WO2013119424A1 - Procédés et systèmes pour ébavurage basé sur un capteur - Google Patents

Procédés et systèmes pour ébavurage basé sur un capteur Download PDF

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Publication number
WO2013119424A1
WO2013119424A1 PCT/US2013/023685 US2013023685W WO2013119424A1 WO 2013119424 A1 WO2013119424 A1 WO 2013119424A1 US 2013023685 W US2013023685 W US 2013023685W WO 2013119424 A1 WO2013119424 A1 WO 2013119424A1
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WO
WIPO (PCT)
Prior art keywords
workpiece
sensor
deburring
blasting media
processing equipment
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Application number
PCT/US2013/023685
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English (en)
Inventor
Hamid R. GHALAMBOR
Original Assignee
Ghalambor Hamid R
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Ghalambor Hamid R filed Critical Ghalambor Hamid R
Publication of WO2013119424A1 publication Critical patent/WO2013119424A1/fr

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Classifications

    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23Q—DETAILS, COMPONENTS, OR ACCESSORIES FOR MACHINE TOOLS, e.g. ARRANGEMENTS FOR COPYING OR CONTROLLING; MACHINE TOOLS IN GENERAL CHARACTERISED BY THE CONSTRUCTION OF PARTICULAR DETAILS OR COMPONENTS; COMBINATIONS OR ASSOCIATIONS OF METAL-WORKING MACHINES, NOT DIRECTED TO A PARTICULAR RESULT
    • B23Q17/00—Arrangements for observing, indicating or measuring on machine tools
    • B23Q17/20—Arrangements for observing, indicating or measuring on machine tools for indicating or measuring workpiece characteristics, e.g. contour, dimension, hardness
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23Q—DETAILS, COMPONENTS, OR ACCESSORIES FOR MACHINE TOOLS, e.g. ARRANGEMENTS FOR COPYING OR CONTROLLING; MACHINE TOOLS IN GENERAL CHARACTERISED BY THE CONSTRUCTION OF PARTICULAR DETAILS OR COMPONENTS; COMBINATIONS OR ASSOCIATIONS OF METAL-WORKING MACHINES, NOT DIRECTED TO A PARTICULAR RESULT
    • B23Q17/00—Arrangements for observing, indicating or measuring on machine tools
    • B23Q17/24—Arrangements for observing, indicating or measuring on machine tools using optics or electromagnetic waves
    • B23Q17/2452—Arrangements for observing, indicating or measuring on machine tools using optics or electromagnetic waves for measuring features or for detecting a condition of machine parts, tools or workpieces
    • B23Q17/2471—Arrangements for observing, indicating or measuring on machine tools using optics or electromagnetic waves for measuring features or for detecting a condition of machine parts, tools or workpieces of workpieces
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B24—GRINDING; POLISHING
    • B24C—ABRASIVE OR RELATED BLASTING WITH PARTICULATE MATERIAL
    • B24C1/00—Methods for use of abrasive blasting for producing particular effects; Use of auxiliary equipment in connection with such methods
    • B24C1/08—Methods for use of abrasive blasting for producing particular effects; Use of auxiliary equipment in connection with such methods for polishing surfaces, e.g. smoothing a surface by making use of liquid-borne abrasives
    • B24C1/083—Deburring

Definitions

  • the present disclosure relates to sensor-based deburring, and more particularly relates to using sensor data to determine deburring schedules.
  • Machined parts may include burrs due to deformation or breakage of material occurring during processes such as grinding, milling, drilling, and cutting.
  • Relatively soft materials such as, for example, aluminum and plastic, may be especially susceptible to forming burrs due to plastic deformation undergone during machining. Burrs may be attached or detached, and may impact the resulting dimensions of the part.
  • Blasting processes may be used to deburr parts.
  • blasting media and processes may alter dimensions of the part via grinding action, and create an untidy mix of the blasting mix and burr material.
  • deburring a workpiece may include sensing a parameter of the workpiece using a sensor, determining a burr metric based at least in part on the parameter, and delivering a blasting media to at least one portion of the workpiece based at least in part on the burr metric.
  • deburring a workpiece may include sensing one or more parameters of the workpiece using a sensor, determining, using
  • burr metrics based at least in part on the output of the sensor
  • performing a blasting schedule based on the one or more burr metrics
  • determining one or more workpiece characteristics based on one or more diagnostic tests.
  • a deburring system may include a reference surface configured to secure a workpiece, a sensor configured to detect burrs on the workpiece and provide an output, a nozzle configured to direct a flow of a blasting media to the workpiece, and processing equipment coupled to the sensor.
  • the equipment may be configured to control the flow of the blasting media based on the output of the sensor.
  • a deburring module may include at least one sensor configured to sense a burr on the workpiece and provide an output, and a nozzle configured to the deliver a flow of a blasting media to the
  • the flow of the blasting media may be controlled by processing equipment based at least in part on the output of the at least one sensor.
  • FIG . 1 shows an illustrative deburring system, in accordance with some embodiments of the present
  • FIG . 2 shows an illustrative deburring system having a deburring module, in accordance with some embodiments of the present disclosure
  • FIG . 3 shows an illustrative deburring system having a deburring module and a metrology module, in accordance with some embodiments of the present disclosure
  • FIG . 4 is a block diagram of an illustrative computer numerical controller (CNC) machine having several tools including a deburring tool, in accordance with some embodiments of the present disclosure
  • FIG . 5 shows a perspective view of an illustrative reference and workpiece, in accordance with some
  • FIG . 6 shows a perspective view of the illustrative reference and workpiece of FIG . 5 , and a deburring tool having two sensors, and a nozzle, in accordance with some embodiments of the present disclosure
  • FIG . 7 shows a perspective view of the illustrative reference, workpiece, and deburring tool of FIG . 6 , during sensing, in accordance with some embodiments of the present disclosure
  • FIG . 8 shows a perspective view of an illustrative CNC machine configured to perform deburring
  • FIG . 9 shows a screenshot of an illustrative
  • FIG . 10 is a flow diagram of illustrative steps for deburring a workpiece based on a burr metric, in
  • FIG . 11 is a flow diagram of illustrative steps for deburring a workpiece based on a burr metric, and checking one or more workpiece characteristics, m accordance with some embodiments of the present
  • FIG . 12 is a flow diagram of illustrative steps for deburring a workpiece using a deburring system and a metrology system, in accordance with some embodiments of the present disclosure.
