U.S. patent application number 13/367196 was filed with the patent office on 2013-08-08 for methods and systems for sensor-based deburring.
The applicant listed for this patent is Hamid R. Ghalambor. Invention is credited to Hamid R. Ghalambor.
Application Number | 20130203320 13/367196 |
Document ID | / |
Family ID | 47679108 |
Filed Date | 2013-08-08 |
United States Patent
Application |
20130203320 |
Kind Code |
A1 |
Ghalambor; Hamid R. |
August 8, 2013 |
Methods and Systems for Sensor-Based Deburring
Abstract
A sensor may be used to determine the presence of burrs on a
workpiece, and a blasting media may be applied to the workpiece to
lessen or eliminate burrs. The blasting media may be applied to the
workpiece using a nozzle. The sensor may be scanned over the
workpiece, and one or more burr metrics may be determined to
qualify or quantify the presence of burrs. Based on the one or more
burr metrics, a blasting schedule may be determined and performed.
One or more characteristics of the workpiece may be checked after
deburring to determine the extent of alteration, if any, of the
workpiece caused by deburring.
Inventors: |
Ghalambor; Hamid R.;
(Irvine, CA) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
Ghalambor; Hamid R. |
Irvine |
CA |
US |
|
|
Family ID: |
47679108 |
Appl. No.: |
13/367196 |
Filed: |
February 6, 2012 |
Current U.S.
Class: |
451/2 |
Current CPC
Class: |
B24C 1/083 20130101;
B23Q 17/2471 20130101; B23Q 17/20 20130101 |
Class at
Publication: |
451/2 |
International
Class: |
B24C 1/04 20060101
B24C001/04; B24C 7/00 20060101 B24C007/00 |
Claims
1. A deburring system comprising: 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, and wherein the processing equipment is
configured to control the flow of the blasting media based on the
output of the sensor.
2. The deburring system of claim 1, wherein the sensor comprises a
camera configured to capture an image of the workpiece.
3. The deburring system of claim 1, wherein the processing
equipment is further configured to control the flow of the blasting
media based on a computer program specific to the workpiece,
wherein the computer program comprises a dimension of the
workpiece.
4. The deburring system of claim 1, further comprising at least one
motion control actuator mechanically coupled to the reference
surface and the nozzle, wherein the at least one motion control
actuator is communicatively coupled to the processing equipment,
and wherein the processing equipment is further configured to
control the at least one motion control actuator to move the
reference surface relative to the nozzle.
5. The deburring system of claim 1, further comprising at least one
motion control actuator mechanically coupled to the reference
surface and the nozzle, wherein the at least one motion control
actuator is communicatively coupled to the processing equipment,
and wherein the processing equipment is further configured to
control the at least one motion control actuator to move the nozzle
relative to the reference surface.
6. The deburring system of claim 1, further comprising: a blasting
media container configured to contain the blasting media; a
blasting media delivery system coupled to the blasting media
container and the nozzle, wherein the blasting media delivery
system configured to deliver the blasting media to the nozzle.
7. The deburring system of claim 6, wherein the blasting media
container is configured to contain dry ice, and wherein the
blasting media delivery system further comprises a blade to shave
dry ice into dry ice particles, and wherein the blasting media
delivery system is further configured to entrain the dry ice
particles with a gas flow and deliver the entrained particles to
the nozzle.
8. The deburring system of claim 6, wherein the blasting media
delivery system further comprises a flexible hose coupled to the
nozzle.
9. The deburring system of claim 1, further comprising a display
screen, wherein the processing equipment is further configured to
display information on the display screen based at least in part on
the output of the sensor.
10. The deburring system of claim 1, wherein the processing
equipment is further configured to determine a burr metric based at
least in part on the output of the sensor.
11. The deburring system of claim 10, wherein the processing
equipment is further configured to control the flow of the blasting
media based at least in part on the burr metric.
12. The deburring system of claim 1, further comprising a metrology
sensor for measuring a characteristic of the workpiece.
13. The deburring system of claim 12, wherein the metrology sensor
for measuring the characteristic of the workpiece comprises at
least one of a flatness sensor for measuring flatness, a dimension
sensor for measuring a dimension, a roughness sensor for measuring
a surface roughness.
14. A deburring module for deburring a workpiece, the deburring
module comprising: 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 workpiece, wherein
the flow of the blasting media is controlled by processing
equipment based at least in part on the output of the at least one
sensor.
