The subject matter disclosed herein relates to a machining center and in particular to a machining center having an integrated noncontact measurement device.
A computer controlled machining center, such as a computational numerical control (CNC) machining center is used to produce complex components. The CNC machining centers can perform 5 and 6 axis operations at very high speeds. These systems typically have an automatic tool changing system that allows the machining center to retrieve a specific tool for each operation without stoppage or intervention from the operator.
While CNC machining centers have improved the ability to accurately machine components, the produced parts still need to be inspected to ensure the components are fabricated according to specification. Historically, the components or a sample group of components were transported to an inspection room where highly skilled inspection operators used measurement devices to determine the dimensions of the component. As metrology devices have improved and new devices such as articulated arm coordinate measurement devices developed, the location of the inspection has moved from the specialized inspection room to areas adjacent the machining center.
While moving the location of the inspection adjacent the machining center has reduced the time and lowered costs, the inspection process still typically requires the machining center to stop operations while the operator performs the inspection. Commonly, the work piece is removed from the machining center when the inspection is performed. Thus the inspection still slows the time to produce components and utilizes additional operator time.
Accordingly, while existing CNC machining centers are suitable for their intended purpose the need for improvement remains, particularly in providing a CNC machining center which reduces the time and cost to perform inspections of a work piece.
According to one aspect of the invention, a computer numerical control (CNC) machining center is provided. The CNC machining center including a spindle configured to receive a cutting tool having a tool mount. A tool magazine is provided that includes a plurality of holders, each holder configured to receive a tool having the tool mount. A primary induction power supply is operably coupled to the spindle. A non-contact three-dimensional (3D) measurement device is provided having the tool mount. The 3D measurement device being movable between one of the tool magazine holders and the spindle, the 3D measurement device having a secondary induction power supply configured to generate electrical power to operate the 3D measurement device when the 3D measurement device is coupled to the spindle.
According to another aspect of the invention, a method of machining a work piece in a CNC machining center is provided. The method comprising: coupling a tool to a spindle; engaging the tool to the work piece to form a feature; moving the tool from the spindle to a tool magazine; moving a non-contact 3D-measurement device from the tool magazine to the spindle; energizing a primary induction power supply; electrically powering the 3D measurement device with the primary induction power supply when it is coupled to the spindle; moving the spindle over the feature with the 3D-measurement device energized; and acquiring 3D coordinates of points on the feature with the 3D-measurement device as the spindle is moved over the feature.
These and other advantages and features will become more apparent from the following description taken in conjunction with the drawings.
The subject matter, which is regarded as the invention, is particularly pointed out and distinctly claimed in the claims at the conclusion of the specification. The foregoing and other features, and advantages of the invention are apparent from the following detailed description taken in conjunction with the accompanying drawings in which:
The detailed description explains embodiments of the invention, together with advantages and features, by way of example with reference to the drawings.
Embodiments of the present invention provide advantages in allowing for the inspection of work pieces being machined within a CNC machining center without having to remove the work piece. Embodiments of the present invention provide advantages in allowing the inspection of the work piece in an automated manner without interruption by the machine operator. Still further embodiments of the invention provide a noncontact measurement device that may be stored and removed from the machining center tool magazine during operation. Still further embodiments of the invention provide advantages in eliminating cables or mechanical connections between the noncontact measurement device and an external computing device.
Referring now to
A spindle seat 32 is movably mounted to the post 30 and movable in a direction 33 substantially perpendicular to the plane formed by the first and second horizontal directions to define the Z-axis of the machining center. A spindle 34 with a tool mount 36 is coupled to the spindle seat 32. As will be discussed in more detail herein, the tool mount 36 is configured to receive a tool (not shown) or a noncontact measurement device 38 during operation. In the exemplary embodiment, the machining center 20 includes a tool magazine 40 arranged to receive and store tools and noncontact measurement device 38. The tool magazine 40 includes a plurality of holders 42 that are similarly configured to receive the shank of a tool or noncontact measurement device 38. The tools and noncontact measurement device 38 may be transferred between the tool magazine 40 and the tool mount 36 automatically during operation as is known in the art, such as with a tool changing arm for example.