  • the present disclosure is directed towards techniques and arrangements for deburring. Processing of materials, especially relatively soft materials, may cause burr formation.
  • deburring materials such as polyether ether ketone (PEEK) , poly ether ketone (PEEK) , nylon, poly amide imide (PAI), poly ether ketone ether ketone ketone (PEKEKK) , poly phenylene sulfide (PPS) , poly phenylene sulfone (PPSO) , poly benzimidazole (PBI), thermoplastic poly imide (TPI), liquid crystal polymers (LCPs) , polytetrafluororethylene (PTFE) , polyvinylidene fluoride (PVDF) , fluoropolymers (e.g., fluorinated ethylene-propylene, perfluoroalkoxy polymer,
  • polychlorotrifluoroethylene polychlorotrifluoroethylene
  • ultra-high-molecular-weight polyethylene UHMWPE
  • any other suitable plastic thermoplastic or metal, any other suitable material, or any combination thereof.
  • a deburring system may include one or more sensors configured to sense a parameter of a workpiece (e.g., a part, an assembly, or other item that may be deburred) , and a nozzle configured to deliver blasting media to a workpiece.
  • the blasting media may abrade the workpiece surface causing, for example, attrition, cleaning, or both, of the workpiece surface.
  • the deburring tool may be a stand-alone tool, a module configured to couple to another tool, or a collection of components adapted to couple separately to another tool.
  • the deburring system may sense the parameter, which may be indicative of a burr, and determine one or more burr metrics.
  • the deburring system may deliver blasting media (e.g., a gas or liquid flow seed with a particulate such as dry ice) to the workpiece, or a portion thereof to reduce the presence of burrs. Because the blasting process may alter the surface (e.g., alter the surface finish) or the bulk (e.g., warp the overall shape) of the workpiece, one or more workpiece
  • blasting media e.g., a gas or liquid flow seed with a particulate such as dry ice
  • FIG . 1 shows an illustrative deburring system 100 , in accordance with some embodiments of the present
  • Deburring system 100 may include reference 120 (e.g., which may include a table top, or other reference surface) , which may be used to secure a workpiece 190 in a controllable position and orientation.
  • Deburring system 100 may include sensor 114 configured to sense a parameter of workpiece 190 , sensor 118 configured to sense a characteristic of workpiece 190 , and nozzle 116 configured to deliver a blasting media (e.g., as shown by jet 117 ) to workpiece 190 .
  • processing equipment 130 may be communicatively coupled to sensor 114 and sensor 118 .
  • processing equipment 130 may be configured to provide power to sensors 114 and 118 , receive signals from sensors 114 and 118 , transmit signals to sensors 114 and 118 , or any combination thereof.
  • Workpiece 190 may include one or more features 192 such as, for example, holes (e.g., blind or through holes), grooves, bosses (e.g., pins, raised lips, or other protruding structure) , any other suitable feature, or any combination thereof.
  • holes e.g., blind or through holes
  • bosses e.g., pins, raised lips, or other protruding structure
  • any other suitable feature or any combination thereof.
  • burrs 194 may be formed.
  • the one or more burrs 194 may include attached burrs (e.g.,
  • Processing equipment 130 may be configured to process received signals, generate control signals, determine metrics, determine parameters, determine characteristics, perform any other suitable processing function, or any combination thereof.
  • Processing equipment 130 may include a processor (e.g., a central processing unit, a microprocessor) , cache, random access memory (RAM) , read only memory (ROM) , any other suitable components, or any combination thereof.
  • a processor e.g., a central processing unit, a microprocessor
  • RAM random access memory
  • ROM read only memory
  • processing equipment 130 may include a sensor interface configured to communicate with sensors 114 and 118 via one or more communicative couplings, which may be a wired connection (e.g., using IEEE 802.3 ethernet interface, universal serial bus interface, or other multi-conductor cable connector interface), wireless coupling (e.g., using IEEE 802.11 "Wi-Fi" interface, Bluetooth interface, or other wireless interface) , optical coupling, inductive
  • Sensor 114 may sense one or more parameters of workpiece 190 . Parameters may include absolute
  • sensor 114 may include a camera configured to capture images of workpiece 190 .
  • sensor 114 may include a CCD camera configured to capture one or more images of one or more features 192 of workpiece 190 .
  • Sensor 118 may sense one or more characteristics of workpiece 190 . Characteristics may include absolute dimensions, relative dimensions, areas, volumes,
  • sensor 118 may include a laser configured to provide a laser beam to the surface of workpiece 190 , and a laser detector configured to detect the reflected laser beam from the surface of workpiece 190 .
  • processing equipment 130 may determine an angle of reflection, an angle of workpiece 190 relative to a reference angle
  • sensor 118 may be scanned over a surface of workpiece 190 (e.g., using coupling 122
  • processing equipment 130 may determine the variation in angle (e.g., the flatness) of the surface of workpiece 190 .
  • processing equipment 130 may be coupled to any or all of couplings 122 , 124 , and 126 , which may mechanically link sensor 118 , sensor 114 , and nozzle 116 , respectively, to reference 120 .
  • Couplings 122 , 124 , and 126 may each include a mechanical or electromechanical coupling between sensor 118 , sensor 114 , and nozzle 116 , and reference 120 .
  • couplings 122 , 124 , and 126 may include one or more motion control actuators (e.g., threaded rod drives, geared drives, pulley drives, stepper motor drives or other suitable drives) controlled by a computer numerical controller (CNC) , which may be included in processing equipment 130 .
  • a motion control actuator may include a linear screw coupled to a stepper motor controlled by processing equipment 130 to provide controlled linear motion, linear position control, or both.
