Method for modifying dimensional accuracy of a workpiece via three-dimensional abrasion

A method comprising:

• during a first processing cycle, navigating an abrasive head across a workpiece according to a first toolpath;
• detecting a first set of positions of the abrasive head traversing the workpiece;
• interpreting a first surface contour of the workpiece based on the first set of positions;
• detecting a first difference between the first surface contour and a first target surface, corresponding to the first surface contour, defined in a target model of the workpiece;
• generating a second toolpath for the workpiece based on the difference;
• and
• during a second processing cycle:
• navigating the abrasive head across the first surface contour of the workpiece according to the second toolpath to reduce the difference;
• and
• based on a sequence of force values output by a force sensor coupled to the abrasive head, deviating the abrasive head from the second toolpath to maintain forces of the abrasive head on the workpiece proximal a target force.

A method comprising:

• accessing a target model representing a workpiece;
• navigating a probe into contact with the workpiece at a set of probe locations on the workpiece;
• detecting a first set of positions of the probe in contact with the workpiece at the set of probe locations;
• interpreting a first surface contour of the workpiece based on the first set of positions;
• detecting a first difference between the first surface contour and a first target contour, corresponding to the first surface contour, defined in the target model;
• assigning a first target force to a first toolpath;
• in response to the first difference exceeding a threshold difference:
• generating the first toolpath spanning the first surface contour;
• and
• during a processing cycle:
• accessing a first sequence of force values output by a force sensor coupled to an abrasive head;
• navigating the abrasive head across the first surface contour on the workpiece according to the first toolpath to remove material from the first surface contour and to reduce the first difference;
• and
• based on the first sequence of force values, deviating the abrasive head from the first toolpath to maintain forces of the abrasive head on the workpiece proximal the first target force;
• generating a second toolpath spanning the first surface contour and a second surface contour on the workpiece;
• assigning the second target force, less than the first target force, to the second toolpath;
• and
• during a second processing cycle:
• accessing a second sequence of force values output by the force sensor;
• and
• via a set of actuators;
• navigating the abrasive head across the first surface contour and the second surface contour according to the second toolpath;
• and
• based on the second sequence of force values, deviating the abrasive head from the second toolpath to maintain forces of the abrasive head on the workpiece proximal a second target force and to abrade the first surface contour and the second surface contour to a target surface finish.

A method comprising:

• during a scan cycle, traversing an optical sensor along a scan path offset from a workpiece;
• accessing a set of scan images captured by the optical sensor while traversing the workpiece during the scan cycle;
• assembling the set of scan images into a virtual model representing the workpiece;
• navigating a probe into contact with the workpiece at a set of probe locations on the workpiece;
• detecting a first set of positions of the probe in contact with the workpiece at the set of probe locations;
• interpreting a first surface contour of the workpiece based on the first set of positions;
• detecting a first difference between the first surface contour and a first target contour, corresponding to the first surface contour, of the workpiece;
• and
• in response to the first difference exceeding a threshold difference:
• generating a first toolpath spanning the first surface contour;
• and
• during a processing cycle succeeding the scan cycle:
• accessing a first sequence of force values output by a force sensor coupled to an abrasive head;
• navigating the abrasive head across the first surface contour on the workpiece according to the first toolpath to remove material from the first surface contour and to reduce the first difference;
• based on the first sequence of force values, deviating the abrasive head from the first toolpath to maintain forces of the abrasive head on the workpiece proximal a first target force;
• and
• detecting a second set of positions of the abrasive head traversing the first surface contour of the workpiece;
• transforming the virtual model into alignment with the first set of positions and the second set of positions;
• and
• storing the virtual model as a digital twin of the workpiece.