15. The deburring module of claim 14, further comprising a frame
mechanically coupled to the nozzle and the at least one sensor,
wherein the frame is configured to be coupled to a motion control
actuator.
16. The deburring module of claim 14, wherein the nozzle is further
configured to be coupled to a blasting media delivery system,
wherein the blasting media delivery system is controllable using
the processing equipment.
17. The deburring module of claim 14, wherein the at least one
sensor comprises a camera configured to capture an image of the
workpiece.
18. The deburring module of claim 14, wherein the at least one
sensor comprises a first sensor and a second sensor, wherein the
first sensor is configured to sense the burr on the workpiece, and
the second sensor is configured to determine a characteristic of
the workpiece.
19. The deburring module of claim 14, wherein the blasting media
comprises a particulate entrained in a gas flow.
20. A method for deburring a workpiece, the method comprising:
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.
21. The method of claim 20, wherein the sensing the parameter of
the workpiece comprises capturing an image of the workpiece using a
camera.
22. The method of claim 21, further comprising applying image
processing to the image using processing equipment.
23. The method of claim 20, wherein the delivering the blasting
media to the at least one portion of the workpiece further
comprises controlling a flow of the blasting media.
24. The method of claim 20, wherein the parameter comprises one of
a distance, an area, a shape, and a volume.
25. The method of claim 20, wherein the sensing the parameter, the
determining the burr metric, and the delivering the blasting media
are performed during a single pass over the workpiece.
26. The method of claim 20, wherein the sensing the parameter is
performed during a first pass over the workpiece, and the
delivering the blasting media is performed during a second pass
over the workpiece, wherein the determining the burr metric is
performed prior to or during the second pass.
27. A method for deburring a workpiece, the method comprising:
sensing one or more parameters of the workpiece using a sensor;
determining, using processing equipment, one or more 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, wherein
the blasting schedule comprises delivering a controlled flow of a
blasting media to the workpiece; and determining one or more
workpiece characteristics based on one or more diagnostic
tests.
28. The method of claim 27, wherein the sensing the parameter and
the performing the blasting schedule are performed during a single
pass over the workpiece.
29. The method of claim 27, wherein the sensing the parameter is
performed during a first pass over the workpiece, and the
performing the blasting schedule is performed during a second pass
over the workpiece, wherein the determining the one or more burr
metrics is performed prior to or during the second pass.
30. The method of claim 27, wherein the one or more diagnostic
tests comprise an optical flatness test.
31. The method of claim 27, wherein the one or more diagnostic
tests comprise an optical dimension test.
32. The method of claim 27, wherein the one or more diagnostic
tests comprise a surface roughness test.
33. The method of claim 27, wherein the one or more diagnostic
tests comprise using a touch probe to measure one or more surface
points of the workpiece, wherein the one or more surface points are
used to determine a dimension of the workpiece.
34. The method of claim 27, further comprising determining whether
to repeat the steps of claim 27 based at least in part on the one
or more workpiece characteristics.
35. The method of claim 27, further comprising receiving a
reference corresponding to the workpiece, wherein the reference
comprises dimension information of the workpiece.
Description
[0001] The present disclosure relates to sensor-based deburring,
and more particularly relates to using sensor data to determine
deburring schedules.
BACKGROUND
[0002] 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.
[0003] Blasting processes may be used to deburr parts. However,
typical 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. Additionally, blasting may only be desired
at particular portions of the part.
SUMMARY
[0004] In some embodiments, 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. In some embodiments, deburring a
workpiece may include sensing one or more parameters of the
workpiece using a sensor, determining, using processing equipment,
one or more 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, and determining one or more workpiece characteristics
based on one or more diagnostic tests.
[0005] In some embodiments, 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
processing equipment may be configured to control the flow of the
blasting media based on the output of the sensor.
[0006] In some embodiments, 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 workpiece. 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.
BRIEF DESCRIPTION OF THE FIGURES
[0007] The above and other features of the present disclosure, its
nature and various advantages will be more apparent upon
consideration of the following detailed description, taken in
conjunction with the accompanying drawings in which:
[0008] FIG. 1 shows an illustrative deburring system, in accordance
with some embodiments of the present disclosure;
[0009] FIG. 2 shows an illustrative deburring system having a
deburring module, in accordance with some embodiments of the
present disclosure;
[0010] FIG. 3 shows an illustrative deburring system having a
deburring module and a metrology module, in accordance with some
embodiments of the present disclosure;
[0011] 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;
[0012] FIG. 5 shows a perspective view of an illustrative reference
and workpiece, in accordance with some embodiments of the present
disclosure;
[0013] 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;
[0014] 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;
[0015] FIG. 8 shows a perspective view of an illustrative CNC
machine configured to perform deburring, in accordance with some
embodiments of the present disclosure;
[0016] FIG. 9 shows a screenshot of an illustrative deburring
application, in accordance with some embodiments of the present
disclosure;
[0017] FIG. 10 is a flow diagram of illustrative steps for
deburring a workpiece based on a burr metric, in accordance with
some embodiments of the present disclosure;
[0018] 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, in accordance with some embodiments
of the present disclosure; and
[0019] 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.