  • three linear screws coupled to respective stepper motors all controlled by processing equipment 130 may be used to provide controlled 3-axis motion, 3-axis position control, or both.
  • a motion control actuator may include a servo motor configured to provide controlled angular motion, angular position control, or both.
  • any or all of couplings 122 , 124 , and 126 may include motion control actuators that are user-controlled.
  • any or of 122 , 124 , and 126 may include linear screws coupled to a hand crank that the user may turn to enact linear motion of the workpiece.
  • any or all of couplings 122 , 124 , and 126 may be fixed structural couplings, and accordingly sensor 118 , sensor 114 , or nozzle 116 may be configured to swivel, turn, or otherwise reorient to vary the sensing region of interest, nozzle target, or both.
  • nozzle 116 may remain in a fixed translational position, but may be able to be rotated to direct a jet of blasting material to different locations on workpiece 190 .
  • any or all of couplings 122 , 124 , and 126 may include a frame or other structural components to which motion control actuators may be mounted.
  • couplings 122 , 124 , and 126 may be similar to the motion control actuators of a bed-type milling machine in which reference 120 may be moved in a plane normal to the sensing or nozzle direction, and
  • deburring system 100 may include blasting media delivery system 140 and optionally blasting media container 150.
  • Blasting media delivery system 140 may include, for example, a shaver, pump, compressor, filter, conduits, flow control components, pressure regulators, orifices, valves, any other suitable components for delivering a blasting media to nozzle 116, or any combination thereof.
  • Blasting media container 150 may include, for example, a tank or other suitable reservoir, configured to contain a blasting media to be delivered to nozzle 116 by blasting media delivery system 140.
  • blasting media container 150 may be configured to contain blocks of dry ice.
  • blasting media delivery system 140 may include a shaver configured to shave the blocks of dry ice into particles, and a gas entrainment system (e.g., including an air compressor and suitable flow conduits) configured to entrain the dry ice particles in a convective flow of air through a flexible conduit (e.g., as shown by conduit 142) to nozzle 116.
  • blasting media container 150 may be configured to contain sand particles (e.g., silicon dioxide or any other metal oxide that may be used as a blasting media) .
  • blasting media delivery system 140 may include a lock-hopper configured to feed the sand particles into a convective gas flow, and a gas entrainment system (e.g., including an air compressor and suitable flow conduits) configured to entrain the sand particles in the convective flow through a flexible conduit to nozzle 116.
  • blasting media container 150 may be configured to contain liquid water.
  • blasting media delivery system 140 may include a liquid pump configured to pump the water through a flexible conduit to nozzle 116. Any suitable blasting media, including solid, liquid, gas, or a combination thereof, may be delivered to nozzle 116 using blasting media delivery system 140 and blasting media container 150 .
  • processing equipment 130 may be configured to control the flow of blasting media through nozzle 116 by controlling components of blasting media delivery system 140 , controlling a property of nozzle
  • processing equipment 130 may be configured to control the speed of an air compressor of blasting media delivery system 140 used to control an entraining air flow used to entrain blasting particulate.
  • processing equipment 130 may be configured to control a valve setting of a flow control valve of blasting media delivery system 140 used to control an entraining air flow used to entrain blasting particulate.
  • processing equipment 130 may be configured to control a feed setting (e.g., speed control, position control, or both) of a linear feed screw of blasting media delivery system 140 used to control a particulate feed rate into an entraining flow.
  • deburring system may include interface 160 , configured to allow user interaction.
  • interface 160 may include a display screen, a touchscreen, a keyboard (e.g., a QWERTY keyboard), a keypad (e.g., a numeric keypad, a command button keypad), a mouse, a speaker, a microphone, any other suitable component configured to receive user input, any other suitable component configured to provide output to a user, or any combination thereof.
  • Processing equipment 130 may be configured to communicate with interface 160 via any suitable communication coupling.
  • interface 160 may include, for example, a cathode ray tube screen, a liquid crystal display screen, a light emitting diode display screen, a plasma display screen, any other suitable display screen that may provide graphics, text, images or other visuals to a user, or any combination of screens thereof.
  • interface 160 may include a touchscreen display, which may provide tactile interaction with a user by, for example, offering one or more soft commands on a display screen.
  • interface 160 may include an audio device may include a microphone, and processing equipment 130 may process audio commands received via interface 160 caused by a user speaking into the
  • Interface 160 may be coupled to processing equipment 130 using any suitable wired connection (e.g., using IEEE 802.3 ethernet, or universal serial bus interface, coaxial cable connection, tip-ring-seal RCA type connection), wireless coupling (e.g., using IEEE 802.11 "Wi-Fi", Infrared, or Bluetooth), optical
  • FIG. 2 shows an illustrative deburring system 200 having a deburring module 210, in accordance with some embodiments of the present disclosure.
  • Couplings internal to deburring module 210 are not illustrated in FIG. 2, but may include wired couplings, wireless couplings, optical couplings, fluid couplings, any other suitable couplings or components, or any combination thereof.
  • sensor 214 and nozzle 216 may be included in deburring module 210, along with any other suitable components.
  • deburring module 210 may be a single tool, configured to be installed on a CNC machine, a test stand, any other suitable system, or any combination thereof.
  • Deburring module 210 may include sensor 214 configured to sense a parameter of workpiece 290, nozzle 216 configured to deliver a blasting media to workpiece 290 (e.g., as shown by jet 217 ) , and optionally a second sensor (not shown)
  • processing equipment 230 may be communicatively coupled to sensor 214 .
  • processing equipment 230 may be configured to provide power to sensor 214 , receive signals from sensor 214 , transmit signals to sensor 214 , or any combination thereof.
  • Workpiece 290 may include one or more features 292 such as, for example, holes, grooves, bosses, any other suitable feature, or any combination thereof.
  • One or more burrs 294 may include attached burrs, detached burrs, debris, or a combination thereof.
  • Processing equipment 230 may be configured to process received signals, generate control signals, determine metrics, determine parameters, determine characteristics, perform any other suitable processing function, or any combination thereof.
