Tool Unit Digital Twin Creation Using Shadow Contour Sensing
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Solution Overview
Problem
Existing machining centers face inefficiencies in creating digital twins of tool units due to the high accuracy requirements for tool presetting and the lack of standardized, accurate data for collision monitoring, leading to significant manual effort and incomplete digital representations.
Innovation Solution
A machining center equipped with a positioning device, lighting device, and image sensor is used to efficiently produce a digital twin of a tool unit by determining the envelope contour with lower accuracy, utilizing larger image sensors and coherent light sources to capture the shadowed area, allowing for quick digitization of tool units.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If high-resolution cameras are used to measure cutting edges with accuracy of 0.001 mm to 0.02 mm, then measurement precision is improved, but the detection window becomes small (only 5 mm x 5 mm to 10 mm x 10 mm area)
Solution Approach 1:
The measurement process is segmented into two distinct functions: (1) high-precision cutting edge measurement using a high-resolution camera with limited detection window, and (2) comprehensive tool unit contour capture using a separate image sensor with larger detection area. This segmentation allows each sensor to be optimized for its specific measurement task without compromise.
Solution Approach 2:
A lighting device is introduced as an intermediary element to illuminate the tool unit for the image sensor. The lighting device includes a coherent light source and optical elements that create structured illumination patterns, enabling the image sensor to capture accurate envelope contour information across a larger area without requiring the high resolution needed for cutting edge measurement.
2Device complexity
If manual data entry or manufacturer data is used to create digital twins, then device complexity is reduced, but measurement precision and data accuracy deteriorate due to lack of standardization and assembly inaccuracies
Solution Approach 1:
The manual or semi-manual data entry process is replaced with an automated optical measurement system. The image sensor captures the actual envelope contour of the assembled tool unit, and a evaluation unit automatically processes this data to generate accurate digital twin information. This substitution eliminates transcription errors and captures real-world assembly variations that manufacturer data cannot reflect.
Solution Approach 2:
The system performs self-measurement of the tool unit's envelope contour without requiring external manual intervention. The positioning device automatically holds and positions the tool unit, the lighting device illuminates it, the image sensor captures the contour, and the evaluation unit processes the data - creating a self-contained automated measurement system that generates accurate digital twins directly from the physical tool unit.
3Manufacturing precision
If detailed characteristic lists according to DIN 4000 standards are used to describe tool geometry, then manufacturing precision is improved for specific parameters, but the ability to capture complete envelope contour deteriorates
Solution Approach 1:
The approach transitions from describing tool geometry through discrete characteristic parameters (length, diameter, etc.) to capturing the complete three-dimensional envelope contour as a continuous geometric surface. This dimensional transformation allows comprehensive representation of the tool's external shape without being limited to standardized characteristic dimensions, enabling accurate collision monitoring while preserving all relevant geometric information.
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
Enables rapid and accurate creation of digital twins of tool units, reducing manual effort and data inaccuracies, facilitating efficient collision analysis and simulation in machining processes.
Implementation Method 1
the image sensor is partially shaded by the tool unit... the envelope contour of the tool unit is determined using the value for the extent of the deactivated area
Data Source
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AI summary
Machining center (1) for machining materials, comprising a machining machine (2a) and a presetting device (5), wherein the presetting device (5) has a positioning device (8), a lighting device (9, 9a) and an image sensor (11), wherein the positioning device (8) holds a tool unit (10) to be illuminated by the lighting device (9, 9a) in front of the image sensor (11) in such a way that the image sensor (11) is partially shaded by the tool unit (10), wherein the image sensor (11) has a larger maximum extent in at least one spatial coordinate direction than the tool unit (10) in the same spatial coordinate direction, and wherein the envelope contour of the tool unit (10) is determined using the value for the extent of the shaded area.