DETAILED DESCRIPTION OF THE FIGURES
[0020] The present disclosure is directed towards techniques and
arrangements for deburring. Processing of materials, especially
relatively soft materials, may cause burr formation. For example,
the techniques disclosed herein may be applied to 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, polyethylenetetrafluoroethylene,
polychlorotrifluoroethylene), ultra-high-molecular-weight
polyethylene (UHMWPE), any other suitable plastic, thermoplastic or
metal, any other suitable material, or any combination thereof.
[0021] 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. Based on the burr metric, 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 characteristics may be determined to gauge these
potential changes.
[0022] FIG. 1 shows an illustrative deburring system 100, in
accordance with some embodiments of the present disclosure.
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. In some embodiments, processing equipment 130 may be
communicatively coupled to sensor 114 and sensor 118. For example,
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. During
forming, machining, or both, of workpiece 190, for example, one or
more burrs 194 may be formed. The one or more burrs 194 may include
attached burrs (e.g., plastically deformed but not broken off),
detached burrs (e.g., plastically deformed and broken off, but
still lying on the surface of workpiece 190), debris (e.g., pieces
of other workpieces or tools lying on the surface of workpiece
190), or a combination thereof.
[0023] 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. In some embodiments, 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 coupling, any other
suitable coupling, or any combination thereof.
[0024] Sensor 114 may sense one or more parameters of workpiece
190. Parameters may include absolute dimensions, relative
dimensions, areas, volumes, any other suitable parameters, or any
combination thereof. In some embodiments, sensor 114 may include a
camera configured to capture images of workpiece 190. For example,
sensor 114 may include a CCD camera configured to capture one or
more images of one or more features 192 of workpiece 190.
[0025] Sensor 118 may sense one or more characteristics of
workpiece 190. Characteristics may include absolute dimensions,
relative dimensions, areas, volumes, flatness, surface properties,
any other suitable characteristics of workpiece 190, or any
combination thereof. In some embodiments, 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. In some
such embodiments, processing equipment 130 may determine an angle
of reflection, an angle of workpiece 190 relative to a reference
angle (e.g., relative to 0.degree. reference top surface of
reference 120). For example, sensor 118 may be scanned over a
surface of workpiece 190 (e.g., using coupling 122 controlled by
processing equipment 130), and processing equipment 130 may
determine the variation in angle (e.g., the flatness) of the
surface of workpiece 190.
[0026] In some embodiments, 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. In some
embodiments, 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. For example, 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. In a further example,
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. In a
further example, a motion control actuator may include a servo
motor configured to provide controlled angular motion, angular
position control, or both. In some embodiments, any or all of
couplings 122, 124, and 126 may include motion control actuators
that are user-controlled. For example, 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. In some embodiments,
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. For
example, 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. In some embodiments, 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. For example, 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 accordingly sensor 118, sensor 114, or nozzle
116 may be moved in a sensing or nozzle direction (e.g., the
spindle axis of a milling machine).
[0027] In some embodiments, 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. For example, blasting
media container 150 may be configured to contain blocks of dry ice.
Accordingly, 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. In a further example, 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). Accordingly, 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. In a further example, blasting
media container 150 may be configured to contain liquid water.
Accordingly, 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.
[0028] In some embodiments, 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 116, or both. For example,
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. In a further example, 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. In a further
example, 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.
[0029] In some embodiments, deburring system may include interface
160, configured to allow user interaction. For example, 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. For example, 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. In
a further example, 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. In a
further example, 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 microphone. 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
coupling, inductive coupling, any other suitable coupling, or any
combination.
[0030] 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. In
some embodiments, sensor 214 and nozzle 216 may be included in
deburring module 210, along with any other suitable components. For
example, 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) configured to sense a characteristic of workpiece 290.
In some embodiments, processing equipment 230 may be
communicatively coupled to sensor 214. For example, 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.
