Watertight Spline Morphing Using As-Executed Manufacturing Data
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Solution Overview
Problem
Current CAx technologies face challenges in integrating as-executed manufacturing data with CAD models to facilitate decision-making, inspection, and simulation due to the lack of automated spatial resolution and linkage between different model representations, leading to inefficiencies in manufacturability, surface finish quality, and dimensional accuracy.
Innovation Solution
A method is developed to determine a warp function that characterizes discrepancies between as-designed and as-executed watertight spline models, allowing for the construction of an as-executed digital twin that maintains semantic PMI data and facilitates interoperability between CAD, CAE, CAM, and CAI domains.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of information
If as-executed manufacturing data is collected from CNC machines, then data availability for decision-making improves, but automated spatial resolution and linkage with CAD models deteriorates due to lack of integration methods
Solution Approach 1:
The patent introduces an intermediary system that collects as-executed manufacturing data from CNC machines and automatically links it with as-designed CAD models through spatial resolution. This intermediary layer resolves the contradiction by providing a structured method to integrate data without requiring direct complex connections between manufacturing systems and design software.
Solution Approach 2:
The patent replaces manual or mechanical methods of data integration with automated computational methods. By using algorithms to automatically resolve spatial relationships and link data streams, the system eliminates the need for complex manual integration processes while maintaining data accuracy and connectivity.
2Adaptability or versatility
If different CAx disciplines use independent model representations, then disciplinary autonomy is maintained, but interoperability and automated spatial resolution deteriorate
Solution Approach 1:
The patent creates a universal framework that can handle multiple CAx disciplines (CAD, CAM, CAE, CAI) simultaneously while maintaining their individual characteristics. The system provides a common interface and methodology for spatial resolution that works across different disciplines, enabling interoperability without forcing uniformity on the underlying model representations.
3Measurement precision
If manual methods are used to link as-designed and as-executed models, then data accuracy can be maintained, but productivity and automation level deteriorate
Solution Approach 1:
The patent implements a self-service system where the automated methodology performs spatial resolution and data linkage without requiring manual intervention. The system automatically resolves spatial relationships, links as-executed data with as-designed models, and maintains accuracy through algorithmic precision, thereby eliminating the need for manual operations while preserving data quality.
4Ease of manufacture
If as-executed data is not spatially resolved with CAD models, then data collection simplicity is maintained, but decision-making capability and digital twin accuracy deteriorate
Solution Approach 1:
The patent performs preliminary spatial resolution and data linkage automatically during the manufacturing process. By pre-establishing the spatial relationships between as-executed data and CAD models before decision-making is required, the system ensures data readiness and accuracy without adding complexity to the data collection process itself.
Data Source
AI summary
Methods and computer systems for methods, computer systems, and computer-readable memory media for determining a warp function. An as-designed watertight spline model of an object is received. A set of sweep points along a sweep trajectory for manufacturing the object are used to determine a sweep surface. Model points are sampled from the as-designed watertight spline model and projected onto nearest as-executed points on the sweep surface. The projected as-executed points are used to construct an as-executed model of the object. A warp function is determined based on a difference between the as-designed watertight spline model and the as-executed model. The warp function is a continuous function approximating differences between the as-designed model and the as-manufactured object. The warp function is stored in a non-transitory computer-readable memory medium.