Labeling Nested Components for Sorting Efficiency

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Solution Overview

Problem

The existing methods for sorting machined components from a CNC machine are time-consuming and imprecise, especially for unskilled or inexperienced workers, due to the dispersed nesting of cut components, which decreases productivity in cabinetry manufacturing.

Innovation Solution

A method involving the production of a plan depicting the cut pattern of the raw material workpiece with labels indicating the location and set of each component, allowing for easy identification and grouping of components based on visible identifiers, enabling unskilled workers to efficiently sort and assemble components for various structures.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Loss of substance

If cut components are nested in a dispersed manner to maximize material usage, then material utilization is improved, but sorting time and complexity increase significantly

Engineering Contradiction:
Improvescrap materialVSAvoidsorting time
Core Design Contradiction:
Loss of substanceVSLoss of time

Solution Approach 1:

The patent applies preliminary action by pre-applying labels to components during the cutting process itself. The labeling system is integrated into the CNC cutting operation, so that as each component is cut, it is immediately labeled with its identification code. This eliminates the need for post-cutting sorting and identification, resolving the contradiction by making the sorting information available before the sorting task begins.

Inventive Principle:
Principle #10Preliminary action

Solution Approach 2:

The patent introduces an intermediary element - the label with identification code - that mediates between the dispersed nested components and the worker's sorting task. Instead of requiring workers to visually inspect and identify components, the label acts as an intermediary carrier of identification information, making the sorting process straightforward despite the dispersed nesting arrangement.

Inventive Principle:
Principle #24Intermediary (Mediator)

2Ease of manufacture

If components are sorted by unskilled workers without assistance, then labor cost is reduced, but sorting accuracy and precision decrease

Engineering Contradiction:
Improvelabor requirementVSAvoidsorting accuracy
Core Design Contradiction:
Ease of manufactureVSMeasurement precision

Solution Approach 1:

The patent implements self-service by making the components self-identifying through the labeling system. Each component carries its own identification code that tells the worker which cabinet it belongs to. This allows unskilled workers to accurately sort components without requiring training or expertise, as the components themselves provide the sorting information through their labels.

Inventive Principle:
Principle #25Self-service

Solution Approach 2:

The label serves as an intermediary that transfers precise identification information from the manufacturing system to the sorting worker. This intermediary enables unskilled workers to achieve high sorting accuracy by providing them with clear, unambiguous identification codes that eliminate the need for skilled judgment or experience.

Inventive Principle:
Principle #24Intermediary (Mediator)

3Measurement precision

If detailed identification methods are used for each component, then sorting accuracy is improved, but the complexity of the identification system increases

Engineering Contradiction:
Improvesorting precisionVSAvoididentification system complexity
Core Design Contradiction:
Measurement precisionVSDevice complexity

Solution Approach 1:

The patent applies segmentation by dividing the identification information into discrete, simple codes that are applied to individual components. Rather than using a complex overall identification system, each component receives a simple label with an identification code that corresponds to its cabinet assignment. This segmented approach maintains high sorting precision while keeping the identification system simple and manageable.

Inventive Principle:
Principle #1Segmentation

Data Source

PatentUS8596461B2Method and means for facilitating material handling
Publication Date: 2013.12.03 THERMWOOD CORP
  • US8596461B2 patent drawing
  • US8596461B2 patent drawing
  • US8596461B2 patent drawing

AI summary

A method of facilitating a sorting of a plurality of components nested in a workpiece, including at least two sets of components, each adapted to be assembled to form a structure, comprising producing a plan replicating the cut pattern of the workpiece, depicting the profiles of the components, each provided with an identifier denoting the location of the component on the workpiece; producing at least one of a plurality of labels, each bearing a distinguishable one of the location indicators and a distinctive, readily visible identifier denoting a different one of the sets of components; applying each of the labels on a nested component of the workpiece corresponding to the profile of the component on the plan, guided by the plan and the applicable location identifiers; removing each of the nested components provided with labels bearing the same readily, visible identifier and grouping all components provided with labels bearing the same identifier, together.