  • Sensor 214 may sense one or more parameters of workpiece 290 . Parameters may include absolute dimensions, relative dimensions, areas, volumes, any other suitable parameters, or any combination thereof.
  • sensor 214 may include a camera configured to capture images of workpiece 290 .
  • sensor 214 may include a CCD camera
  • deburring module 210 may include processing equipment configured to perform signal processing from sensor 214 (e.g., image processing, digitization, filtering, amplification, data storage in memory) separate from or in concert with processing equipment 230 .
  • processing equipment configured to perform signal processing from sensor 214 (e.g., image processing, digitization, filtering, amplification, data storage in memory) separate from or in concert with processing equipment 230 .
  • processing equipment 230 may be coupled to coupling 222 , which may mechanically link deburring module 210 (directly or indirectly) to
  • Coupling 222 may include a mechanical or electromechanical coupling between deburring module 210 and reference 220 .
  • coupling 222 may include one or more motion control actuators controlled by a CNC, which may be included in processing equipment 230 .
  • deburring system 200 may include blasting media delivery system 240 and optionally blasting media container 250 .
  • Blasting media delivery system 240 may include, for example, a shaver, pump, compressor, filter, conduits (e.g., conduit 242 coupled to nozzle 216), flow control components, pressure regulators, orifices, valves, any other suitable
  • Blasting media container 250 may include, for example, a tank or other suitable reservoir, configured to contain a blasting media to be delivered to nozzle 216 by blasting media delivery system 240 .
  • processing equipment 230 may be configured to control the flow of blasting media through nozzle 216 by controlling components of blasting media delivery system 240 , controlling a property of nozzle 216 , or both.
  • deburring system may include interface 260 , configured to allow user interaction.
  • interface 260 may include a display screen, a touchscreen, a keyboard (e.g., a QWERTY keyboard), a keypad (e.g., a numeric keypad, a command button keypad), a mouse, a speaker, a microphone, any other suitable component configured to receive user input, any other suitable component configured to provide output to a user, or any combination thereof.
  • Processing equipment 230 may be configured to communicate with interface 260 via any suitable communication coupling.
  • Interface 260 may be coupled to processing equipment 230 using any suitable wired connection (e.g., using IEEE 802.3 ethernet, or universal serial bus interface, coaxial cable connection, tip-ring-seal RCA type connection) , wireless coupling (e.g., using IEEE 802.11 "Wi-Fi", Infrared, or Bluetooth) , optical coupling, inductive coupling, any other suitable coupling, or any suitable wired connection (e.g., using IEEE 802.3 ethernet, or universal serial bus interface, coaxial cable connection, tip-ring-seal RCA type connection) , wireless coupling (e.g., using IEEE 802.11 "Wi-Fi", Infrared, or Bluetooth) , optical coupling, inductive coupling, any other suitable coupling, or any suitable wired connection (e.g., using IEEE 802.3 ethernet, or universal serial bus interface, coaxial cable connection, tip-ring-seal RCA type connection) , wireless coupling (e.g., using IEEE 802.11 "Wi-
  • FIG . 3 shows an illustrative deburring system 300 having a deburring module 310 and a metrology module 380 , in accordance with some embodiments of the present disclosure.
  • Deburring system 300 may be similar to deburring system 200 , with the addition of metrology module 380 .
  • Metrology module 380 may include sensor 318 configured to sense a characteristic of workpiece 290 , or feature 292 thereof.
  • Sensor 318 may include a camera, laser system (e.g., an optical flatness detector), a mechanical flatness detector, a touch probe (e.g., to determine dimensions of workpiece 290 via a collection of surface touch points) , any other suitable sensor, or any combination thereof.
  • sensor 318 may include a touch probe, and processing equipment 230 may take as input a sequence of touch measurements at a sequence of spatial points based on a computer aided design (CAD) file. Analysis of the sequence of points may be used to determine, for example, a dimension, flatness, surface property, or any other suitable characteristic of workpiece 290 .
  • deburring module 380 may include processing equipment configured to perform signal processing from sensor 318 (e.g., image
  • processing digitization, filtering, amplification, data storage in memory
  • processing equipment 230 may be coupled to coupling 324 , which may mechanically link metrology module 380 (directly or indirectly) to
  • Coupling 324 may include a mechanical or electromechanical coupling between metrology module 380 and reference 220. In some embodiments, coupling 324 may include one or more motion control actuators controlled by a CNC, which may be included in processing equipment 230.
  • metrology module 380 need not be included in deburring system 300.
  • workpiece 290 may be movable from reference 220 to a second reference (not shown) , to which metrology module 380 may be coupled.
  • metrology module 380 may perform one or more metrology operations separate from the deburring operations of deburring system 200.
  • FIG. 4 is a block diagram of an illustrative computer numerical controller (CNC) machine 400 having several tools including a deburring tool 414, in accordance with some embodiments of the present disclosure.
  • CNC machine 400 may include, for example, tool selector 410, tooling head 420, one or more linkages 430, one or more reference surfaces 440, and processing equipment 450.
  • Tool selector 410 may be configured to select from multiple tools such as, for example, machining tool 412 (e.g., a drilling chuck, a lathe toolholder, a milling
  • Processing equipment 450 may be configured to control tool selector 410, tooling head 420 (e.g., a spindle configured to receive a tool selected by tool selector 410) , one or more linkages 430, any of tools 412, 414, 416, and 418, or any combination thereof.
  • processing equipment 450 may include a computer numerical controller configured to control motions of one or more linkages 430 (e.g., which may include linear or rotational actuators) , and
  • CNC machine 400 need not include tool selector 410 , and various tools may be selected and installed by a user.
  • linkages 430 need not be controlled by processing equipment 450 but rather by a user operating hand cranks or other manual actuators.
  • linkages 430 may be controlled by processing equipment 450 in response to user input to interface 460 (e.g., by entering one or more position commands, motion commands, or spatial patterns) .
  • FIG . 5 shows a perspective view of an illustrative reference 550 and workpiece 590 , in accordance with some embodiments of the present disclosure.
