METHOD AND SYSTEM FOR PRECISION CONTROL IN ABRASIVE JET MACHINING

Abstract

The present invention provides an automated abrasive jet machining system that incorporates advanced technologies for precise and efficient material processing. The system includes a robotic arm or gantry for precise positioning, real-time monitoring sensors, adaptive control software, and a data acquisition and analysis module (105). The system offers enhanced precision, consistency, and efficiency, making it suitable for various industries demanding high-quality machining.

Specification

Description:METHOD AND SYSTEM FOR PRECISION CONTROL IN ABRASIVE JET MACHINING
FIELD OF INVENTION
The present invention relates to the field of versatile manufacturing technologies, specifically focusing on the automation and precision control of abrasive jet machining (AJM) processes.

BACKGROUND OF THE INVENTION
The existing invention of patent application number IN202441054060 relates to the field of abrasive water jet machine, it is a high-precision cutting tool that utilizes garnet as an abrasive to effectively slice through hard materials.
The patented invention exhibits notable limitations that hinder their overall effectiveness and precision. It utilizes garnet as abrasive particles to achieve high accuracy in cutting hard materials. In these systems, a fixed abrasive flow rate is deemed sufficient for smooth operation. This simplicity, while advantageous in some respects, overlooks the complexities involved in maintaining optimal machining conditions, particularly for intricate designs. The reliance on a fixed diameter orifice for abrasive flow metering, though reliable, often fails to accommodate variations in workpiece materials or geometries, leading to inconsistent outcomes.
Moreover, while modern abrasive feed systems have made strides by replacing outdated vibratory feeders and solids metering valves with more straightforward orifice systems, they remain constrained by a lack of real-time adaptability. During initial setup, the abrasive flow is calibrated and entered into the control program, eliminating the need for adjustments thereafter. However, this static approach does not account for the dynamic nature of machining processes, where factors such as workpiece wear, changes in material properties, or environmental conditions can significantly impact performance. Additionally, the head mechanism, which focuses the water jet for precise impact, requires careful alignment and can be prone to human error, further complicating the operation.
The present invention addresses these shortcomings through a comprehensive automation system designed for precision control in abrasive jet machining. Unlike the conventional fixed systems, this invention incorporates an automated positioning system that utilizes a robotic arm or gantry for high-precision movement of the abrasive jet nozzle and workpiece. This enables fine adjustments that are crucial for maintaining optimal machining conditions across various applications.
OBJECT OF THE INVENTION
The object of the invention is to provide a fully automated system and a method for precision control in abrasive jet machining that significantly enhances precision, control, and efficiency in the machining process.

SUMMARY OF THE INVENTION
The present invention discloses an automated system for precision control in abrasive jet machining (AJM). This system integrates advanced positioning mechanisms, real-time monitoring sensors, and adaptive control algorithms to enhance the accuracy and efficiency of machining operations. By utilizing a robotic arm or gantry for precise movement, along with sensors that monitor critical parameters such as nozzle distance and abrasive flow rate, the invention allows for dynamic adjustments based on real-time data. Additionally, a data acquisition and analysis module provide insights for continuous improvement and predictive maintenance. This innovative approach is designed to meet the high precision demands of industries such as aerospace, automotive, and electronics, while reducing human error and optimizing resource utilization.

The integration of real-time monitoring sensors allows for continuous oversight of key parameters, such as nozzle distance and abrasive flow rate. This capability not only enhances consistency but also enables immediate corrective actions in response to dynamic changes during the machining process. The adaptive control software employed in this system dynamically adjusts machining parameters based on live data, overcoming the limitations of fixed flow rates and ensuring that the machine operates at peak efficiency regardless of the specific requirements of each task.

Finally, the addition of a data acquisition and analysis module provides insights into the machining process, facilitating predictive maintenance and continuous improvement. This proactive approach contrasts sharply with traditional systems that rely on reactive maintenance, thus enhancing the reliability and longevity of the equipment.
BRIEF DESCRIPTION OF DRAWINGS
Figure 1: Block Diagram for Automated Abrasive Jet Machine.
Figure 2: Detailed View of the Robotic Arm or Gantry System.
Figure 3: Flowchart of the Adaptive Control Software.

