Dynamic Nest Offset and Part Routing for Flexible Automation
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Modern manufacturing and automation systems face complexity due to the need for flexibility, speed, and accuracy over time, particularly when processing different products on shared systems or dealing with maintenance issues, where existing systems lack efficient dynamic adjustment of nest offsets and routing to accommodate changing requirements and tolerances.
Innovation Solution
A system and method that utilize a machine learning module to analyze operational data from conveyor systems and automation stations, determining and implementing adjusted nest offsets and part routing dynamically, allowing for automatic adaptation to operational changes, including controlling accessories and moving elements within the conveyor system.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If manual adjustment of nest offsets and routing is used, then system flexibility is improved, but operational efficiency and response time deteriorate due to increased downtime for maintenance and reconfiguration
Solution Approach 1:
The system automatically monitors operational data, detects when adjustments are needed, determines the appropriate adjustments, and implements them without human intervention. The automation system serves itself by continuously adapting nest offsets and routing based on real-time conditions, eliminating the need for manual reconfiguration and thereby maintaining high operational efficiency while providing system flexibility.
Solution Approach 2:
The system transitions from static, manually-configured nest offsets and routing to dynamic, automatically-adjusted parameters. The automation system continuously modifies nest offsets and routing paths in real-time based on operational data, enabling the system to adapt flexibly to changing conditions without manual intervention and without sacrificing operational efficiency.
2Loss of time
If dynamic adjustment of nest offsets and routing is implemented, then response time to operational changes is improved, but system complexity increases
Solution Approach 1:
The automation system performs multiple functions: it monitors operational data, analyzes when adjustments are needed, determines the appropriate adjustments, and implements them. By consolidating these diverse functions into a single multi-functional system, the patent achieves fast response time while managing complexity through integration rather than proliferation of separate components.
Solution Approach 2:
The system continuously monitors operational data and uses this feedback to automatically determine when nest offset or routing adjustments are needed. This closed-loop feedback mechanism enables rapid response to operational changes while keeping the system manageable through data-driven decision-making rather than complex hard-coded logic.
3Productivity
If automated monitoring and adjustment is used, then machine efficiency is improved, but measurement and analysis requirements increase
Solution Approach 1:
The patent replaces manual monitoring and analysis with automated electronic sensing and data processing. Sensors and controllers automatically capture operational data, and software algorithms automatically analyze this data to determine when adjustments are needed, eliminating the need for manual measurement and analysis while maintaining high machine efficiency.
Solution Approach 2:
The system introduces an intermediary automated monitoring and analysis layer between the physical manufacturing process and the control actions. This intermediary automatically collects operational data, analyzes it using predefined criteria, and triggers adjustments only when necessary, thereby maintaining high machine efficiency while managing data analysis requirements through automated filtering and processing.
Data Source
Figure 1
Figure 2
Figure 3
AI summary
A system and method for dynamic nest and routing adjustment in an automation system. The method includes: operating the automation system; receiving operational data related to the automation system from a conveyor system and at least one automation station; analyzing the operational data to determine if adjustment of nest offsets or routing of parts is required; determining an adjusted nest offset or part routing; implementing the adjusted nest offset or part routing; and return to operating the automation system. The system includes: a controller to operate the automation system; an input for receiving the operational data; a machine learning (ML) module to analyze the operational data to determine if adjustment of nest offsets or routing of parts is required; a processor to determine an adjusted nest offset or part routing; and a configuration module to implement the adjusted nest offset or part routing.