Flat Panel Elements Layered Assembly Waste Reduction
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Solution Overview
Problem
Current methods for producing flat panel elements result in significant waste due to the need for subsequent cutting operations to create sections like windows and doors, and existing systems are inefficient for handling small-area initial parts in large quantities, leading to high production costs and waste rates.
Innovation Solution
The method involves precluding cutouts within the panel elements during assembly by using starting products of varying lengths, where shorter products are used in areas requiring cutouts, allowing for precise and efficient positioning using a positioning unit, thereby minimizing the need for subsequent sawing operations and reducing waste.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If full-area rectangular panel elements are pre-produced using conventional methods, then manufacturing simplicity is maintained, but waste rates increase to 20% or more due to subsequent cutting operations
Solution Approach 1:
The panel element is segmented into multiple layers with individual boards positioned independently within each layer. This allows the first layer to contain boards arranged to form cutout sections (windows, doors, sloping ceilings) while subsequent layers provide structural coverage, eliminating the need to cut sections from solid panels and reducing waste to minimal board trimming.
Solution Approach 2:
The cutout sections are prepared in advance by arranging shorter boards or boards with pre-cut ends in the first layer at the desired positions for windows, doors, and sloping ceilings. This preliminary positioning of boards to define cutout areas eliminates the need for subsequent heavy cutting operations on completed panels, thereby reducing waste material.
2Manufacturing precision
If individual boards are positioned using portal conveyor devices or free-arm robot systems, then positioning precision is improved, but cycle times increase and productivity decreases
Solution Approach 1:
The system uses a positioning unit that automatically adjusts and positions boards within the layer without requiring complex portal conveyors or robot systems. The positioning unit works in conjunction with the layer-by-layer assembly process, allowing boards to be self-positioned through simple mechanical adjustment mechanisms, thereby maintaining precision while significantly reducing cycle times.
3Device complexity
If boards of the same length are used in all layers, then material inventory is simplified, but adaptability to create various section configurations is reduced
Solution Approach 1:
The patent applies local quality by using boards of varying lengths specifically in the first layer where adaptability is needed to create different section configurations (windows, doors, sloping ceilings). Subsequent layers can use standard uniform boards for structural purposes, thus achieving configuration flexibility where needed while maintaining simplicity in the majority of the panel structure.
Data Source
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AI summary
Flat panel elements (1) consisting of layers located on top of one another are produced by the method. Said elements are produced from bar-shaped starting products which are preferably planks and are seated against one another with the longitudinal sides thereof. In order for the cut-outs (23, 24) to be formed during formation of the panel element (1), the starting products have different lengths and are positioned according to the plank layer and the dimensions of the cut-outs (23, 24) in the respective layer of the panel element (1). At least one positioning unit which positions the starting product at any location within the plank layer in at least two directions (X, Y) is used to position the starting product.