DETAILED DESCRIPTION OF THE INVENTION
The following detailed description refers to the accompanying drawings. Wherever possible, the same reference numbers are used in the drawings and the following description to refer to the same or similar elements. Further, substitutions, additions, or modifications may be made to the elements illustrated in the drawings, and the methods described herein may be modified by substituting, reordering, or adding stages to the disclosed methods. Accordingly, the following detailed description does not limit the disclosure. Instead, the proper scope of the disclosure is defined by the appended claims. The present disclosure contains headers. It should be understood that these headers are used as references and are not to be construed as limiting upon the subjected matter disclosed under the header.
The present invention provides an automated abrasive jet machining system that incorporates advanced technologies for precise and efficient material processing. It incorporates a robotic arm or gantry, real-time monitoring sensors, adaptive control algorithms, and data analysis capabilities. This comprehensive approach enables precise control, improved efficiency, and enhanced material processing capabilities, making it a valuable tool for industries requiring high-quality machining.

In an embodiment of the present invention discloses the system for precision control, comprises the following key components:
• Automated Positioning System (101): A high-precision robotic arm or gantry system (108) equipped with stepper motors (103) or servos (103) for accurate and repeatable positioning of the workpiece and abrasive jet nozzle (102). Integrated sensors ensure precise alignment and avoid collisions.
• Abrasive Jet Nozzle (102): A high-pressure nozzle (102) capable of delivering a controlled stream of abrasive particles at high velocity. A system regulates the flow rate of abrasive particles and the pressure of the carrier gas.
• Real-Time Monitoring Sensors: These sensors include nozzle distance sensors, abrasive flow rate sensors, workpiece position sensors, and potentially additional process monitoring sensors for temperature, vibration, or acoustic emissions.
• Adaptive Control Software: A sophisticated control algorithm analyzes data from the monitoring sensors and adjusts machining parameters in real-time, such as nozzle speed, position, abrasive flow rate, and carrier gas pressure.
• Data Acquisition and Analysis Module (105): This module collects and stores data from the monitoring sensors and control system. Advanced data analysis techniques, such as machine learning and statistical analysis, are employed to identify trends, optimize parameters, and predict maintenance needs.
• User Interface: An intuitive user interface (105) allows for programming and controlling the system, including CAD file import and processing, machining parameter setup, real-time process monitoring, and data analysis and visualization.
The automated abrasive jet machining system offers several advantages over traditional methods, including enhanced precision, improved efficiency, consistency, versatility, and data-driven optimization. It is particularly well-suited for industries that require high-precision manufacturing, such as aerospace, automotive, electronics, medical devices, and tool and mold making.

In another embodiment of the present invention discloses the method of precision control in abrasive jet machining comprising following steps:
• positioning a workpiece using an automated positioning system (101);
• delivering an abrasive jet onto the workpiece using a high-pressure nozzle (102);
• monitoring the machining process using real-time sensors;
• adjusting machining parameters in real-time based on sensor data using adaptive control software;
• collecting and analyzing sensor data to optimize the machining process.

Figure 1 provides an overview of the key components and their interactions in the automated abrasive jet machining system. The X-Y table (104) is responsible for moving the workpiece in the horizontal plane, while the angle fixture (106) allows for precise adjustment of the workpiece's orientation. The PC (105) serves as the control center, coordinating the system's operation based on sensor inputs and control algorithms. The abrasive jet nozzle (102) delivers the high-pressure stream of abrasive particles onto the workpiece. Platform (107) is used to place the specimen.

Figure 2 illustrates the robotic arm or gantry system (108) used in the automated abrasive jet machining process. The robot arm (110) is controlled by a joystick (113) to track its position and orientation. The touch-screen interface (109) allows for user interaction and control. The robot-driven C-arm (111) may be used for imaging or visualization purposes and equipped with a navigation system (112) to track its position and orientation.

Figure 3 depicts the adaptive control software responsible for adjusting machining parameters based on real-time sensor data. The software includes components for controlling the system, initializing parameters, adaptive tuning, gain saturation, and feedforward force calculation. The algorithm dynamically adjusts the adaptive gain to ensure optimal machining performance.

