Indoor Workpiece Tracking for Real-Time Metalworking Control
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Solution Overview
Problem
The manual and error-prone process of monitoring and controlling manufacturing processes in steel and sheet metal processing leads to incorrect part allocation and subsequent processing errors due to the complexity of managing diverse workpieces across multiple processing steps and locations, resulting in significant downtime and reduced productivity.
Innovation Solution
An indoor positioning system using electromagnetic signals and mobile units to determine the precise location of workpieces and integrate this data into a production control system, enabling automated and accurate assignment of workpieces to processing steps, even in environments with metallic interference.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If manual monitoring and control processes are used for diverse workpieces, then flexibility in handling different part shapes is maintained, but error rate increases and productivity decreases
Solution Approach 1:
The patent replaces manual mechanical monitoring processes with an automated indoor positioning system using electromagnetic signals (UWB, RFID, Bluetooth). Mobile units attached to workpieces automatically transmit location data to a central control system, eliminating manual tracking while maintaining flexibility in handling diverse part shapes across multiple processing steps
Solution Approach 2:
The patent creates a digital replica of the physical workpiece location and status through mobile units and positioning systems. The control system receives and processes digital position data to generate visualizations and control commands, replacing manual visual inspection and paper-based documentation with automated digital copying of workpiece information
2Device complexity
If manual monitoring of workpiece positions is used, then system complexity is reduced, but measurement precision of workpiece location decreases
Solution Approach 1:
The patent introduces mobile units as intermediary devices between workpieces and the control system. These mobile units equip workpieces with positioning capabilities without requiring complex modifications to the workpieces themselves, achieving precise location measurement through a modular intermediary layer
Solution Approach 2:
The patent employs universal positioning infrastructure (transmitters, receivers, mobile units) that can track any workpiece regardless of shape or size. The same system architecture handles diverse part types across multiple processing steps, achieving measurement precision without proportionally increasing system complexity through standardization
3Productivity
If automated indoor positioning system is implemented, then productivity increases, but device complexity increases
Solution Approach 1:
The patent segments the positioning system into independent modular components: transmitters fixed in the production hall, mobile units attached to workpieces, receivers at processing stations, and a central control system. This segmentation allows incremental implementation and reduces overall system complexity by enabling independent optimization and maintenance of each component
Solution Approach 2:
The patent implements continuous feedback loops where mobile units transmit position data to the control system, which automatically generates control commands and visualizations. This automated feedback mechanism increases productivity by eliminating manual intervention while the modular architecture manages complexity through standardized feedback protocols
4Ease of operation
If manual synchronization of material flow with processing steps is used, then ease of operation is maintained, but loss of time increases
Solution Approach 1:
The patent enables the production system to self-synchronize material flow with processing steps through automated positioning and control. Mobile units on workpieces automatically provide location data, and the control system autonomously generates control commands without requiring manual coordination, reducing time loss while maintaining operational simplicity through automation
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
Enhances production efficiency by reducing manual searches, ensuring accurate workpiece tracking, and enabling flexible, real-time control of manufacturing processes, thereby minimizing downtime and optimizing throughput times.
Implementation Method 1
the transmitting/receiving units and the mobile unit are designed to transmit and receive electromagnetic signals and the analysis unit is designed to determine the positions of the mobile unit in the production hall from the propagation times of the electromagnetic signals
Data Source
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AI summary
Disclosed is the use of an interior tracking system (5) for manufacturing control. The interior tracking system (5) has multiple, fixedly installed transceivers (13) for determining the position of multiple mobile units (15), the position being determined in particular by evaluating the propagation time of electromagnetic (radio) signals. The interior tracking system (5) is used to assign one of the mobile units (15) to one or more workpieces (23) in an industrial manufacturing plant that processes steel and/or sheet metal, to determine the position of the assigned workpieces (13) by localising the assigned mobile unit (15) using the interior tracking system (5) and to integrate the interior tracking system (5) into a manufacturing control system (1) of the industrial manufacturing plant.