[0031] 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.
In some embodiments, sensor 214 may include a camera configured to
capture images of workpiece 290. For example, sensor 214 may
include a CCD camera configured to capture one or more images of
one or more features 292 of workpiece 290. In some embodiments,
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.
[0032] In some embodiments, processing equipment 230 may be coupled
to coupling 222, which may mechanically link deburring module 210
(directly or indirectly) to reference 220. Coupling 222 may include
a mechanical or electromechanical coupling between deburring module
210 and reference 220. In some embodiments, coupling 222 may
include one or more motion control actuators controlled by a CNC,
which may be included in processing equipment 230.
[0033] In some embodiments, 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
components for delivering a blasting media to nozzle 216, or any
combination thereof. 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. In some embodiments, 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.
[0034] In some embodiments, deburring system may include interface
260, configured to allow user interaction. For example, 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
combination.
[0035] 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. For example, 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.
[0036] 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. In some embodiments,
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)
separate from or in concert with processing equipment 230.
[0037] In some embodiments, processing equipment 230 may be coupled
to coupling 324, which may mechanically link metrology module 380
(directly or indirectly) to reference 220 (as shown), or any other
suitable reference (not shown). 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.
[0038] In some embodiments, metrology module 380 need not be
included in deburring system 300. For example, workpiece 290 may be
movable from reference 220 to a second reference (not shown), to
which metrology module 380 may be coupled. Accordingly, metrology
module 380 may perform one or more metrology operations separate
from the deburring operations of deburring system 200.
[0039] 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 toolholder), deburring tool
414 (e.g., having a sensor and nozzle), metrology tool 416 (e.g.,
having a sensor configured to sense a workpiece characteristic),
sensing tool 418, any other suitable tool not included in FIG. 4,
or any combination thereof. 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. For example, 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 resulting relative
positions between tooling head 420 and reference surfaces 440. In
some embodiments, CNC machine 400 need not include tool selector
410, and various tools may be selected and installed by a user. In
some embodiments, linkages 430 need not be controlled by processing
equipment 450 but rather by a user operating hand cranks or other
manual actuators. In some embodiments, 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).
[0040] 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 perspective view of illustrative reference 550 and
workpiece 590 of FIG. 5, and a deburring tool 610 having sensors
614 and 618, and a nozzle 616 configured to deliver blasting media
617, in accordance with some embodiments of the present disclosure.
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. As shown, 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.
[0041] Nozzle 616 is shown delivering a jet of blasting media 617
to workpiece 590 (e.g., during a deburring process). In some
embodiments, a sublimating particulate (e.g., dry ice) may be
entrained in a gaseous flow (e.g., air), which avoids leaving any
significant residue on workpiece 590. 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. In some
embodiments, deburring tool 610 may include all or some of a
blasting media delivery system. For example, 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).
[0042] 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 embodiments of the present
disclosure. 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.
In some embodiments, 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. In some embodiments, sensor 614, sensor 618, or both, may
be configures to perform sensing while blasting media is delivered
to workpiece 590 from nozzle 616. In some embodiments, sensor 614,
sensor 618, or both, may be configures to perform sensing
sequentially with (e.g., before or after) the delivery of blasting
media to workpiece 590 from nozzle 616.
[0043] FIG. 8 shows a perspective view of an illustrative CNC
machine 800 configured to perform deburring, in accordance with
some embodiments of the present disclosure. It will be understood
that 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, as illustrated, 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, includes a horizontal reference surface to which
vice 830 may be affixed. Reference 820 may be movable in the
horizontal plane using one or more actuators (e.g., linear, rotary,
or both), which may be controlled by processing equipment (not
shown). 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 translation), and may have an adjustable
orientation (e.g., via rotation). Although not shown in FIG. 8,
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 that is not illustrated
in FIG. 8) may include display screen 862, configured to provide a
visual display to a user. For example, an image of workpiece 890,
one or more parameter values, one or more characteristics of
workpiece 890, any other information, or any combination thereof,
may be displayed on display screen 862. 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. For example, 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.
In a further example, not shown in FIG. 8, interface 860 may be a
computer system (i.e., having processing equipment) communicatively
coupled to CNC machine 800.
