Morphing of watertight spline models using as-executed manufacturing data
Methods and computer systems for methods, computer systems, and computer-readable memory media for determining a warp function. An as-designed watertight spline model of an object is received. A set of sweep points along a sweep trajectory for manufacturing the object are used to determine a sweep surface. Model points are sampled from the as-designed watertight spline model and projected onto nearest as-executed points on the sweep surface. The projected as-executed points are used to construct an as-executed model of the object. A warp function is determined based on a difference between the as-designed watertight spline model and the as-executed model. The warp function is a continuous function approximating differences between the as-designed model and the as-manufactured object. The warp function is stored in a non-transitory computer-readable memory medium.
1. A computer-implemented method, comprising:
performing, by a computer:
receiving an as-designed watertight spline model of a tangible object, wherein the as-designed watertight spline model is described in a Computer-Aided Design (CAD) model domain;
receiving a set of sweep points along a sweep trajectory for a manufacturing tool, wherein the manufacturing tool manufactures the tangible object along the sweep trajectory;
determining a sweep surface based at least in part on the set of sweep points;
sampling a plurality of model points on the as-designed watertight spline model;
projecting each model point of the plurality of model points onto a nearest as-executed point on the sweep surface to obtain a point-cloud of as-executed points on the sweep surface;
constructing an as-executed model of the tangible object based at least in part on the point-cloud of as-executed points and the as-designed watertight spline model, wherein the as-executed model comprises a watertight spline model, wherein a spline structure of the as-executed model is based at least in part on a spline structure of the as-designed watertight model;
determining a warp function based on a difference between the as-designed watertight spline model and the as-executed model of the tangible object, wherein the warp function comprises a continuous function approximating differences between the tangible object and the as-designed watertight spline model; and
storing the warp function in a non-transitory computer-readable memory medium.
2. The computer-implemented method of claim 1 ,
wherein determining the sweep surface based at least in part on the set of sweep points comprises:
determining an approximate sweep trajectory based on the set of sweep points; and
determining the sweep surface based at least in part on one or more of the approximate sweep trajectory, a physical shape of the manufacturing tool, and metadata associated with the manufacturing tool.
3. The computer-implemented method of claim 2 ,
wherein determining the approximate sweep trajectory based on the set of sweep points comprises interpolating between adjacent sweep points to construct the approximate sweep trajectory.
4. The computer-implemented method of claim 2 , further comprising:
receiving data describing an as-instructed sweep trajectory;
wherein determining the approximate sweep trajectory based on the set of sweep points comprises morphing the as-instructed sweep trajectory based on the set of sweep points.
5. The computer-implemented method of claim 4 , wherein the data describing the as-instructed sweep trajectory comprises:
as-instructed Computer-Aided Manufacturing (CAM) data; or
toolpath instructions.
6. The computer-implemented method of claim 1 ,
wherein each sweep point of the set of sweep points defines a respective location of the manufacturing tool at a respective point in time.
7. The computer-implemented method of claim 1 , further comprising:
manufacturing the tangible object based at least in part on the as-designed watertight spline model, wherein manufacturing the tangible object comprises utilizing the manufacturing tool along the sweep trajectory.
8. The computer-implemented method of claim 1 ,
wherein the manufacturing tool is configured to manufacture the tangible object by utilizing the sweep trajectory.
9. The method of claim 1 , further comprising:
receiving semantic product manufacturing information (PMI) for one or both of the as-designed watertight spline model and the as-executed model,
wherein constructing the as-executed model of the tangible object is performed further based at least in part on the semantic PMI.
10. The method of claim 9 ,
wherein constructing the as-executed model based at least in part on the semantic PMI comprises:
determining one or more constraints of the tangible object based on the semantic PMI; and
interpolating between adjacent as-executed points of the point cloud of as-executed points based on the one or more constraints, wherein the one or more constraints are determined based at least in part on a sampling density of the point cloud of as-executed points indicated by the semantic PMI.
11. The method of claim 9 ,
wherein constructing the as-executed model based at least in part on the semantic PMI comprises:
determining one or more control point derivatives for the as-executed model based at least in part on geometric constraints indicated by the semantic PMI.
