3D Trajectory Generation for Laser Mold Cleaning Automation
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing methods for cleaning molds, such as shot blasting, erode the mold material, leading to deteriorating tolerance and increased costs or frequent replacements, as they require manual programming for each mold type, making the process time-consuming and inefficient.
Innovation Solution
A system and method for automatically generating trajectories using a trajectory generation module with a visual control algorithm and 3D sensor data processing to create 3D models of objects, extract features, and generate paths for laser applications like cleaning, cutting, or polishing, eliminating the need for manual programming and optimizing the cleaning process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If shot blasting is used to clean molds, then cleaning effectiveness is improved, but mold lifespan deteriorates due to material erosion
Solution Approach 1:
The patent replaces the mechanical shot blasting system with a laser-based cleaning system. The laser beam delivers energy to remove contaminants through ablation rather than mechanical impact, eliminating the erosion of mold material while maintaining cleaning effectiveness. This substitution of mechanical energy with optical energy resolves the contradiction between cleaning effectiveness and mold lifespan preservation.
2Manufacturing precision
If manual programming is used for each mold type, then cleaning precision is maintained, but processing time increases
Solution Approach 1:
The system implements self-service through automatic recognition and adaptive trajectory generation. The laser cleaning system automatically identifies mold features and generates cleaning paths without requiring manual programming for each mold type. This automation maintains cleaning precision through real-time adaptation while dramatically reducing processing time by eliminating manual setup operations.
Solution Approach 2:
The system dynamically changes operational parameters based on real-time sensor feedback and recognized mold features. By adapting laser power, scanning speed, and trajectory parameters automatically according to the specific mold geometry, the system maintains high cleaning precision across different mold types without requiring manual reprogramming, thus improving productivity.
3Manufacturing precision
If frequent mold replacements are performed, then manufacturing quality is maintained, but production costs increase
Solution Approach 1:
By replacing mechanical shot blasting with laser cleaning, the system eliminates the harmful erosion that leads to mold tolerance deterioration. This allows molds to maintain their precision specifications for longer periods, reducing the frequency of replacement needed and thereby lowering production costs while maintaining manufacturing quality.
Solution Approach 2:
The patent converts the previously harmful effect of cleaning into a beneficial one. Instead of cleaning methods that damage the mold, the laser cleaning system is controlled to selectively remove only contaminants while preserving the mold material. This transforms the cleaning process from a source of harm to a protective measure that extends mold life and reduces replacement costs.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The system enables precise and efficient cleaning processes by automatically generating trajectories based on object features, reducing manual intervention, extending mold lifespan, and improving processing efficiency without the need for frequent replacements.
Implementation Method 1
A laser can be utilized in many different fields and applications. One example of a laser application is laser cleaning apparatus for cleaning of molds
Data Source
AI summary
A system for automatically generating trajectories of an object includes a trajectory generation module comprising a visual control algorithm and a processor configured via computer executable instructions to receive raw three dimensional (3-D) sensor data of an object, create a 3-D model of the object based on the raw 3-D sensor data, extract object features relating to a shape and/or surface from the 3-D model of the object, and generate trajectories based on the object features of the 3-D model of the object.