Action Chart-Based Control Program Generation for Automated Machines
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Solution Overview
Problem
The development of new automated manufacturing machines is hindered by the need for creating a new control program, which requires expertise and time, leading to delays in introducing new machines to manufacturing sites.
Innovation Solution
A control program generation apparatus and method that automatically generates a control program for automated manufacturing machines by reading an action chart, analyzing it, and combining pre-created program elements to describe the operations of multiple actuators.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a new control program is created manually by a programmer, then the control program can be customized to meet specific manufacturing site requirements, but the development time is excessively long
Solution Approach 1:
The patent applies preliminary action by pre-defining control program templates and actuator operation patterns before actual machine deployment. The system stores multiple actuator types with their inherent degrees of freedom and pre-configured control logic in advance, allowing rapid assembly of customized control programs without manual programming from scratch.
Solution Approach 2:
The patent segments the control program into modular components corresponding to individual actuators and their operations. Each actuator is treated as an independent element with its own control template, allowing the system to assemble customized control programs by selecting and combining appropriate segments rather than creating monolithic custom programs.
2Reliability
If an expert programmer creates the control program, then the program quality and reliability are high, but the programming process cannot start until machine design is complete, causing delays
Solution Approach 1:
The patent enables preliminary preparation of control program templates and actuator configurations before machine design finalization. By pre-defining standard actuator types, their inherent degrees of freedom, and control logic patterns, the system allows parallel development activities without requiring sequential completion of machine design first.
Solution Approach 2:
The patent uses copying by replicating pre-defined actuator control templates and operation patterns for similar actuators in the system. Instead of manually programming each actuator from scratch, the system copies and adapts standardized control elements, maintaining program quality through proven templates while dramatically reducing development time.
3Manufacturing precision
If the programmer learns the operations of various actuators and machine parts, then accurate control programs can be created, but this learning process takes significant time
Solution Approach 1:
The patent applies copying by utilizing pre-documented actuator operation specifications and control patterns that capture expert knowledge. Instead of requiring each programmer to learn actuator operations from scratch, the system provides accessible reference materials and standardized templates that encode operational expertise, allowing accurate program creation without extensive learning periods.
Solution Approach 2:
The patent introduces an intermediary layer of standardized actuator models and control templates that mediate between machine specifications and control program creation. This intermediary layer encapsulates complex actuator operation knowledge, presenting simplified interfaces to programmers while maintaining control accuracy through the structured intermediate representation.
Data Source
AI summary
Element actions of actuators incorporated in an automated manufacturing machine are stored in a manner associated with program elements to perform the element actions. An action chart is used to describe an operation of the automated manufacturing machine, with one element action having an end linked to a start of another element action using a logical operation. The action chart describing the operation of the automated manufacturing machine is read. The element actions on the action chart are converted into the program elements. The program elements are combined together in accordance with the action chart. This allows automatic generation of a control program for controlling the operation of the automated manufacturing machine.