Thermal Processing Tool Distance Calibration for Consistent Standoff
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Solution Overview
Problem
Current thermal processing methods for workpieces require labor-intensive and time-consuming manual calibration of distance controllers, leading to high process stoppage times and costs, especially when dealing with large or complex workpieces that require multiple thermal processing operations.
Innovation Solution
A fully automated method using a CNC controller for initial value finding and calibration of the distance controller, which allows for precise positioning and amplification of distance sensor signals to maintain a consistent working distance, reducing the need for manual intervention and optimizing processing efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If manual calibration of the distance controller is performed, then the processing quality can be maintained, but the process stoppage time and costs increase significantly
Solution Approach 1:
The system performs preliminary automated calibration of the distance controller using CNC controller data before thermal processing begins. The CNC controller calculates the actual distance between the processing tool and workpiece surface in advance, and the distance controller is pre-adjusted to compensate for any deviations, eliminating the need for time-consuming manual calibration during production
Solution Approach 2:
The system enables self-service calibration where the distance controller automatically adjusts itself based on information from the CNC controller. The CNC controller provides positional data, and the distance controller autonomously calculates and applies the necessary calibration corrections without requiring manual intervention or additional measurement devices
2Measurement precision
If manual setup and calibration is performed, then the distance controller can be calibrated, but the labor intensity and costs increase
Solution Approach 1:
The system replaces manual mechanical calibration operations with an automated electronic control system. The CNC controller electronically communicates positional information to the distance controller, which then automatically adjusts its calibration parameters through electronic control, eliminating the need for manual mechanical adjustment procedures
Solution Approach 2:
The CNC controller serves multiple functions: it controls the thermal processing machine operations and simultaneously provides positional data for distance controller calibration. This multi-functionality eliminates the need for separate manual calibration procedures and specialized calibration tools, reducing both labor intensity and costs
3Productivity
If the processing tool position is not precisely controlled, then the processing speed can be increased, but the processing result quality deteriorates
Solution Approach 1:
The system implements a feedback mechanism where the CNC controller continuously monitors the actual position of the processing tool relative to the workpiece surface and communicates this information to the distance controller. The distance controller uses this feedback to make real-time positional corrections, maintaining precise control throughout the thermal processing operation regardless of processing speed
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
This approach significantly reduces process stoppage times and costs by enabling high-precision, automated thermal processing with improved consistency and quality, particularly beneficial for large workpieces or multiple processing operations.
Implementation Method 1
The distance sensor (4) is designed for contactless detection of a distance between the processing tool (3) and the workpiece (1) surface and has a capacitive design
Implementation Method 2
the processing tool (3) is moved in a direction towards the workpiece (1) surface at a speed at which neither the processing tool (3) nor the workpiece (1) can be damaged by the mutual contact
Data Source
AI summary
A method for thermal processing of a workpiece uses a thermal processing machine. The method includes the following steps carried out in an automated manner: setting up the processing machine by producing contact between the processing tool and the workpiece and recording the spatial position of a workpiece surface, positioning the processing tool at a predetermined first and second distance from the workpiece surface and recording the associated signal values of the distance sensor as first and second measured values, and calibrating the distance controller which includes determining a height derivative of the distance sensor signal and an amplification factor for the signal of the distance sensor taking in account the first measured value, the second measured value, the first distance and the second distance; positioning the processing tool at a predetermined working distance from the workpiece surface with the inclusion of the amplification factor; and thermally processing the workpiece.