Bending Machine Camera Guidance for Precise Workpiece Alignment
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Solution Overview
Problem
Operators face challenges in accurately realigning and positioning workpieces during the bending process in sheet metal manufacturing, particularly in small series production, due to limited visibility and the complexity of geometric shapes, leading to potential errors and increased waste.
Innovation Solution
A method utilizing a camera to record the processing area and display work instructions, including graphical representations and symbols, directly in the operator's field of vision, allowing for continuous monitoring and simplifying the coordination of bending operations, with an image recognition program to automate the start of bending deformations upon correct workpiece insertion.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If the operator relies on direct visual monitoring of the processing area, then the operator can observe the bending process, but the limited visibility between bending tools prevents precise alignment and positioning of the workpiece
Solution Approach 1:
A camera is introduced as an intermediary device to capture images of the processing area behind the press beam. These images are then displayed on a display unit positioned in the operator's field of vision, allowing the operator to see the workpiece alignment without direct line-of-sight to the rear processing area.
Solution Approach 2:
The solution transitions from direct spatial observation to remote visual observation by capturing images and displaying them on a separate display unit. This allows the operator to view the processing area from a different spatial dimension (front of press beam) while monitoring events at the rear processing area.
2Loss of information
If the operator must switch between monitoring the processing area and checking work instructions on a separate terminal, then all information is available, but the operator's attention is divided and errors increase
Solution Approach 1:
The work instructions are merged with the live camera images of the processing area and displayed together on the same display unit. This integration allows the operator to view both the current processing state and the required next steps simultaneously in a single field of vision, eliminating the need to switch between separate displays.
Solution Approach 2:
The display of work instructions occurs continuously alongside the camera feed during the entire processing step, allowing the operator to maintain continuous awareness of both the current state and upcoming requirements without interruption or attention switching.
3Adaptability or versatility
If manual positioning of the workpiece is used, then the operator has flexibility, but the complexity of geometric shapes and limited visibility lead to positioning errors and rejected parts
Solution Approach 1:
The camera provides real-time visual feedback of the workpiece position and orientation relative to the bending tools and stops. The operator can see the actual alignment status and make precise adjustments based on this feedback, improving positioning accuracy while maintaining the flexibility of manual positioning.
Data Source
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AI summary
The invention relates to a method for producing a component by forming a workpiece (5) from sheet metal with a bending machine (1) comprising a control device (10) and a production program (14) for operating the bending machine (1), wherein at least two production steps, each involving forming by bending, are performed on the workpiece (5) in a working region (18), and wherein the working region (18) is monitored with a camera (16, 17) and images of the working region (18) are presented to the operator (20) by a display means (19), and wherein, during the performance of a first production step, the images of the working region (18) that are to be presented by the display means (19) are overlaid by an image processing program (15) with working instructions for a subsequent phase of the current, first production step or for a next-following, second production step, and are presented by the display means (19).