Multi-Machine Workpiece Inspection With Feedback Correction
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Solution Overview
Problem
In automated factory manufacturing systems, measuring individual features after each machining operation on successive machine tools reduces overall efficiency, and manual correction of the production process is delayed, affecting the quality of workpieces produced in the meantime.
Innovation Solution
A method where workpieces are successively loaded onto multiple machine tools, then passed to a common dimensional inspection station for measurement, with output signals generated based on the measurements to adjust each machine tool's production process, eliminating the need for intermediate inspection stations and improving cost-effectiveness and quality control.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If intermediate inspection stations are placed between each machine tool to measure features after each machining operation, then measurement precision and quality control are improved, but device complexity and manufacturing cost increase
Solution Approach 1:
The patent merges multiple intermediate inspection stations into a single common inspection station that measures all features after the machining sequence is complete. This consolidation reduces device complexity while maintaining measurement precision through centralized, comprehensive inspection of all workpiece features.
Solution Approach 2:
The common inspection station serves as a universal measuring device that inspects all features produced by multiple different machine tools. This multi-functional approach eliminates the need for dedicated inspection stations for each machine tool, reducing overall system complexity while maintaining quality control.
2Manufacturing precision
If intermediate inspection stations are placed between each machine tool, then quality control is improved, but productivity decreases due to increased measurement time and workpiece handling
Solution Approach 1:
By combining all intermediate inspections into a single post-process inspection at a common station, the patent eliminates multiple separate measurement operations. This reduces total inspection time and minimizes workpiece handling, thereby improving productivity while maintaining quality control through comprehensive final measurement.
Solution Approach 2:
The patent enables continuous machining operations across multiple machine tools without interrupting the workflow for intermediate inspections. The machining sequence proceeds uninterrupted, and inspection occurs continuously after all machining is complete, eliminating downtime and maintaining continuous productive action.
3Manufacturing precision
If manual correction of the production process is performed after inspecting workpieces in a quality control room, then manufacturing precision can be improved, but loss of time occurs because corrections are delayed and do not affect previously produced workpieces
Solution Approach 1:
The patent implements an automated feedback system where measurement data from the common inspection station is immediately transmitted to the respective machine tools. This real-time feedback enables automatic adjustment of machining parameters, ensuring that corrections are applied promptly to subsequent workpieces without manual intervention delays.
Solution Approach 2:
The system performs preliminary corrections by automatically adjusting machine tool parameters based on measurement feedback before the next workpiece is machined. This preliminary action ensures that corrections are made in advance, preventing defects in subsequent workpieces rather than correcting them after the fact.
Data Source
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AI summary
A method is disclosed of producing a workpiece, in which the workpiece is successively loaded onto two or more machine tools (10, 12, 14,16) and in which one or more machining operations are performed to produce one or more features of the workpiece on each machine tool (10, 12, 14,16). After the machining operations on both or all of the machine tools(10, 12, 14,16), the workpiece is passed to a common dimensional inspection station (20, 22, 24). At the common dimensional inspection station (20, 22, 24), dimensions of the features of the workpiece produced by the machining operations on the two or more machine tools (10, 12, 14,16) are measured. Based on the results of measuring the dimensions of the features, two or more output signals are produced which respectively relate to the performance of the two or more machine tools (10, 12, 4,16) which performed the machining operations. Each of the output signals is fed back to the machine tool (10, 12, 14,16) which performed the respective 1 operation, to adjust the production process of each corresponding machine tool (10, 12, 14,16).