Tolerance Testing Component Virtual Setup
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Solution Overview
Problem
Current tolerance testing methods for components, such as rotor stub shafts, are prone to false results due to the need for multiple setup operations and are affected by the positioning of the lathe, leading to inaccuracies in measuring circularity and eccentricity.
Innovation Solution
A method and system that utilize a single test setup to receive and process data measurements, separating relative positioning data and performing a virtual setup to determine if component parameters meet specified tolerances, eliminating the need for multiple physical setups and reducing errors.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If multiple physical setup operations are performed to verify different parameters, then measurement coverage is improved, but measurement precision deteriorates due to positioning errors and wobble
Solution Approach 1:
The patent creates a virtual copy of the component in software, allowing multiple virtual setups to be performed on the digital model without physically repositioning the component. This virtual modeling approach eliminates positioning errors and wobble associated with physical setup operations while maintaining comprehensive parameter verification
Solution Approach 2:
The patent replaces the mechanical setup and measurement system with a computational system. Instead of physically positioning the component multiple times in a lathe, the system uses software to perform virtual setups and measurements on a digital model, substituting mechanical operations with computational processes to eliminate mechanical errors
2Productivity
If the component is repositioned for each parameter verification, then all parameters can be measured, but time consumption increases
Solution Approach 1:
The patent performs preliminary action by creating a complete virtual model of the component before any physical measurements are taken. This digital twin contains all geometric information needed for any parameter verification, allowing all measurements to be performed computationally without repeated physical setup, thereby eliminating setup time and improving testing efficiency
Solution Approach 2:
The patent merges multiple measurement operations into a single computational process. By performing all parameter verifications through virtual setups on the digital model in one continuous computational workflow, the system eliminates the time lost to repeated physical setup operations while maintaining comprehensive measurement coverage
3Reliability
If multiple physical setups are used to verify relative location, then location accuracy is improved, but false results increase due to positioning variability
Solution Approach 1:
The patent creates a precise virtual copy of the component that captures the exact geometry and relative locations of all features. By performing measurements on this digital model rather than the physical component, the system eliminates positioning errors and wobble that cause false results, while maintaining the ability to verify relative location accuracy
Solution Approach 2:
The patent introduces a computational model as an intermediary between the physical component and the measurement process. This digital twin serves as a mediator that eliminates the harmful effect of positioning variability by allowing all measurements to be performed in a virtual environment free from mechanical errors, thereby improving result reliability
Data Source
AI summary
A method and system of tolerance testing a component using data measurements from a single test setup within a test apparatus are described. The method includes receiving the data measurements obtained with the single test setup. The method also includes separating, at the processor, the data measurements from a relative positioning of an element of the test apparatus and performing, at the processor, a virtual setup of the component to obtain additional data measurements related to one or more parts of the component. The method additionally includes determining, at the processor, whether a parameter associated with the one or more parts meets a specified tolerance based on the additional data measurements obtained from the virtual setup.