Process for Graphically Representing a Structure

This invention relates to a process for graphically representing a structure that can be altered by an object, of the type in which both the structure and the object, as well as relative movements between the structure and the object, are represented by respective data structures.

It is a known practice in the field of computer-aided design to represent bodies in perspective on the picture screen of a computer unit by means of internal computer models. In general, the process for generating true-to-measure internal computer models requires a high expenditure both in computation and in memory or storage space, since large data structures must be processed. In general, this approach is not well suited for real time representation of a processing course by means of an economical micro-computer system, for example in a numerically controlled machine tool. The generation of the data structure for the entire workpiece from the component data, i.e., from the workpiece blank and the tool processing paths, would require large storage requirements and large computing time requirements.

At present, path controls on the market for numerically controlled machines assist the programmer in a wide variety of ways in translating a desired surface defined by a technical drawing into a corresponding numerical control program. Many of the known processes for verifying a numerical controlled program in contemporary controls can be classified as follows:

The generally used methods for visualizing programming errors prior to run off of a program include simulation of the workpiece processing with partial three-dimensional representation of the generated contours and the travelled tool paths. However, these representations typically do not show the final workpiece or even geometric linkages between the individual partial contours. Fundamentally, only the individual tool movements are made visible, without reference to the workpiece blank or to other movements. For this reason, the typical graphical representations in use today of the generated contour surfaces by their boundary lines, even in connection with relatively simple processing sequences, are static, difficult to comprehend images.

One prior art process simulates a machining operation by providing two-dimensional representations which are "etched" to simulate the removal of material from the workpiece by the tool. In this process different shadings are erased or changed in order to allow various surface depths on the simulated workpiece to be distinguished during processing. In particular, when processing is accomplished in several planes this approach may lose information. Furthermore, this approach is unsuitable for three-dimensional representations of the workpiece.

Real time simulation of the processing course for monitoring a numerical control program by representing all generated contours without geometric linkage is known.

The two- and three-dimensional processes described above permit only a linkage-free superposition of the tool paths or predefined partial contours without representation of the resulting workpiece contours.

The present invention is directed to a process for depicting a variable structure, which requires no great expenditure in calculation and which is therefore practical for use with relatively simple equipment.

According to this invention, a process for graphically representing a structure is provided which includes the step of generating a set of polygons representative of the structure from the respective stored data structure. A processing region is then determined corresponding to the object or tool and the selected relative movement between the object and the structure. Intersections are then determined between the processing region and only those polygons which overlap the processing region. The data structure for the structure is then altered to reflect changes to those polygons intersected by the processing region in order to represent the altered structure.

This invention provides particular advantages in that the calculation required to implement this process is substantially reduced with respect to the prior art approaches described above. For this reason, the process of this invention can be carried out with a microprocessor system and real time representation is made possible. Furthermore, perspective representations are possible in spite of the severely reduced expenditure in calculation. Similarly, it is possible to use the process of this invention to show enlarged partial views and to represent in color individual processing cycles or surface zones.

The invention itself, together with further objects and attendant advantages, will best be understood by reference to the following detailed description, taken in conjunction with the accompanying drawings.

FIGS. 1a through 1d show a workpiece before and after a first processing operation.

FIGS. 2a through 2d show the workpiece of FIG. 1 in a second processing operation.

FIGS. 3a through 3d show the workpiece of FIGS. 1 and 2 in a third processing operation.

FIGS. 4a through 4d show the workpiece of FIGS. 1, 2 and 3 in a fourth processing operation.

FIG. 5 is a block circuit diagram of a system for executing the preferred embodiment of the method of this invention.

Turning now to the drawings, FIG. 1a represents a workpiece blank R, the visible surface of which is determined by a polygon that bounds the surface FO. A tool constructed as a shaft milling tool which moves through a preprogrammed tool path is represented as a processing polygon BO superimposed on the blank R which defines the surface FO.

In FIG. 1b this situation is represented in side view, in order to indicate the third dimension, corresponding to the processing depth of the tool.

In FIGS. 1c and 1d the workpiece R is represented as processed according to the processing operation indicated in FIGS. 1a and 1b. In FIGS. 1c and 1d it is apparent that the original surface FO has been subdivided by this working operation into three partial surfaces, F1, F2, and F3. The surface F2 lies at a deeper level than the surfaces F1, F3, in correspondence to the so called infeed or depth of cut of the tool.

In order to represent this workpiece processing on the picture screen of a numerically-controlled machine tool, a computer, which may be a micro-computer, is programmed to process data structures indicative of the workpiece, the tool, and relative movements therebetween. The computer generates the polygons FO, BO. The polygon FO is generated from the workpiece data structure and the processing polygon BO is generated from the dimensions of the tool and its preprogrammed path of movement.

The computer is programmed to link these polygons FO, BO such that in accordance with intersection point calculations it is possible to determine where and whether the workpiece and tool are in engagement.

FIGS. 2a and 2b relate to a second processing operation in which the workpiece polygons F1, F2 and F3 are superposed on the processing polygon B1. The workpiece polygons F1-F3 are linked with the processing polygon B1 in accordance with the approach outlined above by calculating intersection points of the polygons, taking into account the third dimension.

