Virtual Geometry Modeling for Machine Tool Inspection Reduction
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Solution Overview
Problem
Existing methods for quality assurance in manufacturing components with machine tools are time-consuming, expensive, and require costly measurement instruments due to unpredictable systematic and random errors, leading to high costs and inefficiencies.
Innovation Solution
A computer-implemented method that generates a virtual geometry of a component using machine information and target geometry, eliminating the need for subsequent inspections by deriving the component's geometry from machine parameters, allowing for 100% inspection and reducing measurement efforts.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If measurement techniques are used to measure the manufactured component, then quality assurance is ensured, but the process becomes time-consuming and expensive
Solution Approach 1:
The patent applies preliminary action by generating a virtual geometry that predicts the actual component geometry before physical measurement occurs. The simulation model incorporates systematic error data and machining parameters to pre-determine the expected geometry, eliminating the need for time-consuming post-manufacturing measurements while ensuring quality assurance.
Solution Approach 2:
The patent creates a virtual copy (virtual geometry) of the manufactured component that replicates its actual geometry including deviations. This digital replica serves as a measurement substitute, allowing quality verification without physical contact with the actual component, thereby reducing measurement time while maintaining assurance quality.
2Manufacturing precision
If measurement techniques are used to measure the manufactured component, then quality assurance is ensured, but the cost increases
Solution Approach 1:
The patent replaces expensive physical measurement instruments and processes with a virtual copying approach. The virtual geometry serves as a cost-free digital replica that can be generated and analyzed without investing in costly measuring equipment, while still providing comprehensive quality assurance for the manufactured component.
Solution Approach 2:
The patent substitutes mechanical measurement systems (tactile coordinate measuring technology, optical fringe projection) with a computational simulation system. By replacing physical measurement infrastructure with software-based virtual geometry generation, the patent eliminates investment costs, maintenance costs, and operational costs associated with mechanical measuring instruments while maintaining quality assurance capabilities.
3Loss of time
If simulation is used to analyze the workpiece, then measurement effort is reduced, but the result becomes inaccurate due to unmodeled technological effects
Solution Approach 1:
The patent incorporates feedback by integrating actual systematic error data from the machining process into the simulation model. The virtual geometry generation uses measured error characteristics from the machine tool and machining system to adjust and refine the predicted component geometry, ensuring high accuracy while maintaining reduced measurement effort.
Solution Approach 2:
The patent applies parameter changes by incorporating specific machining parameters, error data, and technological effect parameters into the simulation model. By adjusting the simulation parameters to reflect actual machining conditions and systematic errors, the patent achieves accurate virtual geometry predictions that match the actual manufactured component without requiring physical measurement.
Data Source
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AI summary
The invention relates to a method, in particular a computer-implemented method, for generating a virtual geometry (32), a method for generating a digital twin, a system for data processing, and a computer program. The invention in particular relates to a method, in particular a computer-implemented method, for generating a virtual geometry of a component (8) which is produced or is intended to be produced by means of a machine tool (2) and which has a target geometry, comprising the steps: ascertaining tool information (12, 14) characterizing at least one tool parameter of the machine tool (2) influencing the geometry of the component (8); determining (230, 240, 250) at least one component factor (30) on the basis of the tool information (12, 14) and the target geometry (10); and generating (260), on the basis of the component factor (30), a first virtual geometry (32) as a digital geometric image of the component (8) which is produced or is intended to be produced.