12. The method of claim 1 ,
wherein constructing the as-executed model of the tangible object based at least in part on the point-cloud of as-executed points and the as-designed watertight spline model comprises performing an interpolation or approximation procedure of the point-cloud of as-executed points to the as-designed watertight spline model.
13. The method of claim 1 ,
wherein the warp function is determined in real time during a manufacturing process of the tangible object using the manufacturing tool, wherein the method further comprises:
modifying the manufacturing process based at least in part on the warp function.
14. The method of claim 13 ,
wherein modifying the manufacturing process based at least in part on the warp function comprises one or more of:
modifying the as-designed watertight spline model to compensate for one or more errors determined from the warp function; and
modifying one or more parameters of a manufacturing machine performing the manufacturing process based on the warp function.
15. The method of claim 14 ,
wherein modifying the one or more parameters of the manufacturing machine based on the warp function comprises:
determining a compensation function based on the warp function; and
providing the compensation function to the manufacturing machine to modify the one or more parameters.
16. The method of claim 1 , further comprising:
displaying, on a display, a colorized visual representation of the warp function.
17. The method of claim 1 ,
wherein constructing the as-executed model of the tangible object based at least in part on the point-cloud of as-executed points and the as-designed watertight spline model comprises:
performing an interpolation or approximation procedure utilizing a spline structure of the as-designed watertight spline model to determine a plurality of degrees, control points and knot vectors of the as-executed model of the tangible object.
18. The method of claim 17 , further comprising:
determining a discrepancy between the knot vectors of the as-executed model of the tangible object and knot vectors of the as-designed watertight spline model; and
performing knot insertion on the knot vectors of the as-designed watertight spline model to remove the determined discrepancy.
19. The method of claim 1 ,
wherein the as-executed model of the tangible object comprises a same spline structure as the as-designed watertight spline model.
20. The computer-implemented method of claim 1 , further comprising:
determining as-planned instructions for an inspection process of the tangible object based at least in part on metadata of the as-designed watertight spline model and the warp function, wherein the as-planned instructions are described in a Computer-Aided Inspection (CAI) model domain;
performing the inspection process on the tangible object according to the as-planned instructions to produce as-inspected data; and
storing the as-inspected data in the non-transitory computer-readable memory medium.
21. The computer-implemented method of claim 1 , further comprising:
determining as-preprocessed instructions for a simulation or analysis process of the tangible object based at least in part on metadata of the as-designed watertight spline model and the warp function, wherein the as-preprocessed instructions are described in a Computer-Aided Engineering (CAE) model domain;
performing the simulation or analysis process on the tangible object according to the as-preprocessed instructions to produce as-simulated data; and
storing the as-simulated data in the non-transitory computer-readable memory medium.
22. The computer-implemented method of claim 1 ,
wherein the set of sweep points comprise as-executed data for the manufacturing tool, wherein the method further comprises:
receiving as-instructed data for the manufacturing tool to manufacture the tangible object;
determining a univariate warp function based on a difference between the as-instructed data and the as-executed data; and
storing the univariate warp function in the non-transitory computer-readable memory medium.
23. A non-transitory computer-readable memory medium comprising program instructions which, when executed by a processor, cause a computer to:
receive an as-designed watertight spline model of a tangible object, wherein the as-designed watertight spline model is described in a Computer-Aided Design (CAD) model domain;
receive a set of sweep points along a sweep trajectory for a manufacturing tool, wherein the manufacturing tool manufactures the tangible object along the sweep trajectory;
determine a sweep surface based at least in part on the set of sweep points;
sample a plurality of model points on the as-designed watertight spline model;
project each model point of the plurality of model points onto a nearest as-executed point on the sweep surface to obtain a point-cloud of as-executed points on the sweep surface;
construct an as-executed model of the tangible object based at least in part on the point-cloud of as-executed points and the as-designed watertight spline model, wherein the as-executed model comprises a watertight spline model, wherein a spline structure of the as-executed model is based at least in part on a spline structure of the as-designed watertight model;
determine a warp function based on a difference between the as-designed watertight spline model and the as-executed model of the tangible object, wherein the warp function comprises a continuous function approximating differences between the tangible object and the as-designed watertight spline model; and
store the warp function in a non-transitory computer-readable memory medium.