Self recognition CNC machining

1. A method of machining a cellular core ( 14 ) having individual cells ( 30 ) arranged laterally in a plurality of columns and longitudinally in a plurality of rows, comprising:

mounting said core ( 14 ) atop a table ( 12 ) in a multi-axis Computerized Numerical Controlled (CNC) machine ( 10 );

scanning said core ( 14 ) atop said table ( 12 ) to recognize said individual cells ( 30 ) arranged laterally in columns and longitudinally in rows and additionally recognize any non-linearity in a column of said scanned cells ( 30 ) when mounted atop said table ( 12 );

generating a machining path (E) from said recognized cells ( 30 ) and matching said non-linearity in said column of scanned cells ( 30 ); and

machining said core ( 14 ) along said generated machining path (E) to machine corresponding cells ( 30 ) sequentially in turn along said scanned column in said core ( 14 ).

2. A method according to claim 1 wherein said CNC machine ( 10 ) further comprises:

an elevated gantry ( 16 ) extending longitudinally across said table ( 12 ), and mounted thereto by a lateral drive system ( 22 );

a carriage ( 20 ) mounted to said gantry ( 16 ) by a longitudinal drive system ( 18 );

a cutter ( 26 ) mounted to said carriage ( 20 ) for travel therewith, and being vertically deployable for machining said core ( 14 ) along said generated machining path (E);

a scanner ( 44 ) mounted to said carriage ( 20 ) for travel therewith for scanning said core ( 14 ) to recognize said cells ( 30 ); and

wherein said scanner ( 44 ) is operated first to scan said core ( 14 ) to generate said machining path (E), and said cutter ( 26 ) is operated in turn to machine said cells ( 30 ) along said generated machining path (E).

3. A method according to claim 2 wherein said CNC machine ( 10 ) further comprises:

a computer ( 34 ) operatively joined to said scanner ( 44 ) for scanning said core ( 14 );

a CNC controller ( 36 ) operatively joined to said lateral and longitudinal drive systems ( 22 , 18 ) for controlling travel of said cutter ( 26 ) along said machining path (E); and

said computer ( 34 ) is configured to generate said machining path (E) from said cells ( 30 ) recognized by said scanner ( 38 ).

4. A method according to claim 3 wherein:

said core ( 14 ) is scanned to recognize corresponding geometric centers ( 38 ) of said cells ( 30 ); and

said machining path (E) is generated laterally along said cell centers ( 38 ) in a corresponding column of said cells ( 30 ).

5. A method according to claim 4 wherein said lateral machining path (E) is non-linear and varies longitudinally greater than a half-width of said cells ( 30 ).

6. A method according to claim 4 wherein:

said core cells ( 30 ) are hexagonal in configuration and distributed generally uniformly both laterally and longitudinally; and

said machining path (E) is configured for cutting said cells ( 30 ) to bifurcate opposite walls thereof.

7. A method according to claim 4 wherein:

said core ( 14 ) comprises Aramid fiber in longitudinally extending ribbons with laterally adjoining cell walls defining hexagonal cells ( 30 );

said cutter ( 26 ) comprises an aggregate head ( 48 ) mounted to a spindle ( 24 ) in said carriage ( 20 ), with said head ( 48 ) having a circular saw blade cutter ( 26 ) extending vertically atop said table ( 12 ); and

said machining path (E) is configured to cut a slot ( 46 ) atop said adjoining cell walls along a column of said cells ( 30 ).

8. A method according to claim 7 wherein:

said aggregate head ( 48 ) includes an odd number of saw blade cutters ( 26 ) spaced apart longitudinally for simultaneously and similarly slotting a corresponding plurality of adjoining cells ( 30 ); and

said machining path (E) is specifically generated for the middle one of said blade cutters ( 26 ), with the remaining blade cutters ( 26 ) following said middle machining path (E) parallel thereto.

9. A method according to claim 3 wherein said machining path (E) has a different profile for different columns of said cells ( 30 ).

10. A method according to claim 9 wherein said different machining profiles are similarly bowed.

11. A method according to claim 9 further comprising a plurality of said cutters ( 26 ) operated simultaneously to simultaneously cut a respective plurality of columns of said cells ( 30 ).

12. A method according to claim 11 wherein said plurality of cutters ( 26 ) simultaneously follow a single machining path (E) for simultaneously cutting a respective plurality of cell columns.

13. A method according to claim 12 wherein said single machining path (E) is configured for a middle column of said cells ( 30 ) being simultaneously machined.