In accordance with this embodiment of this invention, the polygons F1, F2 and F3 are hierarchically ordered. That is, when the processing polygon B1 is superposed on the workpiece polygons F1, F2, F3, intersection point calculations are only made for those polygons that are directly affected by the processing polygon.

In the preferred embodiment of the process of this invention, this is expressed in such a way that the surfaces F1, F2, F3 bounded by the respective polygons can exist with equal status. As shown in FIG. 2a, the processing polygon B1 first intersects the upper edge of the surface F3, then the boundary edge between F3 and F2, and on emergence from the workpiece R again the boundary edge between F3 and F2.

According to this invention, the intersection point determination is performed in the following simple steps:

On entry of the processing polygon B1 into the surface F3, only the surface F3 is affected; neither the surface F2 nor the surface F1 is touched. For this reason, at this point in time the intersection point analysis, taking into account the third dimension, is only performed between the processing polygon B1 and the surface F3. Intersection point calculations with the other surfaces can be omitted, since these other surfaces (F1, F2) are hierarchically not contained in F3.

Even with this simple state of affairs the expenditure in calculation for the polygon linkage is advantageously reduced.

As the processing polygon B1 emerges at the lower edge of F3 and enters F2, the intersection point analysis must take into account the surface F2, again taking into consideration the third dimension.

With the aid of the side view it is apparent that the boundary line between F2 and F3 is altered, but that there are no true points of intersection between the surface F2 and the processing polygon B1.

The surface F3 is thus altered by this processing operation, and in this way the partial surfaces F3.1, F3.2, F3.3 are generated, which are hierarchically contained in the surface F3. Since the surface F1 is hierarchically not contained in the examined surfaces F2, F3, the intersection point analysis does not need to be performed for the surface F1.

In the next processing step, milling is done by the processing polygon B2 into the surface F1, as shown in FIGS. 3a and 3b. Since in accordance with this invention intersection point analysis is only performed for those polygons that are hierarchically contained in the surface being momentarily processed, in this processing step the important advantage of this invention is already clearly shown: the numerous edges of F2, F3.1, F3.2 and F3.3 do not have to be examined at all for possible intersection points, since they are not hierarchically contained in F1. As shown in FIGS. 3c and 3d, this processing operation generates the partial surfaces F1.1 and F1.2.

FIGS. 4a through 4d represent a fourth processing operation, in which a series of linkages must be made between the processing polygon B3 and the polygons F1, F2 and F3 of the workpiece, or to their partial surfaces. The processing polygon B3 intersects the surface F1, or the partial surfaces F1.1 and F1.2 contained within it. Intersection calculations are made on entry into the partial surface F1.2, and on transition from the partial surface F1.2 to the partial surface F1.1. Furthermore, intersection point calculations are performed at the transition of the processing polygon B3 from the partial surface F1.1 to the surface F2, as well as on transition from F2 to F3.2 and F3.3. Except for the partial surface F3.1, each partial surface is altered. The partial surface F3.1 therefore can be left out of consideration for the intersection point calculations. As already described, in this embodiment the intersection point analysis always takes into account the third dimension, so that with the aid of the resulting data structures, the microprocessor generates an altered model of the processed workpiece.

Successively, each tool path is linked with the data structure to generate an altered data structure indicative of the new altered workpiece. In each case the altered workpiece generated in the preceding processing operation is used as a starting point for the next processing operation to determine the starting point of the new processing polygon from the surface. This intersection point determination is continued until the starting surface is again reached.

The above-described process leads to a considerable reduction in the calculation time and memory requirements with respect to conventional processes such as are described, for example, in the reference "Barton, E. E., Buchanan, I: The Polygon Package, Computer-Aided Design, Vol. 12, No. 1, January 1980, pp. 3-11. " Thus, with this invention it is not necessary to set up auxillary data structures. With a low expenditure for computer hardware, it is possible with the aid of the hierarchic data structure described above to examine which polygons overlap the momentary processing polygon. By considering only the momentarily affected polygons in the linkage with the processing polygon, the execution of the process is made possible with smaller computer systems, such as those presently used in numerically-controlled machine tools.

FIG. 5 shows a block circuit diagram of an arrangement for executing the process described above. The control microcomputer 1 includes a working memory 2. The control microcomputer 1 monitors a minicassette in an external memory 3 in order to generate tool paths which are used to control the machine axes of the numerically-controlled machine 5 via the I/O device 4. The microcomputer 1 accepts and processes operator inputs via the keyboard 7 by means of the I/O device 6.

A graphic microcomputer 8 is included which includes a working memory 9 used to prepare dialogue masks for operating dialogues. The graphic microcomputer 8 formats actual values, calculates according to the process described above the graphic data for the representation of the particular workpiece, which is represented by the CRT controller with videogenerator 10 on the color picture screen apparatus 11.

Of course, it should be understood that a range of changes and modifications to the preferred embodiment described above will be apparent to those skilled in the art. It is therefore intended that the foregoing detailed description be regarded as illustrative rather than limiting, and that it be understood that it is the following claims, including all equivalents, which are intended to define the scope of this invention.