Tooling Machine Parameter Adaptation Using Digital Twin Feedback
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Solution Overview
Problem
Manufacturing processes often deviate from desired targets due to environmental influences that conventional control algorithms fail to compensate, leading to suboptimal output work pieces.
Innovation Solution
A method involving a digital simulation of the manufacturing process using a digital twin to emulate the measurement results, allowing adaptation of process parameters to minimize deviations by iteratively adjusting parameters based on geometric feature measurements.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional control algorithms are used to manage manufacturing processes, then the control system remains simple and easy to operate, but the manufacturing precision deteriorates due to inability to compensate for environmental influences
Solution Approach 1:
The patent implements a feedback mechanism where coordinate measuring machines measure geometric features of output work pieces, and the measurement results are fed back to adaptively adjust process parameters of the tooling machine through digital simulation, enabling continuous improvement of manufacturing precision
Solution Approach 2:
The patent performs preliminary digital simulation and parameter adaptation before actual manufacturing by using measured geometric features to predict and adjust process parameters in advance, preventing deviations before they occur
2Adaptability or versatility
If a production model of the object is used for error compensation as disclosed in EP 3045 992 B1, then error compensation becomes possible, but the adaptability deteriorates because the compensation is based on a specific production model rather than being independent
Solution Approach 1:
The patent introduces a digital twin as an intermediary between the physical tooling machine and the measurement results, allowing parameter adaptation without directly modifying the production model, thus achieving both accuracy and independence
Solution Approach 2:
The patent creates a digital copy (digital twin) of the tooling machine that can be virtually adjusted to match measurement results, enabling error compensation independent of the original production model while maintaining high precision
Data Source
AI summary
A method for automatically adapting an adaptable process parameter of a tooling machine, the tooling machine being part of a first or second manufacturing process for physically processing input work pieces into output work pieces. According to the method, at least one geometric feature of an output work piece is measured by a coordinate measuring machine, the geometric feature being a direct or indirect result of the processing with the tool. The measurement result is together with nominal measurement data of the geometric feature fed into a deterministic digital simulation of at least a part of the manufacturing process with a digital model such as a digital twin of the tooling machine and modelled process parameters, therein the adaptable process parameter of the tooling machine, simulating at least a deterministic behavior of the tooling machine relevant for an operation of its tool.