Methods and software for reducing machining equipment usage when machining multiple objects from a single workpiece

• US 10,401,824 B2
• Filed: 01/15/2018
• Issued: 09/03/2019
• Est. Priority Date: 04/14/2016
• Status: Active Grant

• Current Assignee: Proto Labs, Inc.
• Original Assignee: Rapid Manufacturing Group LLC (Proto Labs, Inc.)
• Inventors: Jacobs, II, James L., Stahl, Christopher
• Primary Examiner(s): Masinick, Michael D
• Application Number:
  US15/871,191
• Publication Number:
  US 20180150048A1
• Time in Patent Office: 596 Days
• CPC Class Codes: G05B 19/19 characterised by positioning or contouring control systems, e.g. to control position from one programmed point to another or to control movement along a programmed continuous path
• CPC Class Codes: G05B 19/4097 characterised by using design data to control NC machines, e.g. CAD/CAM G05B19/4093 takes precedence
• CPC Class Codes: G05B 2219/31466 Display position of different workpieces, tools in system
• CPC Class Codes: G05B 2219/31472 Graphical display of process
• CPC Class Codes: G05B 2219/35162 Determine workpiece placement, nesting in blank, optimize, minimize loss material

Abstract

Methods for providing a workpiece computer model including a plurality of objects defined in a body of material. A temporary support frame is provided as part of a two-sided machining process in which the workpiece is partially milled from an obverse side. The machine-control instructions are also based on one or more occupying structures added to the workpiece to fill in one or more excess unoccupied regions of the workpiece that would otherwise be machined away during machining of the objects. Providing such occupying structure(s) reduces the amount of machining that needs to be performed.

Claims

1. A method of providing a workpiece computer model including a plurality of objects defined in a body of material, the method comprising:

receiving, a graphical representation of a temporary support frame to be machined from the body of material, wherein the graphical representation of the temporary support frame includes;

first and second surfaces spaced from one another; and

an opening for receiving graphical representations of computer models of the plurality of objects, the opening extending from the first side to the second side;

receiving a selection of the graphical representations of the plurality of objects to be machined from the workpiece;

locating the graphical representations of the plurality of objects in the opening so that the graphical representations of the plurality of objects are spaced from one another and from the graphical representation of the temporary support frame so as to permit machining of the plurality of objects;

receiving an identification of one or more excess unoccupied regions within the opening after the locating of the graphical representations of the plurality of objects;

for each excess unoccupied region, generating a graphical representation of an occupying structure occupying at least one of the one or more excess unoccupied regions; and

generating a workpiece computer model including a plurality of objects defined in a body of material, wherein the workpiece computer model further comprises information for generating a machine control instruction set for controlling machining equipment to machine the plurality of objects into discrete objects so that when machining operations on the body of material are done, each occupying structure substantially remains as a remnant of the machining.

2. The method according to claim 1, wherein the locating of the graphical representations of the plurality of objects in the opening includes executing automated-nesting algorithms that automatically locate the graphical representations of the plurality of objects within the opening in a manner that consolidates excess unoccupied regions into a smaller number of larger unoccupied regions.

3. The method according to claim 1, wherein the locating of the graphical representations of the plurality of objects in the opening includes clustering the graphical representation of the plurality of objects into a cluster in one region of the opening so as to create an excess unoccupied region partially bordered by the temporary support frame and partially bordered by the cluster.

4. The method according to claim 3, wherein the generating of a graphical representation of an occupying structure for the excess unoccupied region partially bordered by the temporary support frame and partially bordered by the cluster includes generating a graphical representation that moves a portion of an inner perimeter of the graphical representation of the temporary support frame proximate to the cluster.

5. The method according to claim 1, wherein:

the receiving of an identification of one or more excess unoccupied regions includes receiving an identification of an island region surrounded by ones of the graphical representations of the plurality of objects; and

the generating of a graphical representation of an occupying structure includes generating a graphical representation of an island structure.

6. The method according to claim 1, wherein the receiving of an identification of one or more unoccupied regions includes receiving inputs from the user that create an occupying structure in one of the one or more excess unoccupied regions.

7. The method according to claim 6, wherein the receiving of inputs includes receiving inputs that extends a portion of the graphical representation of the temporary support frame toward a cluster of the graphical representations of the plurality of objects within the opening.

8. The method according to claim 6, wherein the receiving of inputs includes receiving inputs that create an island structure surrounded by ones of the graphical representations of the plurality of objects.

9. The method according to claim 1, further comprising executing automated excess unoccupied region identification algorithms, wherein the receiving of an identification of one or more excess unoccupied regions includes receiving an identification of one or more excess unoccupied regions from the executing of the automated excess unoccupied region identification algorithms.

10. The method according to claim 1, wherein generating a graphical representation of an occupying structure includes executing automated occupying structure generating algorithms that generate the graphical representation of the occupying structure.

11. The method according to claim 1, wherein the graphical representation of the temporary support frame includes interlock features.

12. The method according to claim 11, wherein the generating of a graphical representation of an occupying structure includes generating a graphical representation of an occupying structure that includes a graphical representation of at least one interlock feature.

13. The method according to claim 12, wherein the locating of the graphical representations of the plurality of objects in the opening includes clustering the graphical representation of the plurality of objects into a cluster in one region of the opening so as to create an excess unoccupied region partially bordered by the temporary support frame and partially bordered by the cluster.

14. The method according to claim 12, wherein the locating of the graphical representations of the plurality of objects in the opening includes clustering the graphical representation of the plurality of objects into a cluster in one region of the opening so as to create an excess unoccupied region partially bordered by the temporary support frame and partially bordered by the cluster.

15. The method according to claim 14, wherein the graphical representation of at least one interlock feature is included on the portion of the inner perimeter of the graphical representation of the temporary support frame proximate to the cluster.

16. The method according to claim 1, further comprising receiving a selection of the graphical representation of the temporary support frame from a set of predefined graphical representations of differing temporary support frames.

17. The method according to claim 16, wherein the receiving of a selection of the graphical representation of the temporary support frame includes receiving a user selection of the graphical representation of the temporary support frame.

18. The method according to claim 17, further comprising displaying a plurality of the predefined graphical representations of differing temporary support frames in the set of the predefined graphical representations of differing temporary support frames in a manner that allows a user to select a desired one of the displayed plurality of predefined graphical representations of differing temporary support frames.

19. The method according to claim 16, wherein the receiving of a selection of the graphical representation of the temporary support frame includes receiving the selection based on a selection of a particular piece of stock material.