Automated Tooling Setup Assist System for Manufacturing Process Optimization
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Solution Overview
Problem
Determining an optimum spatial arrangement for tools in a manufacturing process is time-consuming and inefficient due to the need for extensive data gathering and evaluation of various tool configurations, especially when transitioning between successful and unsuccessful process runs.
Innovation Solution
An automated manufacturing process tooling setup assist system that includes processors, memory, and tooling spatial arrangement control modules to control tooling transport and positioning devices, allowing for autonomous determination and adjustment of tool spatial arrangements based on process evaluations, enabling data-driven optimization of tool placements.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If manual data gathering and evaluation methods are used to determine tool spatial arrangements, then comprehensive process data can be collected, but the time and effort required increases significantly
Solution Approach 1:
The system enables automated self-evaluation of tool spatial arrangements by having the manufacturing process itself generate the evaluation data through automated sensing and monitoring, eliminating the need for manual data gathering while maintaining comprehensive process assessment
Solution Approach 2:
Manual mechanical data gathering methods are replaced with automated electronic sensing systems, control modules, and computational algorithms that automatically collect, analyze, and interpret process data to evaluate tool spatial arrangements
2Manufacturing precision
If multiple tool configurations are tested to find the optimum arrangement, then the best spatial arrangement can be identified, but the number of process runs required increases
Solution Approach 1:
The system performs preliminary automated evaluation and prediction of tool spatial arrangement performance before actual manufacturing process runs, allowing the optimum arrangement to be identified with fewer physical process runs by using computational models and simulated assessments
Solution Approach 2:
The system implements continuous feedback loops where each process run automatically generates data that is analyzed to improve subsequent tool arrangement decisions, enabling the system to learn from each run and converge on the optimum arrangement more efficiently
3Reliability
If extensive data gathering is performed to ensure successful process runs, then process reliability can be improved, but the complexity of the setup process increases
Solution Approach 1:
The automated evaluation system serves multiple functions simultaneously: it collects process data, evaluates tool spatial arrangements, identifies optimization opportunities, and guides subsequent process runs, thereby improving reliability without proportionally increasing complexity through a multi-functional integrated control module
Solution Approach 2:
The system merges data gathering, data analysis, and decision-making functions into an integrated automated control system that operates as a unified entity, reducing the complexity that would arise from separate manual processes while maintaining comprehensive process monitoring
Data Source
AI summary
An automated manufacturing process tooling setup assist system includes a controller configured to control movement and positioning of tools to provide a first tool spatial arrangement within a workspace. Responsive to an unsuccessful test process run using the tools in the first tool spatial arrangement, the controller may control movement of the tools so as to replace a tool in the first tool spatial arrangement with another tool configured to perform a function of the tool to be replaced. Responsive to a successful test process run using the tools in the first tool spatial arrangement, the controller may control movement of the tools so as to reposition one or more tools in the workspace to provide a second tool spatial arrangement within the workspace different from the first tool spatial arrangement.