Forming Machine Sensor Calibration for Faster Accurate Setup

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Solution Overview

Problem

The existing laminate shear forming machines require costly and time-consuming setup processes involving manual measurements and iterative trials, which are inefficient and prone to errors, especially as machine performance degrades over time.

Innovation Solution

The implementation of a forming machine with a sensor system that establishes baseline parameters and calculates optimal forming positions automatically, allowing for quick and accurate setup without the need for highly-trained personnel to access the machine interior, and providing machine health feedback for position accuracy and repeatability.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Manufacturing precision

If manual dial gage measurement and iterative forming trials are used for setup, then forming accuracy can be achieved, but setup time and material costs increase significantly

Engineering Contradiction:

Improveforming accuracyVSAvoidsetup time

Core Design Contradiction:

Manufacturing precisionVSLoss of time

Solution Approach 1:

The patent replaces manual mechanical dial gage measurements with an automated sensor system that uses electronic coordinate positioning and digital data processing to establish baseline parameters and calculate forming positions, eliminating the need for iterative manual trials

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The forming machine performs self-calibration through automated sensor measurements and coordinate calculations without requiring highly-trained personnel to manually access the machine interior, enabling the system to establish its own baseline parameters automatically

Inventive Principle:

Principle #25Self-service

2Measurement precision

If highly-trained personnel manually measure and establish reference points, then accurate baseline parameters can be obtained, but operational complexity and training requirements increase

Engineering Contradiction:

Improvebaseline parameter accuracyVSAvoidsetup operation simplicity

Core Design Contradiction:

Measurement precisionVSEase of operation

Solution Approach 1:

The system enables self-calibration where the forming machine automatically performs measurements and calculations without requiring highly-trained personnel to manually access the machine interior, making the operation simpler while maintaining accuracy

Inventive Principle:

Principle #25Self-service

Solution Approach 2:

Manual mechanical measurement operations are replaced with automated sensor-based coordinate measurement and digital calculation systems, eliminating the need for skilled manual measurement techniques

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

3Manufacturing precision

If iterative forming trials are performed to establish acceptable forming results, then forming quality can be validated, but material waste and production costs increase

Engineering Contradiction:

Improveforming qualityVSAvoidmaterial waste

Core Design Contradiction:

Manufacturing precisionVSLoss of substance

Solution Approach 1:

The system performs preliminary automated calibration and baseline parameter establishment before actual forming operations, ensuring forming quality is pre-configured correctly to avoid the need for iterative trials that waste material

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

Physical iterative forming trials are replaced with automated digital calibration and virtual parameter optimization, allowing quality validation without consuming additional material

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

4Manufacturing precision

If manual dial gage setup process is used, then initial forming accuracy can be achieved, but the process must be repeated as machine performance degrades

Engineering Contradiction:

Improveforming accuracyVSAvoidsetup efficiency

Core Design Contradiction:

Manufacturing precisionVSProductivity

Solution Approach 1:

The automated sensor system provides continuous feedback on machine performance and position accuracy, enabling monitoring of degradation over time and triggering recalibration only when necessary, rather than requiring repeated manual setup

Inventive Principle:

Principle #23Feedback

Solution Approach 2:

The automated electronic measurement and calculation system replaces manual dial gage procedures, enabling more efficient recalibration when machine performance degrades

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Data Source

PatentUS11331866B2Forming machine with enhanced setup and health feedback

Publication Date: 2022.05.17 THE BOEING CO

AI summary

Systems and methods for forming machine with enhanced setup and health feedback. One embodiment is a forming machine including a positioning system to move a forming member and mandrel relative to one another for forming a shaped part, and a sensor disposed between the forming member and the mandrel. A forming controller obtains a first coordinate position of the forming member and the mandrel in position to produce a target baseline parameter at the sensor prior to placement of a part over the mandrel. The forming controller calculates a second coordinate position of the forming member and the mandrel for forming the part based on the first coordinate position and a thickness of the part. After placement of the part over the mandrel, the forming controller directs the positioning system to move the forming member and the mandrel to the second coordinate position to shape the part.