Tooling Machine 3D Scan Workflow for Unknown Workpiece Geometry
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Solution Overview
Problem
Current methods for machining workpieces with unknown geometries in computer-controlled tooling machines are complex and imprecise, requiring multiple data processing steps across different systems and involving remounting of the workpiece, which complicates the process and reduces precision.
Innovation Solution
A method that involves clamping the workpiece, executing a manually guided 3D line scan to generate a first dataset, processing it to correct errors, using it for rough component geometry generation, generating scan paths for an automatic 3D line scan, and then performing an automatic 3D line scan to achieve precise component geometry, allowing for automated machining without remounting and data transfer between systems.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If a manually guided 3D line scan is performed outside the tooling machine followed by remounting and data transfer, then the workpiece geometry can be determined, but the process complexity increases and measurement precision decreases
Solution Approach 1:
The patent combines the measurement function and machining function into a single tooling machine system. The measurement sensor is integrated into the tooling machine, allowing 3D line scans to be performed directly on the workpiece while clamped in the same device that will subsequently machine it. This eliminates the need for external measurement equipment and multiple data transfer steps between different systems.
Solution Approach 2:
The tooling machine is designed to perform multiple functions: it can both measure workpiece geometry using an integrated measurement sensor and execute machining operations. This multi-functionality allows the same device to handle both measurement and processing tasks, reducing the need for separate specialized equipment and simplifying the overall workflow.
2Manufacturing precision
If multiple data processing steps are performed across different systems, then the workpiece can be measured and prepared for machining, but time consumption and cost increase
Solution Approach 1:
The measurement of workpiece geometry is performed before the machining operation within the same tooling machine, while the workpiece is already clamped in its final position. This preliminary measurement action provides the exact geometry data needed for subsequent machining operations, eliminating the need for remounting and re-measurement, and ensuring that all processing steps are based on the same reference position.
3Ease of operation
If the workpiece is remounted between measurement and machining, then different operations can be performed, but position changes reduce precision
Solution Approach 1:
The measurement and machining operations are merged into a single integrated process within the same tooling machine. The workpiece remains clamped in the same position throughout both operations, eliminating position changes and associated precision losses. The control unit receives measurement data directly from the integrated measurement sensor and uses this data to generate machining paths without requiring workpiece remounting.
Data Source
AI summary
A method for the machining of workpieces that have an unknown workpiece geometry with a tooling machine, said method having the steps of clamping of the workpiece in a clamping device on the tooling machine, execution of a manually guided 3D line scan with a measurement sensor within the tooling machine to determine the workpiece geometry in a first dataset, processing of the first dataset to compensate for errors in the manually guided 3D line scan in order to obtain a second dataset, use of the second dataset for 3D CAD surface generation by the tooling machine for the generation of a rough component geometry, use of the rough component geometry for the generation of scan paths for an automatic 3D line scan, execution of an automatic 3D line scan of the workpiece with the measurement sensor within the tooling machine in order to obtain a third dataset, use of the third dataset for 3D CAD surface generation for the generation of a precise component geometry, and automated machining of the workpiece by the tooling machine based on the precise component geometry, and a tooling machine for the execution of the method are provided.