In the exemplary embodiment, an induction power supply 35 (
It should be appreciated what while the tool magazine 40 is illustrated with the holders 42 extending perpendicular to the Z-axis about the circumference of the tool magazine 40, this is for exemplary purposes and other tool magazine and holder configurations are possible. For example, the tool magazine may have holders that extend radially from the outer diameter/periphery of the tool magazine. In another embodiment, the holders may be oriented in a direction parallel to the Z-axis. In another embodiment, the tool magazine may include a conveyor type system that follows a serpentine path. Further, while the tool magazine 40 is illustrated as being mounted directly adjacent the spindle 34, in other embodiments, the tool magazine may be remotely mounted from the spindle. Further, the tool magazine may be remotely located in an enclosure that may be selectively isolated (e.g. with a movable door) to shield the tool magazine and the tools stored therein from debris, cooling fluid and lubricants used during the machining process.
The sliding seat 28 is driven along first horizontal direction 27 by a threaded rod 44 that is rotated by a servo motor 46. Similarly, the post 30 is driven in the second horizontal direction 31 by a threaded rod 48, which is rotated by a servo motor 50. The spindle seat 32 is moved along the Z-axis 33 by a threaded rod 52, which is rotated by a servo motor 54. It should be appreciated that while embodiments herein describe a threaded rod and servo motor arrangement, this is for exemplary purposes and the claimed invention should not be so limited. In other embodiments, other devices such as hydraulic or linear actuators may be used. Further, in some embodiments, the work table 24 may be mounted to rails and movable in multiple directions relative to the spindle seat 32. The work table 24 may also be mounted to a vertical shaft 56 that allows rotation of the work table 24 relative to the base 22.
The machining center 20 may further include a controller 62 (
The controller 62 may be in the form of a general-purpose computing device, also referred to as a processing device. The components of the controller may include, but are not limited to, one or more processors or processing units, a system memory, and a bus that couples the various system components including system memory to the processor. System memory can include computer system readable media in the form of volatile memory, such as random access memory (RAM and/or cache memory. The controller 62 may further include removable/non-removable volatile/non-volatile storage media, such as but not limited to magnetic media or optical media for example.
A program/utility, having a set of program modules, may be stored in memory by way of example, and not limitation, as well as an operating system, one or more application programs, other program modules, and program data. Each of the operating system, one or more application programs, other program modules, and program data or some combination thereof, may include an implementation of a networking environment. Program modules generally carry out the functions or methodologies of embodiments of the invention described herein.
The controller 62 may also communicate with one or more devices, such as a keyboard 64, a pointing device, a display 66, etc.; one or more devices that enable a user to interact with controller 62; or any devices (e.g. a communications circuit, network card, etc.). Such communication may occur via Input/Output (I/O) interfaces. Controller 62 may further communicate via one or more networks, such as a local area network (LAN), a general wide-area network (WAN), or a public network (e.g. the Internet) via a communications circuit. The communications may be via a wired communications medium (e.g. Ethernet, USB, etc.) or a wireless communications medium. The wireless communications medium may include IEEE 802.11 (WiFi), a Bluetooth® (IEEE 802.15.1 and its successors), RFID, near field communications (NFC), or cellular (including LTE, GSM, EDGE, UMTS, HSPA and 3GPP cellular network technologies) for example. It should be appreciated that the controller 62 is further configured to communicate with a communications circuit 68 in 3D measurement device 38.
In one embodiment, the machining center 20 may further include a first temperature sensor 63 and a second temperature sensor 65 (
It should be appreciated that while embodiments herein describe a three-axis machining center, this is for exemplary purposes and the claimed invention should not be so limited. In other embodiments, the machining center 20 may have more or fewer axes. Further, the machining center may be a vertical machining center, a horizontal machining center, a CNC milling machine, a CNC lathe, a CNC grinding machine or a CNC gear cutting machine for example.
Referring now to
The 3D measurement device 38 also includes a controller 86 that may be a digital circuit, the controller having a microprocessor 88 that includes memory 90, for example, or an analog circuit. The controller 86 is electrically coupled to the projector 70 and cameras 76 to provide operational control during operation. In one embodiment, the controller 86 is in asynchronous bidirectional communication with the controller 62 (
The 3D measurement device 38 further includes a tool mount 96. The tool mount 96 is sized and shaped to be received in both the holders 42 of tool magazine 40 and the spindle 34. The tool mount 96 may further have one or more features that allow the machining center to transfer in an automated manner the 3D measurement device 38 between the tool magazine 40 and the spindle 34.