  • Arrangement 500 includes workpiece 590 secured to plate 560 (e.g., via bolts and or a clamp that are not shown) .
  • Plate 560 is coupled to reference 550 using illustrative linear actuators 510 (e.g., which may include a screw and stepper motor assembly) configured to move plate 560 relative to reference 550 in the plane defined by the double-tipped arrows in FIG . 5 .
  • FIG . 6 shows a
  • Arrangement 600 may be used to sense one or more parameters of workpiece 590 , and deliver blasting media 617 based on a burr metric determined by processing equipment (not shown) , a user (not shown), or both.
  • deburring tool 610 may be configured to travel in a direction normal to the plane of motion of plate 560 and reference 550, as shown by the double-tipped arrow in FIG. 6 (e.g., similar to a bed-type milling machine) .
  • Deburring tool 610 is mechanically coupled to frame 620 having an internal linear actuator (not shown) , allowing relative motion of deburring tool 610 and frame 620 in one dimension, and movement in up to three dimensions relative to workpiece 590.
  • Nozzle 616 is shown delivering a jet of blasting media 617 to workpiece 590 (e.g., during a deburring process) .
  • a sublimating particulate e.g., dry ice
  • a gaseous flow e.g., air
  • Nozzle 616 may be fed by conduit 660, which may couple to a blasting media delivery system (not shown) .
  • the flow of blasting media through nozzle 616 may be pulsed (e.g., periodic or aperiodic), continuous, or a combination thereof, depending upon the desired blasting schedule.
  • deburring tool 610 may include all or some of a blasting media delivery system.
  • deburring tool 610 may include a flow control valve (not shown) , controlled by suitable processing equipment (not shown) via communicative coupling 662 (e.g., a ribbon cable as shown in FIG. 6 or any other suitable communicative coupling) .
  • communicative coupling 662 e.g., a ribbon cable as shown in FIG. 6 or any other suitable communicative coupling
  • FIG. 7 shows a perspective view of illustrative reference 550, workpiece 590, and deburring tool 610 of FIG. 6, during sensing, in accordance with some
  • Arrangement 700 illustrates sensing processes of deburring tool 610, using sensors 614 and 618.
  • Sensor 614 is shown as a camera, although any suitable sensor may be used.
  • Sensor 614 may be configured to capture one or more images of workpiece 590.
  • deburring tool 610 may include a lamp or other light source, configured to aid sensor 614 in capturing the one or more images of workpiece 590.
  • Sensor 618 is shown illustratively as a laser scanning sensor, having a laser source and a laser detector, although any suitable sensor may be used.
  • Sensor 618 may be configured to scan the surface of workpiece 590 to check for flatness. Sensor 618 may provide a laser beam to the surface of workpiece 590, and may detect the reflected beam from workpiece 590.
  • Changes in the reflection angle may be used to determine a surface profile of workpiece 590, which may be used to determine flatness.
  • sensor 614, sensor 618, or both may be configures to perform sensing while blasting media is delivered to workpiece 590 from nozzle 616.
  • sensor 614, sensor 618, or both may be configures to perform sensing
  • FIG. 8 shows a perspective view of an illustrative CNC machine 800 configured to perform deburring, in accordance with some embodiments of the present
  • CNC machine 800 is illustrative, and that the present disclosure may be implemented using any suitable CNC machine, any other suitable machine, or any combination thereof.
  • CNC machine 800 includes tooling head 850, tool holder 812, sensor 814, nozzle 816, vice 830 (e.g., for clamping workpiece 890) mounted to reference 820, and interface 860.
  • Reference 820 as shown in FIG. 8,
  • Tooling head 850 may be configured to be moved in the vertical direction, adjusting the distance between workpiece 890 and sensor 814 and the tip of nozzle 816 . Accordingly, the relative positions of workpiece 890 and the illustrated tools (i.e., sensor 814 and nozzle 816 ) may be adjustable in one, two, or three spatial dimensions (e.g., via
  • nozzle 816 may be coupled to a blasting media delivery system, which may be configured to deliver a suitable blasting media to nozzle 816 for blasting workpiece 890 .
  • Interface 860 e.g., which may be controlled by
  • processing equipment may include display screen 862 , configured to provide a visual display to a user.
  • display screen 862 configured to provide a visual display to a user.
  • Interface 860 may include keypad 864 , having one or more hard command buttons, alphanumeric keys, any other suitable hard buttons configured to allow user input, or any combination thereof.
  • a user may use interface 860 to provide a sensing schedule, a blasting schedule, or both, to CNC machine 800 for performing a deburring procedure.
  • interface 860 may be a computer system (i.e., having processing equipment)
  • CNC machine 800 communicatively coupled to CNC machine 800 .
  • FIG . 9 shows a screenshot 900 of an illustrative deburring application, in accordance with some
  • screenshot 900 is illustrative, showing some exemplary information which may be provided by an interface (e.g., of a system such as CNC machine 800 of FIG . 8 , or CNC machine 400 of FIG . 4 ) .
  • an interface e.g., of a system such as CNC machine 800 of FIG . 8 , or CNC machine 400 of FIG . 4 .
  • processing equipment may determine any of the information displayed in screen shot 900 , but not necessarily display the information to a user.
  • Screenshot 900 includes image position display 902 , nozzle position display 904 , workpiece position display 906 , burr metric display 908 , blast media type display 910 , blast media property display 912 , workpiece
  • image position display 902 may include Cartesian coordinates (e.g., relative to some reference) of the center of an image captured by a sensor (e.g., a camera) of a deburring system.
  • nozzle position display 904 may include Cartesian coordinates (e.g., relative to some reference) of a nozzle of a deburring system.
  • nozzle position display 906 may include Cartesian coordinates (e.g., relative to some reference) of a workpiece undergoing a deburring technique.
  • burr metric display 908 may include a numerical value quantifying the presence of a burr (e.g., a burr size such as 0.05 mm) .
  • blasting media type display 910 may include an alphanumeric display of a blasting media indicator (e.g., a type of media, an index corresponding to a particular blasting media) .
