Surface Fitting and Toolpath Planning for Complex Part Processing
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Solution Overview
Problem
Existing surface fitting methods for robot platforms are inaccurate and computationally intensive, especially when dealing with large and complex surfaces, leading to inefficiencies and unsatisfactory processing quality due to manual programming and reliance on CAD models that may not accurately represent the actual workpiece.
Innovation Solution
The system employs automatic surface fitting using overlapping sub-patches and Root Mean Squared Error (RMSE) analysis to generate coefficients for characterizing surfaces, allowing for accurate waypoint configuration and reduced robotic arm vibration through smooth curve transitions, thereby improving processing accuracy and efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If traditional triangle mesh methods are used for surface representation, then surface characteristics can be obtained, but calculation time increases significantly for dense point cloud
Solution Approach 1:
The patent divides the dense point cloud into multiple sparse point clouds through segmentation, reducing the computational burden on each individual processing unit while maintaining overall surface representation accuracy. This allows parallel processing and significantly reduces calculation time compared to processing the entire dense point cloud as a single mesh structure.
2Manufacturing precision
If higher mesh density is used to increase accuracy, then manufacturing precision improves, but calculation time increases prohibitively
Solution Approach 1:
The patent applies different processing strategies to different regions of the surface based on local characteristics. High-accuracy surface fitting is applied only where necessary, while other regions use computationally efficient approximations. This local quality approach maintains manufacturing precision where critical while avoiding prohibitive calculation times across the entire surface.
3Adaptability or versatility
If manual programming is used for path planning, then adaptability to complex surfaces can be achieved, but productivity decreases due to skilled labor requirements
Solution Approach 1:
The patent implements automatic path generation algorithms that self-adapt to complex surface geometries without requiring manual programming. The system automatically processes the surface data, generates appropriate toolpaths, and optimizes processing parameters, eliminating the need for skilled manual programming while maintaining high adaptability to various surface types.
4Productivity
If sharp angles are used in path design for turning, then path efficiency improves, but robotic arm vibration increases
Solution Approach 1:
The patent replaces sharp angular transitions in the toolpath with curved transitions. This curvature modification eliminates abrupt directional changes that cause robotic arm vibration, while maintaining path efficiency through optimized curve geometry. The smooth transitions reduce mechanical stress and vibration without significantly increasing path length or processing time.
Data Source
AI summary
Systems and methods for surface fitting of a surface of an object, for path planning, and for processing a surface of a part are disclosed. The method includes receiving, at a processor, a point cloud or a mesh of the surface; dividing, by the processor, the point cloud to a plurality of overlapping sub-patches; determining by the processor, a first Root Mean Squared Error (RMSE) of the overall surface; and in response to the first RMSE being smaller or equal to the user set RMSE, generating, by the processor, coefficients for characterizing the surface.