Flatbed Workpiece Sorting Using Image Comparison Signals

Solution Overview

Problem

The existing methods for sorting workpieces produced by flat bed machine tools, such as laser cutting or punching, are time-consuming and error-prone, especially when dealing with a high variety of part shapes, as they rely on visual comparison and paper-based sorting, which becomes inefficient and prone to errors, especially for small or reflective workpieces.

Innovation Solution

A method that involves imaging the sorting table with cameras to generate sorting image data sets before and after a workpiece is removed, comparing these images to generate a sorting signal containing information about the workpiece's type, position, and shape, and using this signal to support the sorting process by guiding the operator to the correct workpiece collection point, with integration into a Manufacturing Execution System (MES) for real-time monitoring and feedback.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Device complexity

If visual comparison with job drawing is used for sorting workpieces, then the sorting process can be performed with simple equipment, but the sorting time increases and error rate increases especially with high part diversity

Engineering Contradiction:

Improvesorting equipment complexityVSAvoidsorting speed

Core Design Contradiction:

Device complexityVSProductivity

Solution Approach 1:

The patent replaces the mechanical visual comparison process with an optical imaging system. A camera captures images of workpieces on the sorting table, and image processing algorithms automatically identify and classify parts, substituting the operator's visual inspection with automated optical-mechanical systems.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The patent creates digital copies (images) of the workpieces and their positions on the sorting table. These image data are processed to generate sorting signals that guide the operator, replacing the need for physical job drawings and manual visual comparison with digital replicas and automated processing.

Inventive Principle:

Principle #26Copying

2Device complexity

If visual comparison with job drawing is used for sorting workpieces, then the sorting process can be performed with simple equipment, but the error rate increases especially with high part diversity

Engineering Contradiction:

Improvesorting equipment complexityVSAvoidsorting accuracy

Core Design Contradiction:

Device complexityVSReliability

Solution Approach 1:

The patent replaces the mechanical visual comparison process with an optical imaging system. A camera captures images of workpieces on the sorting table, and image processing algorithms automatically identify and classify parts, substituting the operator's visual inspection with automated optical-mechanical systems.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The system provides real-time feedback by displaying processed image data and generating sorting signals that indicate the correct destination for each workpiece. This feedback loop allows the operator to verify and correct sorting decisions, significantly reducing errors compared to unaided visual inspection.

Inventive Principle:

Principle #23Feedback

3Measurement precision

If optical markings are projected onto workpieces to facilitate sorting, then part identification is improved, but small or reflective workpieces still present detection difficulties

Engineering Contradiction:

Improvepart identification accuracyVSAvoiddetectability of markings

Core Design Contradiction:

Measurement precisionVSDifficulty of detecting and measuring

Solution Approach 1:

Instead of marking the workpieces themselves (which is difficult for small or reflective parts), the patent inverts the approach by marking the sorting table or background and using image processing to identify workpieces by their presence, shape, and position relative to the markings. This eliminates the need to directly mark difficult-to-mark parts.

Inventive Principle:

Principle #13The other way round (Inversion)

Solution Approach 2:

The patent creates digital copies (images) of the workpieces and their positions on the sorting table. These image data are processed to generate sorting signals that guide the operator, replacing the need for physical job drawings and manual visual comparison with digital replicas and automated processing.

Inventive Principle:

Principle #26Copying

4Device complexity

If paper-based sorting is used for small workpieces, then the sorting process can be performed with simple equipment, but the sorting time increases and efficiency decreases

Engineering Contradiction:

Improvesorting equipment complexityVSAvoidsorting time

Core Design Contradiction:

Device complexityVSLoss of time

Solution Approach 1:

The patent replaces the mechanical visual comparison process with an optical imaging system. A camera captures images of workpieces on the sorting table, and image processing algorithms automatically identify and classify parts, substituting the operator's visual inspection with automated optical-mechanical systems.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The imaging system operates continuously to capture images of the sorting table as workpieces are removed and replaced. This continuous imaging and processing eliminates the intermittent nature of paper-based sorting, maintaining a steady workflow and reducing overall sorting time.

Inventive Principle:

Principle #20Continuity of useful action

Applied Scientific Principles

This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.

Function Achieved in This Case

This approach significantly reduces errors and increases efficiency by providing real-time sorting support, allowing for quick and accurate assignment of workpieces to their correct storage locations, even for complex or reflective materials, thereby optimizing production processes and reducing throughput times.

Implementation Method 1

imaging the sorting table with a plurality of spatially adjacent workpieces and generating a first sorting image data set based on this

Methodology Applied

Scientific EffectOptical imaging: Photography

Data Source

PatentEP3529001B1Sorting support method and flat bed machine tool

Publication Date: 2021.12.29 TRUMPF WERKZEUGMASCHINEN GMBH & CO KG

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AI summary

The invention relates to a method for supporting a sorting process of workpieces (9) arranged on a sorting table (21), said workpieces having been produced in particular by a laser cutting or punching flat bed machine tool (3) by means of a processing plan (16), comprising a providing of a processing image data set (16') of the processing plan (16), which was based on the arrangement of at least one workpiece (9). The method according to the invention further relates to an imaging-based capturing of the sorting table (21) having a plurality of workpieces (9) arranged spatially adjacent to each other and a generating of a first sorting image data set (27), and a repeated image-based capturing of the sorting table (21) and a generating of a second sorting image data set (29), once at least one workpiece (9) of the plurality of workpieces (9) arranged spatially adjacent to each other has been removed from the sorting table (21). According to the invention, the method comprises a comparing of the sorting image data sets (27, 29), incorporating the processing image data set (16'), wherein a sorting signal is generated which contains information that comprises the type, the position and/or the shape of the at least one removed workpiece (9).