Advantages of the Present Invention:
1. Enhanced Precision: The automated positioning system (101) and real-time monitoring ensure precise control of the abrasive jet nozzle (102), resulting in highly accurate machining of complex geometries.
2. Improved Efficiency: Adaptive control algorithms optimize the machining process by adjusting parameters based on real-time data, reducing waste and improving productivity.
3. Consistency: Automated systems minimize human error and ensure consistent results, even for large-scale production.
4. Versatility: The system can be adapted to handle a wide range of materials and applications, from precision cutting to surface finishing.
5. Data-Driven Optimization: The ability to collect and analyze data enables continuous improvement and optimization of the machining process.
6. Reduced Human Error: Automation minimizes the risk of errors caused by human factors, such as fatigue or inexperience.
7. Increased Safety: By automating hazardous tasks, the system can reduce the risk of injuries to operators.
8. Improved Quality Control: Real-time monitoring and data analysis can help identify and address potential quality issues before they become significant problems.
9. Cost-Effectiveness: In the long term, the automated system can lead to cost savings through improved efficiency, reduced waste, and higher quality products.
10. Scalability: The system can be scaled to meet the needs of different production volumes and manufacturing environments.

EXAMPLE
• Positioning a Workpiece: An automated positioning system (101) ensures the workpiece is accurately aligned for machining, which is crucial for achieving desired tolerances.
• Delivering an Abrasive Jet: A high-pressure nozzle (102) propels an abrasive mixture at the workpiece, enabling effective material cutting or shaping. The selection of abrasives for nozzle (102) design can significantly influence the machining outcome.
• Monitoring the Machining Process: Real-time sensors continuously gather data on various parameters, such as pressure, flow rate, and surface conditions. This monitoring allows for immediate feedback on the machining state.
• Adjusting Machining Parameters: Adaptive control software processes the sensor data and makes real-time adjustments to parameters like abrasive flow rate, nozzle speed, or pressure. This adaptability can help maintain optimal cutting conditions despite variations in the workpiece or environment.
• Collecting and Analyzing Sensor Data: The accumulated sensor data is analyzed to identify trends and optimize the machining process over time. This may include refining parameters for different materials or improving overall efficiency and quality.


While the invention is amenable to various modifications and alternative forms, some embodiments have been illustrated by way of example in the drawings and are described in detail above. The intention, however, is not to limit the invention by those examples and the invention is intended to cover all modifications, equivalents, and alternatives to the embodiments described in this specification.
The embodiments in the specification are described in a progressive manner and focus of description in each embodiment is the difference from other embodiments. For same or similar parts of each embodiment, reference may be made to each other.
It will be appreciated by those skilled in the art that the above description was in respect of preferred embodiments and that various alterations and modifications are possible within the broad scope of the appended claims without departing from the spirit of the invention with the necessary modifications. , Claims:We Claim:
1. An automated precision control in abrasive jet machining system comprising:
i) an automated positioning system (101);
ii) a high-pressure abrasive jet nozzle (102);
iii) real-time monitoring sensors for temperature, vibration, or acoustic emissions;
iv) adaptive control software for adjusting machining parameters based on sensor data;
v) a data acquisition and analysis module (105) for collecting and processing sensor data.
2. The automated precision control in abrasive jet machining system as claimed in claim 1, wherein the automated positioning system (101) includes a robotic arm or gantry.
3. The automated precision control in abrasive jet machining system as claimed in claim 1, wherein the automated positioning system (101) is driven by stepper motors or servos (103) for accurate and repeatable positioning of the workpiece and abrasive jet nozzle (102).
4. The automated precision control in abrasive jet machining system as claimed in claim 1, wherein the real-time monitoring sensors include nozzle distance sensors, abrasive flow rate sensors, workpiece position sensors, and potentially additional process monitoring sensors.
5. The automated precision control in abrasive jet machining system as claimed in claim 1, wherein the adaptive control software adjusts machining parameters such as nozzle speed, abrasive flow rate, and carrier gas pressure.
6. The automated precision control in abrasive jet machining system as claimed in claim 1, further comprising a user interface (105) for programming and controlling the system.
7. The automated precision control in abrasive jet machining system as claimed in claim 1, wherein the data acquisition and analysis module (105) stores machine learning algorithms to identify trends, optimize parameters, and predict maintenance needs.
8. The automated precision control in abrasive jet machining system as claimed in claim 1, wherein the automated positioning system (101) and real-time monitoring ensure precise control of the abrasive jet nozzle (102), resulting in highly accurate machining of complex geometries.
9. A method of precision control in abrasive jet machining comprises the following steps:
i) positioning a workpiece using an automated positioning system (101);
ii) delivering an abrasive jet onto the workpiece using a high-pressure nozzle (102);
iii) monitoring the machining process using real-time sensors;
iv) adjusting machining parameters in real-time based on sensor data using adaptive control software;
v) collecting and analyzing sensor data to optimize the machining process.

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