Virtual Part Probing for Repeatable Fixture Plate Positioning
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Solution Overview
Problem
Conventional manufacturing methods face challenges in achieving high-accuracy and high-precision part positioning, requiring extensive calibration and on-machine probing, which can be time-consuming and inefficient, especially for high-mix, low-volume production scenarios.
Innovation Solution
An automated method for physical assembly validation using standardized components and virtual models, which generates a probing routine to verify that physical objects match their virtual counterparts, allowing for repeatable and precise positioning without the need for comprehensive on-machine probing or intermediary calibration.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional manufacturing methods are used for part positioning, then manufacturing accuracy can be achieved, but extensive calibration and on-machine probing are required which increases time consumption and reduces efficiency
Solution Approach 1:
The patent applies preliminary action by pre-defining fixture retention positions and creating virtual models of fixtures and parts before physical manufacturing. The virtual model includes predetermined positions where parts will be retained, allowing the system to plan and validate the entire assembly process in advance without requiring extensive on-machine calibration during actual production
Solution Approach 2:
The patent uses copying by creating a virtual model that replicates the physical fixture and part assembly. This virtual representation allows for simulation and validation of the manufacturing process, enabling accurate part positioning to be verified in the virtual environment before physical execution, thereby reducing the need for time-consuming on-machine probing
2Reliability
If standardized components and virtual models are used for assembly validation, then repeatable and precise positioning is achieved without extensive on-machine probing, but the initial setup and virtual model creation require additional complexity
Solution Approach 1:
The patent applies universality by creating standardized fixture retention positions that can accommodate multiple different parts and fixtures. The virtual model system serves multiple functions including fixture design, part positioning validation, and manufacturing process simulation, making the initial complexity investment worthwhile through long-term repeatability and reduced on-machine intervention
Solution Approach 2:
The system applies self-service by using the virtual model to automatically validate whether physical components are assembled correctly without requiring external measurement and calibration equipment. The probing routine automatically compares physical assembly against the virtual model, enabling the system to self-verify accuracy without extensive manual intervention
3Measurement precision
If comprehensive on-machine probing is performed to validate physical assemblies, then measurement accuracy is improved, but manufacturing throughput is reduced due to the time required for extensive probing and calibration
Solution Approach 1:
The patent performs measurement and validation actions preliminarily by validating the virtual model against design requirements before physical manufacturing begins. This pre-validation ensures that the virtual representation accurately reflects the intended geometry and retention positions, allowing rapid validation of physical assemblies during production without requiring extensive on-machine probing
Solution Approach 2:
The virtual model serves as a copy of the physical assembly that can be rapidly validated against design requirements. This virtual copy allows for quick comparison and validation of physical components during manufacturing without requiring time-consuming direct measurement of every physical part, thereby maintaining measurement precision while improving throughput
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.