Substitute Workpiece Collision Checking for Machine Tool Setup
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Solution Overview
Problem
Current methods for collision checking in machining processes are either costly, complex, or pose risks to original machining components due to inadequate visibility and reliance on optical or geometric/mathematical checks, which can lead to damage during the setup of new machining processes on machine tools.
Innovation Solution
A method using substitute machining components, such as partial replicas of the workpiece and tool, made from flexible materials like plastic or cardboard, which are rotated to simulate the relative positions of the original components, allowing for safer and more straightforward collision detection without damaging the original equipment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If optical collision checking is performed with original machining components, then collision detection is possible, but the risk of damage to expensive tools and workpieces increases
Solution Approach 1:
The patent applies the copying principle by creating a substitute workpiece that replicates the essential geometric features and dimensions of the original workpiece. This substitute model allows the operator to perform collision checking by positioning the tool relative to the replica, thereby detecting potential collisions without risking damage to the expensive original workpiece and tool. The substitute workpiece is specifically designed to reproduce critical surfaces and features that could be affected by tool interference.
Solution Approach 2:
The patent implements this principle by using a substitute workpiece that is intentionally made as a low-cost replica, acceptable to be damaged or discarded after serving its collision detection purpose. This disposable substitute absorbs the risk of damage during the setup phase, protecting the valuable original workpiece and expensive tooling from potential harm while maintaining reliable collision detection capability.
2Measurement precision
If geometric/mathematical collision checking software is used, then collision detection accuracy is improved, but the complexity and cost of the system increases
Solution Approach 1:
Instead of implementing complex geometric/mathematical software to simulate and calculate potential collisions, the patent uses a physical substitute workpiece that replicates the actual workpiece geometry. This physical replica allows the operator to visually and manually verify tool paths and positions, achieving accurate collision detection through direct observation rather than through complicated computational models.
Solution Approach 2:
The substitute workpiece serves its own purpose of collision detection without requiring external complex software systems. The geometric features of the substitute workpiece itself provide the reference needed for collision checking, eliminating the need for separate computational software and reducing overall system complexity while maintaining detection precision.
3Measurement precision
If the workpiece is replicated completely, then collision checking accuracy is improved, but the manufacturing effort and cost of the substitute increases
Solution Approach 1:
The patent applies segmentation by identifying and replicating only the critical portions of the workpiece that are relevant for collision detection, rather than creating a complete replica. The substitute workpiece includes only those surfaces, features, and dimensions that could potentially interfere with the tool or tool holder during the machining cycle. This selective replication significantly reduces manufacturing complexity and cost while maintaining sufficient accuracy for collision detection purposes.
Solution Approach 2:
The substitute workpiece is designed with local quality by concentrating manufacturing precision and effort only on the specific regions and features that are critical for collision checking. Non-critical portions of the workpiece are either omitted or reproduced with lower fidelity, optimizing the trade-off between detection accuracy and manufacturing ease by allocating resources only where locally necessary.
Data Source
AI summary
A method for collision checking of a machining process is disclosed. A process-specific cycle is provided for the machining process. Multiple machining components are moved relative to one another with at least one machine axis on a machine tool. The machining components have at least one workpiece and one tool. The workpiece rotates about a workpiece axis and the tool rotates about a tool axis. At least one checking position is identified and corresponds to a relative position of the machining components set with the at least one machine axis. In order to check a respective checking position for collisions, a substitute machining component is used during the reproducing, which is a replica of the corresponding machining component.