14. A method according to claim 3 wherein:

said core ( 14 ) is initially mounted atop a vacuum table ( 12 ) operatively joined to a vacuum pump 50 );

a mat ( 52 ) is placed atop said core ( 14 ) to cover a major portion thereof for allowing vacuum from said vacuum pump ( 50 ) to clamp downwardly said mat ( 52 ) atop said core ( 14 ) for restraining lateral and longitudinal movement of said core ( 14 ) during operation of said CNC machine ( 10 ); and

a minor portion of said core ( 14 ) is not covered by said mat ( 52 ) to define a target zone in said core ( 14 ) exposed for both scanning and machining thereof in sequence.

15. A method according to claim 14 wherein:

a plurality of said mats ( 52 ) are placed atop said core ( 14 ) to collectively cover said major portion, with each mat ( 52 ) having a width generally equal to the width of said exposed target zone;

said target zone is indexed by shuffling successively an adjacent mat ( 52 ) to cover a preceding target zone; and

said core ( 14 ) is scanned and machined successively along said indexed target zones.

16. A method according to claim 3 wherein:

said core ( 14 ) is scanned in a narrow field-of-view; and

a plurality of machining paths (E) are generated from said narrow scan to sequentially machine said cells ( 30 ) in multiple passes laterally and longitudinally.

17. A method according to claim 3 wherein:

said scanner ( 44 ) comprises a digital camera operatively joined to said computer ( 34 ), and having sufficient resolution for optically recognizing individual cells ( 30 ) in said core ( 14 );

said computer ( 34 ) is configured to identify corresponding geometric center points ( 38 ) of said optically recognized cells ( 30 ), and join together said center points ( 38 ) in a machining path (E) for a corresponding column of said cells ( 30 ); and

said machining path (E) generated in said computer ( 34 ) is configured for use in said CNC controller ( 36 ) to effect machining of said core ( 14 ) by said cutter ( 26 ).

18. A method according to claim 3 wherein:

said core cells ( 30 ) are hexagonal in configuration and distributed generally uniformly both laterally and longitudinally;

said core ( 14 ) is scanned to recognize corresponding geometric centers ( 38 ) of said cells ( 30 ); and

said machining path (E) is generated laterally along said cell centers ( 38 ) in a corresponding column of said cells ( 30 ), and configured for cutting said cells ( 30 ) to bifurcate opposite walls thereof.

19. A method according to claim 18 wherein:

said core ( 14 ) comprises Aramid fiber in longitudinally extending ribbons with laterally adjoining cell walls defining said hexagonal cells ( 30 );

said cutter ( 26 ) comprises an aggregate head ( 48 ) mounted to a spindle ( 24 ) in said carriage ( 20 ), with said head ( 48 ) having a circular saw blade cutter ( 26 ) extending vertically atop said table ( 12 ); and

said machining path (E) is configured to cut a slot ( 46 ) atop said adjoining cell walls along a column of said hexagonal cells ( 30 ).

20. A Computerized Numerical Controlled (CNC) machine ( 10 ) for machining a cellular core ( 14 ) having individual cells ( 30 ) arranged laterally in a plurality of columns and longitudinally in a plurality of rows, comprising:

an elevated gantry ( 16 ) extending longitudinally across a table ( 12 ) for supporting said core ( 14 ), and mounted to said table ( 12 ) by a lateral drive system ( 22 );

a carriage ( 20 ) mounted to said gantry ( 16 ) by a longitudinal drive system ( 18 );

a cutter ( 26 ) mounted to said carriage ( 20 ) for travel therewith, and being vertically deployable for machining said core ( 14 ) atop said table ( 12 ) and along a machining path (E);

a CNC controller ( 36 ) operatively joined to said lateral and longitudinal drive systems ( 22 , 18 ) for controlling travel of said cutter ( 26 ) along said machining path (E);

a scanner ( 44 ) mounted to said carriage ( 20 ) for travel therewith for scanning said core ( 14 ) to recognize said individual cells ( 30 ) thereof arranged laterally in columns and longitudinally in rows;

a computer ( 34 ) operatively joined to said scanner ( 44 ) and configured to scan said core ( 14 ) to recognize said cells ( 30 ) and any non-linearity in a column of said scanned cells ( 30 ) when said core ( 14 ) is mounted atop said table; and self-generate said machining path (E) from said cells ( 30 ) self-recognized by said scanner ( 44 ), with said machining path (E) matching said non-linearity in said column of scanned cells ( 30 ); and

wherein said computer ( 34 ) is further configured to operate said scanner ( 38 ) first to scan said core ( 14 ) and pre-generate said machining path (E), and then operate said cutter ( 26 ) second in turn through said CNC controller ( 36 ) to machine said cells ( 30 ) along said self-generated machining path (E) sequentially in turn along said scanned column in said core ( 14 ).