Methods for generating a digital twin of a workpiece in finishing processes

A method comprising:

• accessing a virtual model representing a workpiece;
• accessing a toolpath comprising:
• a first keypoint corresponding to a first model vertex located on the virtual model;
• and
• a second keypoint corresponding to a second model vertex located on the virtual model;
• accessing a target force assigned to the workpiece;
• during a processing cycle:
• accessing a sequence of force values output by a force sensor coupled to a sanding head;
• via a set of actuators:
• navigating the sanding head across the workpiece according to the toolpath;
• and
• based on the sequence of force values, deviating the sanding head from the toolpath to maintain forces of the sanding head on the workpiece proximal the target force;
• detecting a first position of a reference surface, on the sanding head, in contact with the workpiece when the sanding head occupies the first keypoint;
• detecting a second position of the reference surface in contact with the workpiece when the sanding head occupies the second keypoint;
• modifying the virtual model to align:
• the first model vertex on the virtual model to the first position of the reference surface;
• and
• the second model vertex on the virtual model to the second position of the reference surface;
• and
• storing the virtual model as a digital three-dimensional record of the workpiece.

A method comprising:

• accessing a virtual model of a workpiece;
• accessing a toolpath defined for the workpiece;
• accessing a target force assigned to the workpiece;
• during a processing cycle:
• accessing a sequence of force values output by a force sensor coupled to a sanding head;
• via a set of actuators:
• navigating the sanding head across the workpiece according to the toolpath;
• and
• based on the sequence of force values, deviating the sanding head from the toolpath to maintain forces of the sanding head on the workpiece proximal the target force;
• and
• detecting a sequence of positions of a reference surface on the sanding head in contact with the workpiece;
• and
• generating a digital three-dimensional record of the workpiece by transforming the virtual model into alignment with the sequence of positions of the reference surface.