In the exemplary embodiment, the 3D measurement device 38 is a laser line probe (LLP) or line scanner. The principle of operation of a line scanner is shown schematically in
One of the calculations described herein above yields information about the distance of the object from the line scanner—in other words, the distance in the z direction, as indicated by the coordinate system 120. The information about the x position and y position of each point 110 or 116 relative to the line scanner is obtained by the other dimension of the photosensitive array 78, in other words, the y dimension of the photosensitive array. Since the plane that defines the line of light as it propagates from the projector 70 to the object is known from the coordinate measuring capability of the machining center 20 to track the position of the spindle, it follows that the x position of the point 110 or 116 on the work piece surface is also known. Hence all three coordinates—x, y, and z—of a point on the object surface can be found from the pattern of light on the two-dimensional photosensitive array 78.
It should be appreciated that the LLP 100 may include a second camera 76 arranged on a side of the projector 70 opposite the other camera 76. Both cameras 76 view the same projected light but from different angles. This provides advantages in allowing an area not visible to the camera on one side of the projector to be imaged by the camera on the opposite side, and vice versa.
In another embodiment, the 3D measurement device 38 is an image scanning device that uses structured light. Referring now to
To determine the coordinates of the pixel, the angle of each projected ray of light 136 intersecting the work piece 58 in a point 146 is known to correspond to a projection angle phi (φ), so that φ information is encoded into the emitted pattern. In an embodiment, the system is configured to enable the φ value corresponding to each pixel in the imaged pattern to be ascertained. Further, an angle omega (Ω) for each pixel in the camera is known, as is the baseline distance “D” between the projector 70 and the camera 76. Therefore, the distance “Z” from the camera 76 to the location that the pixel has imaged using the equation:
Thus three-dimensional coordinates may be calculated for each pixel in the acquired image.
In general, there are two categories of structured light, namely coded and uncoded structured light. A common form of uncoded structured light relies on a striped pattern varying in a periodic manner along one dimension. These types of patterns are usually applied in a sequence to provide an approximate distance to the object. Some uncoded pattern embodiments, such as the sinusoidal patterns for example, may provide relatively highly accurate measurements. However, for these types of patterns to be effective, it is usually necessary for the scanner device and the object to be held stationary relative to each other. Where the scanner device or the object are in motion (relative to the other), then a coded pattern may be used. A coded pattern allows the image to be analyzed using a single acquired image. Some coded patterns may be placed in a particular orientation on the projector pattern (for example, perpendicular to epipolar lines on the projector plane), thereby simplifying analysis of the three-dimensional surface coordinates based on a single image.
Epipolar lines are mathematical lines formed by the intersection of epipolar planes and the source plane 148 or the image plane 150 (the plane of the camera sensor) in
Referring now to
With the 3D measurement device 38 mounted in the spindle 34, the spindle seat 32 is moved, such as by actuation of the servo motors 46, 50, 54 in the directions 27, 31, 33. The 3D measurement device 38 may then be moved adjacent the features 60 and the desired measurements acquired in step 206. These acquired measurements may be then by transmitted to the controller 62 via the wireless communications medium in step 208. The 3D measurement device is returned to the tool magazine in step 210. The acquired measurements may be compared with predetermined values and determine if the formed features 60 are within a predetermined specification in step 212. As discussed above, one or more temperature sensors may be used to compensate the measurements to account for dimensional changes based on the thermal coefficient of expansion. Thus, the machining center 20 is able to automatically form a feature 60 and perform an inspection of the dimensions without intervention from the operator. It should be appreciated that if the dimensions are out of specification, the machining center 20 may alert the operator, or automatically take other corrective action (e.g. perform further machining operation).
While the invention has been described in detail in connection with only a limited number of embodiments, it should be readily understood that the invention is not limited to such disclosed embodiments. Rather, the invention can be modified to incorporate any number of variations, alterations, substitutions or equivalent arrangements not heretofore described, but which are commensurate with the spirit and scope of the invention. Additionally, while various embodiments of the invention have been described, it is to be understood that aspects of the invention may include only some of the described embodiments. Accordingly, the invention is not to be seen as limited by the foregoing description, but is only limited by the scope of the appended claims.
The present Application is a nonprovisional application claiming benefit of U.S. Provisional Application Ser. No. 62/025205 filed on Jul. 16, 2014 entitled Measurement Device for Machining Center, the contents of which are incorporated by reference in their entirety.
Number | Date | Country | |
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62025205 | Jul 2014 | US |