Automated Chip Removal via Image-Guided Robot
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Solution Overview
Problem
Existing machining systems struggle to reliably remove machining chips from workpieces and machining tools, especially when dealing with tough materials like aluminum or stainless steel, as these chips tend to form long strips and intertwine, leading to reduced machining accuracy and potential tool damage, requiring frequent human intervention.
Innovation Solution
A machining system equipped with a robot, an image capturing device, and a removal tool that uses image processing to detect and remove machining chips automatically, allowing for selective use of different removal tools and operations based on chip position and amount, with a result judging unit to ensure effective removal without human intervention.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If high-pressure cleaning spray is used to remove machining chips, then small iron-based chips can be removed effectively, but long strip chips from tough materials cannot be removed reliably
Solution Approach 1:
The robot system is designed to selectively use multiple different removal tools (gripper, scraping tool, high-pressure cleaning spray) depending on the chip type detected. The system can adapt between removing small iron-based chips using high-pressure spray and long strip chips from tough materials using grippers or scraping tools, making the system universal for different chip removal scenarios
Solution Approach 2:
The system uses an image capturing device and image processing unit to automatically detect chip accumulation and determine which removal tool to use, eliminating the need for human operators to manually check and decide on chip removal methods. The system serves itself by autonomously monitoring and selecting appropriate removal actions
2Manufacturing precision
If machining operation is interrupted periodically for manual chip removal, then machining accuracy is maintained, but productivity decreases
Solution Approach 1:
The image capturing device continuously or periodically captures images of the workpiece and machining tool during the machining process, and the image processing unit continuously analyzes these images to detect chip accumulation. This allows the system to maintain machining accuracy by detecting chips in real-time without interrupting the machining operation, thereby maintaining continuous productivity
Solution Approach 2:
The system uses image capturing and processing to provide continuous feedback on chip accumulation conditions. Based on this feedback, the control unit automatically determines when and how to remove chips, enabling the system to maintain machining accuracy through automated monitoring and response without requiring periodic manual interruptions
3Extent of automation
If automated removal system is implemented, then human intervention is eliminated, but system complexity increases
Solution Approach 1:
The system replaces manual mechanical chip removal operations with an automated system consisting of an image capturing device, image processing unit, and robot-controlled removal tools. The image processing unit automatically analyzes captured images to detect chip accumulation, and the robot automatically executes removal operations based on this analysis, substituting human mechanical operations with automated sensing and actuation systems
Solution Approach 2:
The image capturing device and image processing unit serve as intermediaries between the machining process and the chip removal execution. These intermediaries automatically detect chip accumulation conditions and translate them into control signals for the robot, enabling automated decision-making and execution without requiring direct human intervention while managing system complexity through modular architecture
Data Source
AI summary
Disclosed is a machining system wherein provisions are made to be able to remove machining chips reliably without requiring human intervention. The machining system includes: an image processing unit which detects the position and amount of machining chips by comparing images captured of a workpiece and a machining tool before and after execution of a machining step; a condition judging unit which, based on the detected amount of machining chips, determines whether or not there is a need to execute a removal step; and a result judging unit which judges the result of the removal step by comparing the images captured of the workpiece W and the machining tool before and after the execution of the removal step.