Forming Machine Controller Using Image-Based Determination Areas
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Solution Overview
Problem
Existing forming machine control systems are complex and require manual input to calculate distances and determine object positions, making it difficult to simply limit operation speed and ensure safety during operations.
Innovation Solution
A controller system that uses image data from sensors to set determination areas based on the bolster shape of the forming machine, detects object entry into these areas, and adjusts operation speed accordingly, without the need for manual input or distance calculations, while distinguishing between the operator and workpiece using HOG feature values and similarity calculations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the position of the finger is calculated from image coordinates and distance computation is performed, then the operation speed can be limited based on safety distance, but the control process becomes complicated
Solution Approach 1:
The sensing area is divided into multiple determination areas (first determination area, second determination area, third determination area) with different safety requirements. Each area corresponds to a different operation speed limit, allowing simplified control by detecting which area the operator enters rather than calculating precise distances.
Solution Approach 2:
The system changes the parameter of operation speed based on the determined area. When an operator enters a determination area, the operation speed is limited according to the safety distance associated with that area, avoiding complex real-time distance calculations while maintaining safety.
2Adaptability or versatility
If multiple determination areas are set based on bolster shape with varying magnification, then the detection coverage is improved, but the system complexity increases
Solution Approach 1:
The determination areas are defined based on the bolster shape which is a common component across different forming machine types. By using the bolster shape as the reference framework and applying varying magnification, the system achieves universal applicability across different machine configurations without requiring machine-specific calibration for each case.
3Reliability
If the operation speed is limited based on the determined area, then the safety is improved, but the productivity decreases
Solution Approach 1:
Different determination areas have different safety requirements and correspond to different operation speed limits. The first determination area (closest to the bolster) has the strictest speed limitation, while areas farther away allow higher speeds. This local differentiation ensures safety where needed while maintaining productivity in safer zones.
Data Source
AI summary
A controller controls operation of a forming machine capable of forming a workpiece. The controller includes: an object determination unit configured to determine an object other than the workpiece and the forming machine based on image data sensed by a sensor; a setting unit configured to set a plurality of determination areas based on a bolster shape of the forming machine included in the image data; a detection unit configured to detect entry of the object into each of the plurality of determination areas set by the setting unit; and a control unit configured to limit operation speed of the forming machine based on the determination area in which the entry of the object has been detected by the detection unit.