Edge Modification Roller with Integrated Position Sensing
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Solution Overview
Problem
Existing edge modification technologies face challenges with accuracy and cost due to complex sensor systems, high maintenance requirements, and limitations in handling varying shapes and sizes of panels, often resulting in inaccuracies and increased operational expenses.
Innovation Solution
An edge modification method and apparatus that calculates a desired force direction based on the differential position of a roller along the edge, applying a predetermined force substantially normal to the edge, allowing for precise edge tape application without complex sensing mechanisms, and featuring a cutter assembly for trimming excess edge band.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If complex sensor systems with multiple rollers are used to determine edge contour and apply pressure, then the accuracy of force vector application is improved, but the device complexity and cost increase significantly
Solution Approach 1:
The patent extracts the sensing function from separate complex sensor mechanisms and integrates it directly into the pressure roller itself. The pressure roller is configured to sense its own position and orientation while applying pressure, eliminating the need for additional sensing rollers and linkages. This reduces device complexity while maintaining measurement accuracy through direct feedback from the pressure application point.
Solution Approach 2:
The patent merges the pressure application function and the sensing function into a single integrated pressure roller assembly. By combining these functions, the system eliminates the complexity of separate sensor mechanisms while ensuring that the force vector is applied accurately at the point of contact. The integrated design reduces the number of parts and simplifies the overall system architecture.
2Manufacturing precision
If pre-programmed CNC control is used to follow object contour and apply tape, then manufacturing precision is improved, but productivity decreases due to slow processing speed
Solution Approach 1:
The patent implements preliminary action by pre-configuring the pressure roller with sensing capabilities and control algorithms that enable it to automatically adapt to any edge contour in real-time. This eliminates the need for pre-programming specific object shapes, as the system is pre-equipped with the intelligence to handle varying geometries. The result is both high precision and improved productivity through faster processing of diverse panels.
Solution Approach 2:
The patent introduces dynamics by enabling the pressure roller to dynamically adjust its position, orientation, and pressure application in real-time as it follows the edge contour. This dynamic adaptation allows the system to handle varying panel shapes and sizes without reprogramming, maintaining manufacturing precision while significantly improving productivity through continuous, uninterrupted processing.
3Ease of operation
If hand lay-up techniques are used to apply edging, then adaptability to different operators is improved, but manufacturing precision and consistency deteriorate due to variability in pressing force
Solution Approach 1:
The patent implements feedback control by equipping the pressure roller with sensing capabilities that continuously monitor its position and the force being applied. This real-time feedback enables the system to automatically adjust pressure application to maintain consistent adhesion across different panels and operators. The feedback mechanism ensures manufacturing precision while preserving ease of operation, as the system self-corrects rather than requiring operator skill.
Solution Approach 2:
The patent applies self-service by designing the pressure roller to automatically sense and adjust its own pressure application without external intervention. The system monitors its own performance and makes real-time corrections to maintain consistent adhesion. This eliminates the variability introduced by different operators while keeping the system easy to operate, as no specialized skill is required to achieve consistent results.
Data Source
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AI summary
An improved method of edge modification such as edge banding comprising placing a roller in contact with an edge and measuring a first position of the roller. Subsequently moving the contact roller along the edge to a second position and measuring the second position before calculating a desired force direction from the first and second position measurements, applying a force via the pressure roller in the desired force direction.