Adaptive Workpiece Sorting After Flatbed Tool Disruptions
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Solution Overview
Problem
Conventional sorting methods for workpieces produced in flatbed machine tools, such as laser cutting or punching machines, face disruptions due to events like tool collisions, leading to process inefficiencies, reduced automation, and increased manual intervention, as they cannot adapt to changes in workpiece positions or states during the sorting process.
Innovation Solution
A sorting method that analyzes process information created during manufacturing to detect disruptions, allowing for automatic modification of the sorting process, including adjusting gripper positions and sequences, and prioritizing workpieces based on disruption probabilities to enhance reliability and speed.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional scheduled sorting methods are used, then the sorting process is automated and efficient under normal conditions, but the process reliability deteriorates when disruptions occur (e.g., tool collisions displacing workpieces)
Solution Approach 1:
The sorting process transitions from a static scheduled approach to a dynamic adaptive approach. The controller continuously monitors process information and automatically modifies the sorting process in real-time based on detected disruptions, enabling the system to adapt to changing conditions while maintaining automation and reliability
Solution Approach 2:
The system implements a feedback mechanism where process information from manufacturing is continuously analyzed to detect disruptions. This feedback loop enables the controller to identify sorting disruptions and automatically modify the sorting process, ensuring reliable operation even when disruptions occur
2Extent of automation
If the sorting device repeatedly attempts to remove displaced workpieces, then the degree of automation is maintained, but the process speed deteriorates and other workpieces may be further displaced
Solution Approach 1:
The system performs preliminary detection of sorting disruptions by analyzing process information before removal attempts are made. By identifying displaced workpieces in advance, the controller can modify the sorting process to avoid unsuccessful attempts, thereby maintaining automation while improving sorting speed and preventing further displacement of other workpieces
3Manufacturing precision
If manual intervention is called in to sort disrupted workpieces, then the sorting accuracy is improved, but the productivity deteriorates and the degree of automation is reduced
Solution Approach 1:
The sorting system performs self-service by automatically detecting disruptions through process information analysis and autonomously modifying its own sorting process. This eliminates the need for manual intervention while maintaining sorting accuracy and preserving high productivity through continued automation
Data Source
AI summary
A sorting method automatically sorts workpieces produced in a flatbed machine tool according to a scheduled sorting process by a sorting device. The method includes: providing at least one piece of process information created as a result of manufacturing of the workpieces; analyzing the at least one piece of process information, such that it is determined whether there is a sorting disruption; and upon determining that there is the sorting disruption, automatically modifying the sorting process.