In a device and method for determining a contact between a tool and a workpiece, which are displaceable relative to each other, the tool or workpiece being rotationally fixedly connected to a shaft, the device includes a measuring arrangement including a measuring scale rotationally fixedly disposed on the shaft and at least one position encoder disposed in a stationary manner relative to the shaft, and a processing device. The position encoder is adapted to scan the measuring scale and to generate position values indicating a position of the shaft. The position values are fed to the processing device, which determines contact between the tool and the workpiece by evaluating a progression of the position values and signals the result of the evaluation by the status of a displacement signal.

A method of manufacturing a feature in a part with a cutting tool, includes machining a semi-finished shape of the feature, determining an actual position of at least one target point on a surface of the semi-finished shape, and computing a difference between the determined position of the at least one target point and a nominal position of the at least one target point on a digitized model of the part having the semi-finished shape of the feature. As a function of the difference, a correction to a position of the cutting tool on a nominal tool path to achieve the final shape of the feature from the semi-finished shape is determined, and the correction is used to define a corrected tool path. The finished shape of the feature is then machined with the cutting tool by moving the cutting tool along the corrected tool path.

The CNC machining device 1 includes a tool magazine 20, a spindle 26, an automatic tool replacing device, a CNC controller 32, a sensor head 10 configured to generate measurement data corresponding to a distance from a surface of the object, and a personal computer 40. The sensor head 10 generates measurement data (X, Z) at regular intervals. The CNC controller 32 generates position coordinate data (x, y, z, xθ, yθ, zθ) at regular intervals. The sensor head 10 transmits the measurement data to the personal computer 40 through first radio communication RC1. The sensor head 10 transmits a synchronization signal for synchronizing the measurement data and the position coordinate data to the CNC controller 32 through second radio communication RC2.

A touch trigger probe interface for a machine tool is described that includes a probe communication portion for receiving probe event information from a touch trigger probe. A machine tool communication portion is also provided for outputting probe event information to a numerical controller of the machine tool. The machine tool communication portion outputs the probe event information as digital data packets, for example over a digital data bus. The digital data packets may include a time stamp and/or the touch trigger probe interface may receive timing information from the machine tool. A touch trigger probing system and a machine tool system including the probe interface are also described.

Systems, apparatuses and methods are described for integrating an electronic metrology sensor with precision production equipment such as computer numerically controlled (CNC) machines. For example, a laser distance measuring sensor is used. Measurements are taken at a relatively high sample rate and converted into a format compatible with other data generated or accepted by the CNC machine. Measurements from the sensor are synchronized with the position of the arm of the machine such as through the use of offsets. Processing yields a detailed and highly accurate three-dimensional map of a workpiece in the machine. Applicable metrology instruments include other near continuously reading non-destructive characterization instruments such as contact and non-contact dimensional, eddy current, ultra-sound, and X-Ray Fluorescence (XRF) sensors.

A manufacturing control system for an additive, subtractive, or hybrid machining system implements a morphic manufacturing approach that integrates in situ inspection and related decision-making into the manufacturing process. After execution of a machining or deposition operation, the system performs a sensor scan to collect sensor measurement data for the resulting part while the part remains in the manufacturing work cell. The measurement data is compared with an as-designed digital model of the part to determine whether further machining or deposition is necessary to bring the finished part into tolerance with the model. If necessary, the system performs another additive and/or subtractive manufacturing operation on the part based on analysis of the measurement data to bring the part into tolerance. The measured inspection data can be stored in association with each manufactured part for auditing purposes or for creation of part-specific digital twins.

A touch trigger probe interface for a machine tool is described that includes a probe communication portion for receiving probe event information from a touch trigger probe. A machine tool communication portion is also provided for outputting probe event information to a numerical controller of the machine tool. The machine tool communication portion outputs the probe event information as digital data packets, for example over a digital data bus. The digital data packets may include a time stamp and/or the touch trigger probe interface may receive timing information from the machine tool. A touch trigger probing system and a machine tool system including the probe interface are also described.

A method for calibrating a CNC processing apparatus is provided that can significantly reduce the amount of operation time required for sensor calibration. A method of the present invention for calibrating a non-contact sensor in a CNC processing apparatus 1 includes a first step, a second step and a third step. In the first step, the center coordinates of a reference instrument are measured with a contact probe and thereby the machine coordinates of the center of the reference instrument are determined. In the second step, after a non-contact sensor 110 is mounted onto a spindle 26, the center coordinates of the reference instrument are measured only one time with the non-contact sensor 110, and thereby the non-contact sensor coordinates of the center of the reference instrument are determined. In the third step, calculations are made to determine the amount of displacement required to bring the non-contact sensor coordinates obtained in the second step into agreement with the machine coordinates obtained with the contact probe in the first step.

A manufacturing control system for an additive, subtractive, or hybrid machining system implements a morphic manufacturing approach that integrates in situ inspection and related decision-making into the manufacturing process. After execution of a machining or deposition operation, the system performs a sensor scan to collect sensor measurement data for the resulting part while the part remains in the manufacturing work cell. The measurement data is compared with an as-designed digital model of the part to determine whether further machining or deposition is necessary to bring the finished part into tolerance with the model. If necessary, the system performs another additive and/or subtractive manufacturing operation on the part based on analysis of the measurement data to bring the part into tolerance. The measured inspection data can be stored in association with each manufactured part for auditing purposes or for creation of part-specific digital twins.

A system and method for manufacturing a component is provided that includes a CNC machine tool, a correction module, and a system controller. The CMM module is controllable to determine a set of multi-axis coordinates surface points on the component. The correction module is in communication with the CMM module and stored reference inspection data. The system controller is in communication with the CNC machine tool, the correction module, and stored instructions. The instructions when executed cause the system controller to: a) control the CNC machine tool to modify a surface of the component; b) control the CMM module to determine multi-axis coordinates for surface points; c) determine surface position variances using the reference inspection data and the multi-axis coordinates; d) determine if surface position variances exceed a threshold; and e) create correction action instructions for controlling the CNC machine if surface position variances exceed the threshold.