Virtual Component Geometry for Measurement-Free Quality Assurance
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Solution Overview
Problem
Current methods for quality assurance in component manufacturing are time-consuming and costly, especially for complex geometries, due to the need for extensive measurement processes, which can account for up to 25% of component costs and require significant investment in measuring equipment and maintenance.
Innovation Solution
A computer-implemented method that generates a virtual geometry of a component by acquiring machine information and nominal geometry, determining component factors, and creating a digital geometric image, thereby eliminating the need for subsequent measurement processes and enabling 100% inspection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If traditional measurement methods are used for quality assurance, then measurement precision can be achieved, but measurement time and costs increase significantly
Solution Approach 1:
The patent performs virtual measurements during the simulation phase before actual production, creating a digital twin that predicts component geometry. This preliminary action eliminates the need for subsequent physical measurements, reducing measurement time while maintaining precision through the virtual geometry model
Solution Approach 2:
The patent creates a virtual copy (digital twin) of the physical component that replicates its geometric properties. This copying approach allows quality assurance to be performed on the virtual model rather than the physical part, significantly reducing measurement time and costs while maintaining measurement precision
2Manufacturing precision
If traditional measurement methods are used for quality assurance, then geometry can be verified, but investment costs and maintenance requirements increase
Solution Approach 1:
The patent replaces physical measuring equipment with a virtual measurement system based on simulation data. The digital twin generation process substitutes mechanical measurement devices with computational models, eliminating the need for expensive measuring equipment while maintaining geometry verification capability
Solution Approach 2:
By creating a virtual copy of the component through digital twin technology, the patent eliminates the need for physical measurement equipment. The virtual geometry serves as a substitute for physical measurement, reducing investment costs and maintenance requirements while verifying component geometry
3Reliability
If comprehensive measurement processes are performed, then quality assurance coverage is improved, but productivity decreases
Solution Approach 1:
The patent performs quality assurance checks during the simulation phase before production, when the digital twin is generated. This preliminary quality verification ensures comprehensive coverage without slowing down actual production, as the virtual measurements are computed alongside the manufacturing simulation
Data Source
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, and a data processing system and computer program. In particular, the invention relates to a method, in particular a computer-implemented method, for generating a virtual geometry of a component (8) which is produced and/or is to be produced with a processing machine (2) and which comprises the steps: Acquisition of machine information (12, 14) which characterizes at least one machine parameter of the processing machine (2) influencing a geometry of the component (8), determination (230, 240, 250) of at least one component factor (30) based on the machine information (12, 14) and the nominal geometry (10), and generation (260) of a first virtual geometry (32) as a digital geometric image of the component (8) produced and/or to be produced based on the component factor (30).