Workpiece Feature Softening With Vision-Guided Laser Path Correction
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Solution Overview
Problem
Existing methods for softening edges and corners of workpieces, such as machining and mechanical deburring, are inconsistent and prone to surface imperfections, making it challenging to achieve precise control and uniform results, especially on larger parts with varying tolerances.
Innovation Solution
A system and method utilizing machine vision and data-guided laser material redistribution to soften features by generating a nominal path, determining the actual location of defining points on a workpiece, and adjusting the path to guide a laser machine for accurate softening without material removal, ensuring precise control and minimizing surface imperfections.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If mechanical finishing operations are used to soften edges and corners, then the severity of features is reduced, but manufacturing precision and consistency deteriorate due to inexact results and lack of process control
Solution Approach 1:
The patent replaces mechanical finishing operations with a laser-based material redistribution system. The laser melts and redistributes material along precisely controlled paths to soften edges and corners, eliminating the imprecision and inconsistency inherent in mechanical methods while maintaining excellent edge dimension control and surface quality.
Solution Approach 2:
The patent changes the fundamental parameter of the softening process from mechanical contact to thermal energy input. By controlling laser power, speed, and path parameters, the system achieves precise material redistribution with consistent results, resolving the contradiction between reducing edge severity and maintaining manufacturing precision.
2Object-affected harmful factors
If mechanical finishing operations are applied to soften features, then edge and corner severity is reduced, but surface quality deteriorates due to scratching and scoring
Solution Approach 1:
The patent substitutes mechanical contact-based finishing with a non-contact laser process. The laser melts and redistributes material without physical contact, completely eliminating scratching and scoring while still achieving the desired softening of edges and corners, thus resolving the contradiction between reducing feature severity and maintaining surface quality.
3Ease of manufacture
If mechanical finishing is used on larger parts with varying tolerances, then some areas are softened, but accuracy deteriorates due to difficulty in following the preferred profile over significant distances
Solution Approach 1:
The patent replaces mechanical finishing tools with a laser system guided by vision technology and automated positioning. This allows precise following of complex profiles over large distances and varying tolerances, maintaining accuracy while treating the entire part surface, thus resolving the contradiction between ease of manufacture and profile accuracy.
Solution Approach 2:
The patent uses vision systems to capture the actual geometry of the part and creates a digital model that guides the laser path. This copying approach allows the system to adapt to varying tolerances and maintain precise profile following over significant distances, resolving the accuracy issue while maintaining ease of manufacture.
4Object-affected harmful factors
If mechanical finishing operations are used to soften edges, then feature severity is reduced, but process consistency deteriorates due to inexact results and variation introduction
Solution Approach 1:
The patent replaces mechanical finishing with a laser-based material redistribution process controlled by vision systems and automated positioning. This substitution eliminates the variability and inconsistency of manual or automated mechanical operations, achieving highly consistent and repeatable edge softening results while maintaining the desired reduction in edge sharpness.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The solution provides consistent and accurate edge softening, eliminating variations caused by part forming and fixturing errors, resulting in high-quality, repeatable results without applying mechanical forces to unintended areas of the workpiece.
Implementation Method 1
softening by the material movement machine includes melting the feature by a laser without expressing material from the workpiece, to modify the feature as the softening
Data Source
AI summary
Methods and systems are provided for softening a feature of a workpiece. A method for feature softening includes generating a nominal path for softening the feature. Defining points of the workpiece are selected for accuracy of the softening. The workpiece is formed, fixtured in a workstation and imaged. From the imaging and by a processor, an actual location of the defining points on the workpiece as formed and fixtured in the workstation is determined. The processor determines an error between the actual location of the defining points and the design location of the defining points; generates a revised path for softening the feature of the workpiece; guided a material movement machine along the revised path; and softens, by the material movement machine, the feature of the workpiece.