  • blasting media property display 912 may include an alphanumerical display of a blasting media property such as a flow rate, a pressure, a seeding density (e.g., mg CO 2 particles per cc
  • characteristic display 914 may include a numerical value quantifying a workpiece characteristic (e.g., a surface deviation of 0.05 mm) .
  • Image display 916 may be based on information received from a sensor of a deburring system implementing the deburring application.
  • Image display 916 of FIG . 9 shows an illustrative image of a workpiece 950 having features (e.g., machined holes 952 , 954 , and 956 ) near edge 958 .
  • Holes 952 and 954 both exhibit burrs (i.e., burrs 953 and 955 , respectively) , while hole 956 is relatively clean.
  • Hole 952 exhibits circumferential burr 953 , shown by the dashed circle indicating the radial edge of the hole excluding burr 953 .
  • Hole 954 exhibits relatively smaller burr 955 than burr 953 .
  • Edge 958 also exhibits a burr 960 , exhibited as an excursion from the straight edge shown by the dashed line in FIG . 9 .
  • image position display 902 may
  • images such as the image displayed in image display 916 may be used by processing equipment to determine a burr metric (e.g., as displayed in burr metric display 908 ) .
  • the processing equipment may use an image processing
  • the processing equipment may apply image processing (e.g., edge finding techniques) to the image of image display 916 , and may determine that hole 952 has a diameter 0.05 mm less than an expected value.
  • the processing equipment may accordingly determine that burr 953 is 0.05 mm thick, and may quantify this deviation from the expected value with a burr metric (e.g., calculate a burr metric of 0.05) .
  • the processing equipment may apply image processing to the image of image display 916 , and may determine that hole 954 has an irregular edge relative to an expected edge (e.g., a circle in this example) .
  • the processing equipment may accordingly determine that burr 955 is present, and may quantify this deviation from the expected value with a burr metric (e.g., calculate a burr metric based on the size of the burr) .
  • the processing equipment may apply image processing to the image of image display 916 , and may determine that holes 952 and 954 exhibit burrs, and may apply a qualitative assessment as a burr metric (e.g., the workpiece or each feature thereof is "sufficiently burr-free" or "insufficiently burr-free") .
  • the processing equipment may apply image processing to the image of image display 916 , and may apply a predetermined image template (e.g., including the expected edges of the workpiece and features) to the processed image to determine deviations from the
  • the processing equipment may implement any suitable image processing techniques such as, for example, feature extraction (e.g., edge detection, predetermined pattern detection) .
  • the processing equipment may take as input a computer aided design (CAD) file for use as a template with which to compare one or more images of a workpiece.
  • CAD computer aided design
  • a deburring system may provide image display 916 to a user via an interface, and the user may identify the presence of a burr (e.g., using an interface) . The user may accordingly input a command to the interface to deburr the portion of the workpiece identified as having the burr.
  • FIG . 10 is a flow diagram 1000 of illustrative steps for deburring a workpiece based on a burr metric, in accordance with some embodiments of the present disclosure.
  • the illustrative techniques of flow diagram 1000 may be implemented in accordance with any of the systems disclosed herein.
  • Step 1002 may include sensing one or more parameters of the workpiece, using one or more sensors.
  • the one or more sensors may include a camera, an acoustic system (e.g., ultrasound emitters and detectors), a laser system (e.g., configured to scan the workpiece and features thereof) , any other suitable sensors or sensing systems configured to sense a parameter of a workpiece, or any combination thereof.
  • the deburring system may include a camera configured to capture images of the workpiece.
  • a deburring system may include multiple sensors for sensing one or more
  • Parameters may include distances, areas, shapes, any other absolute or relative parameters, or any combination thereof.
  • Step 1004 may include processing equipment
  • the processing equipment may determine a quantitative burr metric. For example, the processing equipment may determine a length scale indicative of a burr size, an actual dimension of a feature, a deviation of an actual feature dimension from an expected
  • processing equipment may determine a representative length scale indicative of multiple dimensions, multiple features, or both such as an average burr size, an average actual dimension of a feature, an average deviation of an actual feature dimension from an expected dimension, any other suitable averaged value, any other suitable value representative of a set of values, or any combination thereof.
  • the processing equipment may determine a qualitative burr metric. For example, the processing equipment may determine a category of a workpiece, or a feature thereof, such as "burr-free", “burr present”, “sufficiently burr-free”, “insufficiently burr-free”, any other suitable
  • the processing equipment may determine a letter grading or other hierarchical quality identifier (e.g., "A” being sufficiently burr-free, and "F” requiring further deburring) .
  • a letter grading or other hierarchical quality identifier e.g., "A” being sufficiently burr-free, and "F” requiring further deburring.
  • Any suitable quantitative burr metric, qualitative burr metric, or both, may be
  • Step 1006 may include the deburring system delivering a blasting media to the workpiece using a nozzle and blasting media delivery system based on the burr metric of step 1004 .
  • the deburring system may include a blasting media delivery system, and optionally a blasting media container, configured to deliver a suitable blasting media to the workpiece via a nozzle of the deburring system.
  • a quantitative burr metric may be compared with a threshold value, and the deburring system may deliver the blasting media based on the comparison.
  • the processing equipment may determine a burr size (i.e., a burr metric) and compare the burr size to a threshold at step 1006 . If the burr metric exceeds the threshold, the processing equipment may transmit control signals to the blasting media delivery system to deliver blasting media.
  • the processing equipment may control one or more blasting media properties such as a flow rate, a
  • FIG. 11 is a flow diagram 1100 of illustrative steps for deburring a workpiece based on a burr metric, and checking one or more workpiece characteristics, in accordance with some embodiments of the present
  • flow diagram 1100 may be implemented in accordance with any of the systems disclosed herein.
  • Step 1102 may include sensing one or more parameters of the workpiece, using one or more sensors.
  • the one or more sensors may include a camera, an acoustic system (e.g., ultrasound emitters and detectors), a laser system (e.g., configured to scan the workpiece and features thereof) , any other suitable sensors or sensing systems configured to sense a parameter of a workpiece, or any combination thereof.
