Methods and apparatus for manufacturing a plurality of parts with tool path correction

Patent metadata

Field	Value
Publication number	US-11378931-B2
Application number	US-201916434101-A
Country	US
Kind code	B2
Filing date	Jun 6, 2019
Priority date	Jun 8, 2018
Publication date	Jul 5, 2022
Grant date	Jul 5, 2022

Abstract

A method of manufacturing a plurality of parts receives cutting instructions to produce a part based on a nominal model of the part. After cutting a given part, the method measures at least one particular feature of the given part with a coordinate measuring machine and subsequently calculates an error of the given part by determining an initial deviation between the cutting instructions and the nominal model. The cutting instructions are then adjusted based on the error to obtain updated cutting instructions, where the updated cutting instructions have a reduced deviation from the initial deviation with regard to the nominal model. The method then uses the updated cutting instructions to produce another part having a reduced error deviation from the nominal model.

First claim

What is claimed is:

1. A method of manufacturing a plurality of parts, the method comprising:
receiving cutting instructions to produce a part based on a nominal model of the part, the cutting instructions comprising a plurality of lines of code that define one or more machine tool passes;
driving a machine tool with the cutting instructions to produce a given part;
measuring the given part with a coordinate measuring machine by measuring at least one particular feature of the given part;
calculating an error map of the given part by determining an initial deviation between the cutting instructions and the nominal model, the initial deviation being a function of the measured at least one particular feature of the given part and a corresponding at least one particular feature of the nominal model;
adjusting the cutting instructions by editing at least one line of code from the plurality of lines of code that define the one or more machine tool passes based on the error map to obtain updated cutting instructions, the updated cutting instructions having a reduced deviation from the initial deviation with regard to the nominal model; and
using the updated cutting instructions to produce another part.

2. The method of claim 1 , the cutting instructions further comprise a series of discrete points that coordinate a cutting path of a machine tool, each of the discrete points having a coordinate set defined in a machine tool coordinate plane.

3. The method of claim 2 ,
calculating the error map of the given part further comprises calculating the deviation of the measured at least one particular feature from the corresponding at least one particular feature of the nominal model in a coordinate measuring machine coordinate plane for each of the at least one particular features, and
adjusting the cutting instructions based on the error map further comprises adjusting at least one coordinate set of the cutting instructions in the machine tool coordinate plane.

4. The method of claim 1 , adjusting the cutting instructions further comprises:
identifying a particular set of the cutting instructions responsible for cutting the at least one particular feature of the given part; and
adjusting the particular set of the cutting instructions to compensate for at least part of the initial deviation of the at least one particular feature of the given part.

5. The method of claim 1 further comprising:
associating the at least one particular feature of the given part with a corresponding set of the cutting instructions using a relationship between the cutting instructions and the nominal model, and the measured at least one particular feature and the nominal model.

6. The method of claim 1 , the initial deviation including an error deviation magnitude and an error deviation direction for each of a plurality of points making up the at least one particular feature of the given part.

7. The method of claim 1 , wherein the lines of code comprise G-code, and wherein editing at least one line of code from the plurality of lines of code comprises editing said G-code.

8. A method of producing a machined part, the method comprising:
directing use of electronic instructions for producing a given part, the instructions comprising a series of cutting instructions comprising a plurality of lines of code that coordinate a cutting path of a machine tool as a function of an electronic nominal model of the part;
receiving inspection results of the given part produced using the electronic instructions, the inspection results showing one or more error deviations from the nominal model, each error deviation being associated with a particular feature of the given part as produced;
identifying a set of the cutting instructions associated with a particular feature of the given part;
associating the error deviation(s) of the particular feature of the given part with the identified set of the cutting instructions; and
editing at least one line of code from the plurality of lines of code of the identified set of the cutting instructions to correct at least part of the error deviation(s) of the particular feature.

9. The method of claim 8 , directing use of the electronic instruction for producing the given part results in the given part having a series of particular features along the cutting path of the machine tool.

10. The method of claim 8 , each error deviation includes an error magnitude and an error direction associated with a discrete point of the particular feature.

11. The method of claim 8 , editing the identified set of the cutting instructions to correct for at least part of the error deviation(s) of the particular feature further comprises:
identifying a specific coordinate set of the cutting instructions responsible for forming a discrete point of the particular feature;
associating an error deviation of the discrete point of the particular feature with the identified specific coordinate set; and
editing the specific coordinate set of the cutting instructions to correct at least part of the associated error deviation.

12. The method of claim 8 , wherein the lines of code comprise G-code, and wherein editing at least one line of code from the plurality of lines of code comprises editing said G-code.

13. A computer program product for use on a computer system for producing a machined part, the computer program product comprising a tangible, non-transient computer usable medium having computer readable program code thereon, the computer readable program code comprising:
program code configured for directing use of electronic cutting instructions for producing a given part, the cutting instructions comprising a plurality of lines of code that coordinate a cutting path of a machine tool as a function of an electronic nominal model of the part;
program code configured for receiving inspection results of the given part produced using the electronic cutting instructions, the inspection results showing one or more error deviations from the nominal model, each error deviation being associated with a particular feature of the given part as produced;
program code configured for identifying a set of the cutting instructions associated with a particular feature of the given part;
program code configured for associating the error deviation(s) of the particular feature of the given part with the identified set of the cutting instructions; and
program code configured for editing at least one line of code from the plurality of lines of code of the identified set of the cutting instructions to correct at least part of the error deviation(s) of the particular feature.

14. The medium of claim 13 , the program code configured for directing use of the electronic instruction for producing the given part results in the given part having a series of particular features along the cutting path of the machine tool.

15. The medium of claim 13 , each error deviation including an error magnitude and an error direction associated with a discrete point of the particular feature of the given part.

16. The medium of claim 13 , the program code configured for editing the identified set of the cutting instructions to correct for at least part of the error deviation(s) of the particular feature further comprises:
program code configured for identifying a specific coordinate set of the cutting instructions responsible for forming a discrete point of the particular feature;
program code configured for associating an error deviation of the discrete point of the particular feature with the identified specific coordinate set; and
program code con

Assignees

• Hexagon Technology Ct Gmbh

Inventors

• Wilcox William
• Jeffers David

Classifications

• G05B19/404 Primary

  characterised by control arrangements for compensation, e.g. for backlash, overshoot, tool offset, tool wear, temperature, machine construction errors, load, inertia (G05B19/19, G05B19/41 take precedence) · CPC title

• G05B19/401

  characterised by control arrangements for measuring, e.g. calibration and initialisation, measuring workpiece for machining purposes (G05B19/19 takes precedence) · CPC title

• G05B19/40931

  concerning programming of geometry · CPC title

• G05B19/4083

  Adapting program, configuration · CPC title

• G05B19/19 Primary

  characterised by positioning or contouring control systems, e.g. to control position from one programmed point to another or to control movement along a programmed continuous path · CPC title