Virtual Part Probing for Precise Fixture Alignment
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Solution Overview
Problem
Conventional manufacturing methods face challenges in achieving high-accuracy and high-precision part positioning and validation within a working volume, particularly in rapid prototyping and high-mix, low-volume production, due to the need for comprehensive on-machine probing and intermediary calibration.
Innovation Solution
The method involves generating a virtual model of the physical object, creating a probing routine based on this model, and using standardized components and fixture retention positions to validate the physical object's alignment, allowing for repeatable and precise positioning without the need for extensive calibration, thereby decoupling fixturing from toolpath creation and enabling orthogonal variation in fixtures and parts.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If conventional on-machine probing and intermediary calibration are used for part positioning and validation, then measurement accuracy is improved, but device complexity and time consumption increase
Solution Approach 1:
The patent creates a virtual model (copy) of the physical assembly that contains all positioning and validation information. This virtual copy replaces the need for complex physical probing systems, as the virtual model can be processed and validated computationally without physical measurement devices.
Solution Approach 2:
The patent replaces mechanical probing systems with a computational approach using virtual models. Instead of using physical probes to measure and validate parts, the system uses software-based validation against the virtual model, eliminating complex mechanical measurement devices.
2Manufacturing precision
If comprehensive on-machine probing is performed for validation, then manufacturing precision is improved, but productivity decreases
Solution Approach 1:
The patent performs validation checks in the virtual model before physical assembly occurs. By validating the virtual assembly first, the system prevents errors before they occur in physical manufacturing, eliminating the need for time-consuming post-assembly probing and rework.
Solution Approach 2:
The virtual model serves as a digital twin that can be validated instantly without affecting physical production. This copying approach allows comprehensive validation to occur in silico, maintaining high manufacturing precision without slowing down physical productivity.
3Ease of manufacture
If standardized components and fixture retention positions are used, then ease of manufacture is improved, but adaptability to different part configurations decreases
Solution Approach 1:
The patent uses a virtual model that can be dynamically reconfigured for different part configurations while maintaining standardized physical fixtures. The virtual representation adapts to various scenarios, allowing the same physical fixture setup to serve multiple purposes through software-based differentiation.
Solution Approach 2:
The standardized fixtures with retention positions serve multiple functions by working with different part configurations through the virtual model. The universal fixture design, combined with adaptive virtual modeling, allows one physical system to handle diverse manufacturing scenarios.
4Ease of operation
If decoupling fixturing from toolpath creation is implemented, then ease of operation is improved, but device complexity increases
Solution Approach 1:
The patent separates the fixturing system from the toolpath creation process by using independent virtual models for each. The fixturing validation occurs in the virtual assembly model, while toolpaths are generated separately based on validated fixture positions, allowing independent optimization and simplification of each subsystem.
Data Source
AI summary
A method for automated part probing using a physical machine defining a physical working volume, the method including: generating a virtual model based on a virtual part design received from a user account, the virtual model comprising a virtual part model, based on the virtual part design, virtually fixed to a virtual fixture plate arranged within a virtual working volume representative of the physical working volume; generating a probing routine based on the virtual model; sending the probing routine to the machine; receiving probe outputs from the machine; and validating the virtual model based on the probe outputs.