Film Stacking Alignment on Workpiece Carriers With Overhang Detection
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Solution Overview
Problem
The issue of films being lifted together during stacking due to adhesive forces, leading to incorrect placement on a workpiece carrier, causing disruptions and waste in the lamination process, and potential damage to the production system.
Innovation Solution
An arrangement and method involving a gripping device, sensor-based control, and a drive device to ensure films are aligned correctly on a workpiece carrier, using a sensor to detect overhangs and an ejection station to remove incorrectly stacked films, preventing further processing and damage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If films are lifted from the stack using adhesive forces, then films can be removed from the stack, but multiple films are lifted together causing incorrect placement
Solution Approach 1:
A sensor (optical sensor, camera, or laser scanner) detects the actual position and contour of each film after it is placed on the workpiece carrier. This detection information is fed back to the control device, which compares the actual position with the desired position and determines whether the film is correctly placed, enabling real-time monitoring and correction of placement errors
Solution Approach 2:
The patent replaces purely mechanical gripping systems with a sensor-based detection and control system. Optical sensors, cameras, or laser scanners detect film position, and the control device processes this information to determine correct placement, substituting mechanical feedback with electronic/optical feedback for more precise control
2Productivity
If films are incorrectly placed on the workpiece carrier, then the stacking process continues, but waste and damage occur in subsequent lamination
Solution Approach 1:
The sensor detects and the control device determines whether films are correctly placed on the workpiece carrier before the lamination process begins. This preliminary inspection allows incorrect stacking to be identified and corrected in advance, preventing waste and damage in subsequent lamination steps
Solution Approach 2:
The sensor-based detection system provides real-time feedback on film placement quality, allowing the control device to identify incorrect stacking before it causes downstream problems. This feedback loop enables early intervention to maintain production reliability
Data Source
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AI summary
The invention relates to an arrangement (100) for collating a plurality of films (106, 110, 134) on a workpiece carrier (102) with the same edges, comprising a first film stack (104) with first films (106) and at least one second film stack (108) with second films (110), a workpiece carrier (102) which is designed to receive a plurality of the films (106, 110) in a stacked manner, at least one gripping device (112) for removing one film (106, 110) from each of the film stacks (104, 108) and placing it on the workpiece carrier (102) or on a film (106) already present there, and a sensor-based control device (114) which is designed to detect a contour of the stack (116) of films (106, 110, 134) on the workpiece carrier (102) or a contour of the workpiece carrier (102) to record and check for themselves,whether a protrusion (118) is present due to an incorrectly transported film (120) of the first film stack (104) or the second film stack (108). The invention further relates to a corresponding method.