[0044] FIG. 9 shows a screenshot 900 of an illustrative deburring
application, in accordance with some embodiments of the present
disclosure. It will be understood that 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). In some embodiments,
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 characteristic display 914, image display
916, any other suitable information display not shown in FIG. 9, or
any combination thereof. For example, 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. In a further example, nozzle
position display 904 may include Cartesian coordinates (e.g.,
relative to some reference) of a nozzle of a deburring system. In a
further example, nozzle position display 906 may include Cartesian
coordinates (e.g., relative to some reference) of a workpiece
undergoing a deburring technique. In a further example, 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). In a further
example, 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). In a
further example, 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.sub.2 particles
per cc entraining gas), a temperature, an exit velocity of blasting
media from a nozzle, any other suitable blasting media property, or
any combination thereof. In a further example, characteristic
display 914 may include a numerical value quantifying a workpiece
characteristic (e.g., a surface deviation of 0.05 mm).
[0045] 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. In some embodiments, image position display 902 may correspond
to the image displayed in image display 916. In some embodiments,
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). In some such embodiments,
the processing equipment may use an image processing algorithm to
determine one or more dimension of a workpiece, a dimension of a
feature of the workpiece. For example, 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). In a further
example, 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). In a further example, 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"). In a further example,
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 template.
The processing equipment may implement any suitable image
processing techniques such as, for example, feature extraction
(e.g., edge detection, predetermined pattern detection). For
example, 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. In a further example, 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.
[0046] 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.
[0047] 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. For example, the deburring system may include
a camera configured to capture images of the workpiece. In some
embodiments, a deburring system may include multiple sensors for
sensing one or more parameters of the workpiece. Parameters may
include distances, areas, shapes, any other absolute or relative
parameters, or any combination thereof.
[0048] Step 1004 may include processing equipment determining a
burr metric based at least in part on the one or more parameters of
step 1002. In some embodiments, 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. In a further example, 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. In some embodiments, 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
categorization, or any combination thereof. In a further example,
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). Any suitable
quantitative burr metric, qualitative burr metric, or both, may be
determined by the processing equipment based on the sensed
parameter of step 1002.
[0049] 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. In some
embodiments, 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. In some embodiments, a
quantitative burr metric may be compared with a threshold value,
and the deburring system may deliver the blasting media based on
the comparison. For example, at step 1004 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 pressure, a seeding
density, a temperature, an exit velocity of blasting media from a
nozzle, any other suitable blasting media property, or any
combination thereof.
[0050] 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 disclosure. The illustrative techniques of flow
diagram 1100 may be implemented in accordance with any of the
systems disclosed herein.
[0051] 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. For example, the deburring system may include
a camera configured to capture images of the workpiece. In some
embodiments, a deburring system may include multiple sensors for
sensing one or more parameters of the workpiece. Parameters may
include distances, areas, shapes, any other absolute or relative
parameters, or any combination thereof.
[0052] Step 1104 may include determining a burr metric based at
least in part on the one or more parameters of step 1102. In some
embodiments, 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. In a further example, 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. In some embodiments, 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
categorization, or any combination thereof. In a further example,
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). Any suitable
quantitative burr metric, qualitative burr metric, or both, may be
determined by the processing equipment based on the sensed
parameter of step 1102.
[0053] 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. In some
embodiments, 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. In some embodiments, a
quantitative burr metric may be compared with a threshold value,
and the deburring system may deliver the blasting media based on
the comparison. For example, at step 1104 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 pressure, a seeding
density, a temperature, an exit velocity of blasting media from a
nozzle, any other suitable blasting media property, or any
combination thereof.
[0054] Step 1108 may include one or more workpiece characteristics
using a metrology tool such as a metrology sensor. 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. In some
embodiments, 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. In a further example, a
laser beam reflected from the workpiece surface to a photodetector
may be used to determine variations in the surface flatness. In
some embodiments, 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 techniques) may be applied to
the image to determine dimensions, flatness, or both of the
workpiece. In some embodiments, a roughness sensor may be used to
determine the workpiece characteristic. For example, a contact
probe may be used to measure surface roughness (e.g., a rugosity
value, or roughness value). In a further example, a microscope
(e.g., a scanning laser microscope, an optical microscope) may be
used to determine a surface profile and corresponding roughness. In
a further example, an interferometer may be used to determine a
surface profile and corresponding roughness. In some embodiments, a
touch probe (e.g., a stylus configured to contact the workpiece)
may be used to determine one or more surface points (e.g.,
coordinates) of the workpiece to generate a surface profile,
determine one or more dimensions, or both.
[0055] In some embodiments, step 1108 may be performed to determine
whether the blasting schedule of step 1106 has appreciably altered
the workpiece. For example, 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.degree. C.), and
step 1108 may be performed to determine if any warping of the
workpiece has occurred due to temperature gradients. In a further
example, 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. In a further example,
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.