  • the deburring system may include a camera configured to capture images of the workpiece.
  • a deburring system may include multiple sensors for sensing one or more
  • Parameters may include distances, areas, shapes, any other absolute or relative parameters, or any combination thereof.
  • Step 1104 may include determining a burr metric based at least in part on the one or more parameters of step 1102.
  • the processing equipment may determine a quantitative burr metric. For example, the processing equipment may determine a length scale indicative of a burr size, an actual dimension of a feature, a deviation of an actual feature dimension from an expected dimension, any other suitable length scale, or any combination thereof.
  • the processing equipment may determine a representative length scale indicative of multiple dimensions, multiple features, or both such as an average burr size, an average actual dimension of a feature, an average deviation of an actual feature dimension from an expected dimension, any other suitable averaged value, any other suitable value representative of a set of values, or any combination thereof.
  • the processing equipment may determine a qualitative burr metric. For example, the processing equipment may determine a category of a workpiece, or a feature thereof, such as "burr-free”, “burr present”, “sufficiently burr-free”, “insufficiently burr-free”, any other suitable
  • the processing equipment may determine a letter grading or other hierarchical quality identifier (e.g., "A” being sufficiently burr-free, and "F” requiring further deburring) .
  • a letter grading or other hierarchical quality identifier e.g., "A” being sufficiently burr-free, and "F” requiring further deburring.
  • Any suitable quantitative burr metric, qualitative burr metric, or both, may be
  • Step 1106 may include the deburring system delivering a blasting media to the workpiece using a nozzle and blasting media delivery system based on the burr metric of step 1104 .
  • the deburring system may include a blasting media delivery system, and optionally a blasting media container, configured to deliver a suitable blasting media to the workpiece via a nozzle of the deburring system.
  • a quantitative burr metric may be compared with a threshold value, and the deburring system may deliver the blasting media based on the comparison.
  • the processing equipment may determine a burr size (i.e., a burr metric) and compare the burr size to a threshold at step 1106 . If the burr metric exceeds the threshold, the processing equipment may transmit control signals to the blasting media delivery system to deliver blasting media.
  • the processing equipment may control one or more blasting media properties such as a flow rate, a
  • Step 1108 may include one or more workpiece
  • the one or more characteristics may include dimensions (e.g., lengths, angles, areas, or volumes of the workpiece, or a feature thereof) , surface characteristics (e.g., surface roughness, surface flatness), any other suitable characteristics, or any combination thereof.
  • a laser sensor may be used to determine the workpiece characteristic. For example a line of sight laser measurement may be used to map points, edges, or faces of with workpiece to check dimensions, flatness/ straightness , or both.
  • a laser beam reflected from the workpiece surface to a photodetector may be used to determine variations in the surface flatness.
  • an imaging sensor may be used to determine the workpiece characteristic. For example a camera may be used to capture an image of the workpiece, and image processing (e.g., edge finding techniques, feature finding
  • a roughness sensor may be used to determine the workpiece characteristic.
  • a contact probe may be used to measure surface roughness (e.g., a rugosity value, or roughness value) .
  • a microscope e.g., a scanning laser microscope, an optical microscope
  • an interferometer may be used to determine a surface profile and corresponding roughness.
  • a touch probe e.g., a stylus configured to contact the workpiece
  • step 1108 may be performed to determine whether the blasting schedule of step 1106 has appreciably altered the workpiece.
  • step 1106 may include blasting the workpiece with a flow of entrained dry ice particles (e.g., which at 1 atm sublimate at a temperature of about -78.5° C) , and step 1108 may be performed to determine if any warping of the workpiece has occurred due to temperature gradients.
  • step 1106 may include blasting the workpiece with dry ice particles, and step 1108 may be performed to determine if one or more dimensions of features (e.g., holes, edges, grooves or other features) of the workpiece have been altered.
  • step 1106 may include blasting the workpiece with dry ice particles, and step 1108 may be performed to determine if the abrasion of the dry ice particles has altered the surface roughness of the workpiece.
  • FIG . 12 is a flow diagram 1200 of illustrative steps for deburring a workpiece using a deburring system and a metrology system, in accordance with some embodiments of the present disclosure.
  • the illustrative techniques of flow diagram 1200 may be implemented in accordance with any of the systems disclosed herein.
  • Step 1202 may include processing equipment receiving a CAD file (e.g., an *.iges file), a computer aided machining (CAM) file, a scanned image file, any other suitable reference that includes dimension and feature information of a workpiece, or any combination thereof.
  • a CAD file e.g., an *.iges file
  • CAM computer aided machining
  • the processing equipment may retrieve a CAD file corresponding to a particular workpiece from memory storage.
  • the processing equipment may receive user input of a CAD file in the form of a removable memory storage device.
  • the processing equipment may host a CAD application, with which a user may generate a CAD file of a particular workpiece.
  • Panel 1250 shows an illustrative CAD file of a workpiece .
  • Step 1204 may include processing equipment
  • the sensing schedule may include a sequence of positions (e.g., of a sensor relative to the reference of step 1202 .
  • a sensing schedule may include a desired sensing path generated from a CAD file along the workpiece as shown by the solid arrow in panel 1252 .
  • Step 1206 may include the deburring system performing the sensing schedule determined at step 1204 .
  • the deburring system may include a CNC machine having one or more linear actuators configured to move a sensing tool relative to the workpiece according to the sensing schedule.
  • the deburring system may adjust the target area of a sensor on the workpiece (e.g., adjust the focus and angle of a camera directed at the workpiece) according to the sensing schedule.
  • step 1204 may include the processing equipment processing and storing sensor output as the sensing schedule is performed.
  • the processing equipment may process and store a sequence of images taken as a camera is scanned over the surface of the workpiece.
