution Approach 1:
The system implements feedback mechanisms where downstream applications provide information about their specific requirements back to the model generation system. This feedback loop allows the system to optimize model representations for each application's needs, avoiding redundant conversion operations by preparing models with the appropriate level of detail and format characteristics beforehand.
Data Source
AI summary
Determining a warp function between two watertight spline models. A first watertight spline model of a first object and a set of points and associated metadata from a second object are received. A second watertight spline model of the second object is constructed based on the set of points, the metadata, and the first watertight spline model. A warp function is determined based on a difference between the first watertight spline model and the second watertight spline model. The warp function is a continuous function approximating differences between the first object and the second object. The warp function is stored in a non-transitory computer-readable memory medium.