[0056] 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.
[0057] 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. For example, the processing equipment may
retrieve a CAD file corresponding to a particular workpiece from
memory storage. In a further example, the processing equipment may
receive user input of a CAD file in the form of a removable memory
storage device. In a further example, 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.
[0058] Step 1204 may include processing equipment determining a
sensing schedule based on the reference of step 1202. The sensing
schedule may include a sequence of positions (e.g., of a sensor
relative to the workpiece), times, velocities (e.g., of a sensor
relative to the workpiece), accelerations (e.g., of a sensor
relative to the workpiece), sensor identifications (e.g., which
sensor to use at a particular location), sensor properties (e.g.,
focus distance, sensor angle, sensor output conditioning), any
other suitable information, or any combination thereof. For
example, 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. For
example, 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. In a further
example, 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. In some embodiments, step 1204 may include the processing
equipment processing and storing sensor output as the sensing
schedule is performed. For example, the processing equipment may
process and store a sequence of images taken as a camera is scanned
over the surface of the workpiece.
[0059] Step 1208 may include processing equipment determining a
blasting schedule based on the sensor schedule, or a portion
thereof, performed at step 1206. 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
workpiece), blasting media identifications (e.g., which blasting
media to use at a particular location), blasting media properties
(e.g., what flow rate of blasting media to use at a particular
location), any other suitable information, or any combination
thereof. For example, 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. At each blasting
location, 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.
[0060] In some embodiments, steps 1206 and 1210 may be performed in
substantially real time (e.g., during a single pass over the
workpiece). For example, the sensor may move according to a
schedule relative to the workpiece, sensing parameters of one or
more features. The nozzle may move according to the same schedule
(e.g., may be rigidly attached to the sensor, or may be
independently controlled) but at a lag behind the sensor. As the
sensor captures information, the processing equipment may determine
a burr metric in real time, and determine a desired blasting
schedule in real time. Accordingly, the deburring system may
perform a single pass over the surface of the workpiece, during
which both sensing and blasting may be performed. In some
embodiments, steps 1206 and 1210 may be performed in sequentially.
For example, the sensor may move according to a schedule relative
to the workpiece, sensing parameters of one or more features. After
the sensor makes a first pass, the processing equipment may
determine one or more burr metrics (e.g., a scalar field of burr
metrics), and determine a desired blasting schedule based on the
one or more burr metrics. Accordingly, 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. In some embodiments, step 1206, step 1208, or
both, may include determining a burr metric based at least in part
on the sensor output of step 1206.
[0061] Step 1212 may include processing equipment determining one
or more workpiece characteristics based on a sensor output. During
blasting at step 1210, 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. For example, 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). In some
embodiments, different sensors may be used to perform steps 1206
and 1212.
[0062] Step 1214 may include processing equipment determining
whether a workpiece is sufficiently burr-free. In some embodiments,
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 determines that
the workpiece is sufficiently burr-free, then the workpiece need
not be further inspected or deburred, and may undergo subsequent
processing apart from deburring. In some embodiments, if the
processing equipment determines that the workpiece is sufficiently
burr-free, 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). In some embodiments, if the
processing equipment determines that the workpiece is not
sufficiently burr-free, then 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.
[0063] Step 1216 may include processing equipment determining
whether a workpiece characteristic determined at step 1212 is
acceptable. In some embodiments, the processing equipment may
compare the one or more characteristics to predetermined thresholds
or tolerances. For example, 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. In a further example, one or more dimensions of the
workpiece (or point measurements) measured at step 1212 may
compared to corresponding tolerances, and if the dimensions are
within the tolerances, the one or more dimensions may be determined
to be acceptable. In a further example, 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 embodiments, the processing
equipment may provide the one or more workpiece characteristic
values to a user via an interface. In some such embodiments, the
interface may be configured to receive a user input as to whether
the characteristic is acceptable or not.
[0064] The foregoing is merely illustrative of the principles of
this disclosure and various modifications may be made by those
skilled in the art without departing from the scope of this
disclosure. The above described embodiments are presented for
purposes of illustration and not of limitation. The present
disclosure also can take many forms other than those explicitly
described herein. Accordingly, it is emphasized that this
disclosure is not limited to the explicitly disclosed methods,
systems, and apparatuses, but is intended to include variations to
and modifications thereof, which are within the spirit of the
following claims.
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