Feature-Based Alignment for Automated Bending of Malleable Objects
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Solution Overview
Problem
Existing systems lack efficient methods to automate the manipulation of malleable objects, such as metal strips, into precise target shapes due to variations in physical properties and features, requiring manual adjustments and complex bending operations.
Innovation Solution
A computing device with a processor and communication interface is used to determine the difference in position between a malleable object and a target shape by aligning features and calculating errors, allowing for automated bending and shaping based on feature alignment and error quantification.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If manual bending operations are performed on metal strips to form dies, then customization and flexibility in die shape are achieved, but time consumption and labor intensity increase significantly
Solution Approach 1:
The system performs preliminary scanning of the metal strip to detect actual feature positions and measurements before bending operations begin. This advance detection allows the system to pre-calculate compensation values and adjust bending parameters, eliminating the need for time-consuming manual trial-and-error adjustments during the actual forming process.
Solution Approach 2:
The patent replaces manual mechanical measurement and adjustment operations with an automated optical scanning system and computer-controlled bending mechanism. The scanning system captures precise feature locations, and the computer system automatically calculates and executes bending corrections, substituting human operators and manual tools with automated mechanical and computational systems.
2Adaptability or versatility
If individual metal strips are bent manually to account for physical property variations, then manufacturing flexibility is maintained, but manufacturing precision and consistency deteriorate due to human error
Solution Approach 1:
The system implements a feedback loop where the scanning system continuously monitors the actual positions of features on each metal strip, compares them against the target die shape requirements, and automatically adjusts bending parameters based on detected deviations. This closed-loop control ensures that variations in metal strip physical properties are compensated for, maintaining consistent manufacturing precision across all strips.
Solution Approach 2:
The system enables the metal strip to essentially correct its own positioning errors through automated detection and compensation. The scanning system identifies feature misalignments, and the computer-controlled bending mechanism automatically applies the necessary corrections without requiring manual intervention, allowing each strip to self-adjust to achieve the target shape.
3Productivity
If automated bending systems are implemented without feature-based alignment, then productivity increases, but manufacturing precision decreases due to inability to account for strip variations
Solution Approach 1:
The system uses feature-based alignment as a universal reference framework that works across all metal strip variations. By identifying and aligning to physical features (holes, notches, bends) that are consistently present on each strip, the system creates a common reference system that enables automated bending to achieve high precision regardless of variations in strip properties, making the automated process universally applicable to all strips.
Data Source
AI summary
Systems and methods of determining a difference of position between a malleable object and a target shape are described herein.