  • Step 1208 may include processing equipment
  • the blasting schedule may include a sequence of positions (e.g., of a nozzle relative to the workpiece), times, velocities (e.g., of a nozzle relative to the workpiece), accelerations (e.g., of a nozzle relative to the
  • a blasting schedule may include a desired blasting path generated along the workpiece as shown by the solid arrow in panel 1252 , based on the reference of step 1202 , and the sensor output from step 1206 .
  • Panel 1254 shows a desired nozzle path, illustrated by the solid arrow, corresponding to an illustrative blasting schedule.
  • the spatial path, relative timing, or both, of the blasting schedule and the sensing schedule may be, but need not be, the same.
  • Step 1210 may include the deburring system delivering blasting media to the workpiece according to the blasting schedule determined at step 1208 .
  • the deburring system may adjust the blasting media type, flow rate, any other suitable property, or any combination thereof according to the blasting schedule.
  • the blasting schedule may include general blasting information (e.g., for blasting the entire workpiece without finer spatial variation) , feature-specific blasting information (e.g., for blasting one or more features with a specific blasting media having specific properties), position-specific blasting information (e.g., for blasting one or more spatial positions with a specific blasting media having specific properties) , any other suitable information, or any combination thereof.
  • steps 1206 and 1210 may be performed in substantially real time (e.g., during a single pass over the workpiece) .
  • the sensor may move according to a schedule relative to the
  • the nozzle may move according to the same schedule (e.g., may be rigidly attached to the sensor, or may be
  • the processing equipment may determine a burr metric in real time, and determine a desired blasting schedule in real time.
  • the deburring system may perform a single pass over the surface of the workpiece, during which both sensing and blasting may be performed.
  • steps 1206 and 1210 may be performed in sequentially.
  • the sensor may move according to a schedule relative to the workpiece, sensing
  • the processing equipment may
  • burr metrics e.g., a scalar field of burr metrics
  • the deburring system may perform a second pass over the surface of the workpiece with the nozzle, during which blasting may be performed.
  • the deburring system may use real time deburring, sequential deburring, or a combination thereof.
  • step 1206, step 1208, or both, may include determining a burr metric based at least in part on the sensor output of step 1206.
  • Step 1212 may include processing equipment
  • Step 1210 determining one or more workpiece characteristics based on a sensor output.
  • the workpiece may undergo changes in surface roughness, dimensions, and/or other properties.
  • a sensor coupled to the processing equipment may be used to sense the one or more characteristics.
  • Step 1212 may include determining if such changes have occurred, and if so, whether the changes are acceptable.
  • Panel 1256 shows an illustrative touch sensor used to measure one or more spatial points of a workpiece surface. The touch sensor may be used to generate a sequence of surface points, from which surfaces, dimensions, any other suitable absolute or relative reference geometry, or any combination thereof may be determined. In some embodiments, the same sensor may be used to perform both steps 1206 and 1212.
  • a camera may be used to sense parameters of the workpiece (e.g., by capturing one or more images of the workpiece and applying image processing) , and also sense characteristics of the workpiece (e.g., by capturing one or more images of the workpiece and applying image processing) .
  • different sensors may be used to perform steps 1206 and 1212.
  • Step 1214 may include processing equipment
  • step 1214 may include repeating steps 1204 and 1206 to determine whether the blasting schedule of steps 1208 and 1210 were adequate. In some embodiments, if the processing equipment
  • the processing equipment may proceed to step 1216 (this procession not shown in FIG. 12) . In some embodiments, if the processing equipment determines that the workpiece is not sufficiently burr-free, then the processing equipment may proceed to the step 1216 as shown. In some embodiments, if the processing equipment determines that the workpiece is not sufficiently burr-free, then the processing equipment may repeat any or all of steps 1204-1212 (also shown) .
  • the processing equipment may require user input to proceed to further deburring, or performing other processes. For example, if the workpiece is determined to be insufficiently burr-free, a user inspection and input (e.g., to a suitable interface) may be required before the processing equipment proceeds.
  • Step 1216 may include processing equipment
  • the processing equipment may compare the one or more
  • a surface roughness determined at step 1212 may be compared to a roughness threshold, and if the roughness exceeds the threshold (e.g., larger than an upper threshold or less than a lower threshold) , the roughness may be determined to be unacceptable.
  • the threshold e.g., larger than an upper threshold or less than a lower threshold
  • one or more dimensions of the workpiece (or point measurements) measured at step 1212 may compared to corresponding tolerances, and if the
  • the one or more dimensions may be determined to be acceptable.
  • a flatness of the workpiece measured at step 1212 may compared to a corresponding flatness tolerance, and if the flatness is within the tolerances, the flatness may be determined to be acceptable. If the processing equipment determines that the one or more characteristics are not acceptable, the processing equipment may stop the deburring process, indicate re- machining may be necessary, indicate to a user that further inspection may be necessary, indicate to a user to discard the workpiece, any other suitable processing function, or any combination thereof. In some
  • the processing equipment may provide the one or more workpiece characteristic values to a user via an interface.
  • the interface may be configured to receive a user input as to whether the characteristic is acceptable or not.

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  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Physics & Mathematics (AREA)
  • Optics & Photonics (AREA)
  • Finish Polishing, Edge Sharpening, And Grinding By Specific Grinding Devices (AREA)

Abstract

L'invention se rapporte à un capteur pouvant être utilisé pour déterminer la présence de bavures sur une pièce, et à un agent de décapage pouvant être appliqué à la pièce afin de diminuer ou d'éliminer les bavures. L'agent de décapage peut être appliqué à la pièce à l'aide d'une buse. Le capteur peut balayer la pièce, et une ou plusieurs mesures métriques de bavures peuvent être déterminées pour qualifier ou quantifier la présence de bavures. Sur la base de la ou mesures métriques de bavures, un programme de décapage peut être déterminé et réalisé. Une ou plusieurs caractéristiques de la pièce peuvent être vérifiées après l'ébavurage afin de déterminer l'étendue de la modification, le cas échéant, de la pièce provoquée par l'ébavurage.
PCT/US2013/023685 2012-02-06 2013-01-29 Procédés et systèmes pour ébavurage basé sur un capteur WO2013119424A1 (fr)

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