Tool Digital Twin Creation Using Shadow Imaging in Machining Centers
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Solution Overview
Problem
Current machining centers face inefficiencies in creating a digital twin of tool units due to the high accuracy requirements for tool preset and collision monitoring, which is time-consuming and labor-intensive, especially when dealing with complex tool geometries and incomplete manufacturer data.
Innovation Solution
A machining center equipped with a positioning apparatus, illumination apparatus, and image sensor that uses a large image sensor to determine the shaded area of the tool unit with reduced accuracy, allowing for quick and efficient creation of a digital twin by imaging the complete tool in few steps, and a method involving a measuring grid to calculate the enveloping contour using commercially available image sensors.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If high resolution cameras are used to measure cutting edges with accuracy between 0.001 mm and 0.02 mm, then measurement precision is improved, but the recording window becomes very small (only 5 mm×5 mm to 10 mm×10 mm area)
Solution Approach 1:
The measurement process is segmented into two distinct stages: (1) high-resolution optical measurement of cutting edges for precise position data, and (2) low-resolution shadow photography for capturing the complete tool envelope. Each stage uses appropriate imaging methods for its specific purpose, avoiding the need for a single system to achieve conflicting requirements simultaneously.
Solution Approach 2:
A shadow photograph serves as an intermediary representation of the tool envelope. Instead of directly measuring the physical tool dimensions with high-resolution cameras, the patent uses shadow images captured by low-resolution cameras as a mediator to define the collision-free envelope, which then guides the high-resolution cutting edge measurements.
2Measurement precision
If manual data entry for enveloping contour is performed, then collision monitoring accuracy is improved, but the effort and time required increases significantly
Solution Approach 1:
The system performs self-measurement by automatically capturing shadow photographs of the tools and generating the enveloping contour data without human intervention. The measurement apparatus autonomously positions tools, captures images, and processes data to create digital twins, eliminating manual data entry while maintaining accuracy.
Solution Approach 2:
Manual mechanical measurement and data entry processes are replaced by an automated optical measurement system. The patent substitutes human operators with an automated apparatus that uses shadow photography and image processing to extract enveloping contour data, significantly reducing time while maintaining precision.
3Adaptability or versatility
If manufacturer-specific datasets are used for tool enveloping contour, then data availability is improved, but data format uniformity and accuracy deteriorate
Solution Approach 1:
The patent changes the fundamental parameter of measurement from relying on manufacturer-provided dimensional data to using direct optical shadow imaging. This parameter change allows the system to work with any tool regardless of manufacturer data availability, while automatically generating uniform, accurate enveloping contour data through image processing.
4Loss of information
If complete digitization of tool inventory is performed using traditional methods, then digital twin completeness is improved, but the effort over several man-years increases
Solution Approach 1:
The measurement apparatus autonomously performs complete digitization of the tool inventory without requiring manual intervention for each tool. The system automatically captures shadow photographs, processes images to extract enveloping contours, and stores digital twin data, enabling rapid comprehensive digitization that reduces effort from several man-years to a fraction of that time.
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 digitization of tool units with reduced measurement time and effort, suitable for both tool chucks and cutting tools, and allows for efficient collision analysis with sufficient accuracy for operational safety.
Implementation Method 1
the image sensor is partially shaded by the tool unit. The enveloping contour of the tool unit is determined using the value for the extent of the shaded area.
Data Source
AI summary
The invention relates to a processing centre (1) or cutting materials, consisting of a cutting machine (2a) and an adjusting device (5), wherein the adjusting device (5) has a positioning device (8), an illumination device (9, 9a) and an image sensor (11), wherein the positioning device (8) holds a tool unit (10) to be illuminated by the illumination 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 greater maximum extension in at least one spatial coordinates direction than the tool unit (10) in the same spatial coordinates direction, and wherein the outline contour of the tool unit (10) is determined using the value for the extension of the shaded region.