Laser Marking of DIN Rail Devices With Image-Based Position Correction
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Solution Overview
Problem
Existing methods for marking electrical devices on mounting rails are time-consuming and imprecise, especially on longer rails with size tolerances and deviations due to device alignment and environmental factors, leading to incorrect positioning and increased movement costs.
Innovation Solution
A method that uses image acquisition to correct marking positions, groups markings into levels for efficient application without moving the laser head or rail, and prioritizes movements to minimize unnecessary actions, with a device featuring a pivoting rail and laser head for precise marking.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If the mounting rail is equipped with a large number of electrical devices and each device is marked in several positions with possibly different orientations, then the marking precision can be improved by correcting positions based on image evaluation, but the marking time increases due to the large number of markings and pivoting operations required
Solution Approach 1:
The patent divides the marking process into multiple marking levels, where each level contains markings that can be applied without moving the laser head or support rail. This segmentation allows the system to batch process markings that share the same positioning requirements, reducing the total number of movement operations while maintaining precise positioning through image-based correction for each level.
Solution Approach 2:
The patent performs image acquisition and position correction before the actual marking process. By evaluating the actual positions of electrical devices on the mounting rail beforehand and calculating corrected marking positions, the system prepares all necessary positioning data in advance. This preliminary action ensures that when markings are applied, the laser head can operate efficiently with minimal adjustments, resolving the contradiction between precision and speed.
2Adaptability or versatility
If the mounting rail length increases from one meter to more than one meter, then more electrical devices can be accommodated, but the positioning accuracy decreases due to cumulative size tolerances and gaps that cause deviations of a few millimeters
Solution Approach 1:
The patent implements a feedback mechanism where an image acquisition device captures the actual positions of electrical devices on the mounting rail. This visual feedback allows the system to detect deviations caused by cumulative tolerances and gaps in longer rails. The control unit then uses this feedback information to calculate and apply position corrections, ensuring accurate marking positions regardless of the rail length or device arrangement variations.
3Adaptability or versatility
If the laser head and support rail are moved frequently to apply markings at different positions and orientations, then all required markings can be applied, but the marking process time increases due to the numerous movement operations
Solution Approach 1:
The patent segments the marking instructions into multiple marking levels based on the positioning requirements. Each marking level groups together all markings that can be applied without moving the laser head or support rail. By processing one marking level at a time and only moving between levels when necessary, the system minimizes the frequency of movement operations while still applying all required markings across different positions and orientations.
Solution Approach 2:
The patent merges multiple marking operations into batching processes where the laser head and support rail are positioned once for each marking level, and multiple markings are applied during that stationary position. This merging of operations reduces the total number of movement cycles required, thereby reducing the overall marking process time while maintaining complete marking coverage.
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
This approach allows for precise and efficient marking of electrical devices on mounting rails by correcting positions and optimizing movement sequences, significantly reducing marking time and improving accuracy.
Implementation Method 1
a laser head (21) for applying the marking (5) to the electrical devices (2)
Implementation Method 2
an image of at least one section of the mounting rail (1) and at least one electrical device (2) is created by an image acquisition device (25)
Data Source
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AI summary
The invention relates to a method for marking electrical appliances (2) which are arrangeable in a row, and which are arranged on a support rail (1), with the aid of a laser head (21), wherein the support rail (1) is pivotable about the longitudinal axis thereof, and the laser head (21) is guided so as to be movable at least along the longitudinal axis of the support rail (1). The method comprises the following steps: - specifying a number of marking instructions, each comprising a marking content and a position and an orientation of the surface to which the marking content is to be applied; - creating an image of at least a section of the support rail (1) and at least one electrical device (2) from an image capture device, and correcting at least one of the positions at which one of the marking contents is to be applied on the basis of an evaluation of the image; - grouping the marking instructions in marking levels (3) in such a way that all the marking instructions of one marking level (3) can be applied by the laser head (21) without a movement of the laser head (21) or of the support rail (1), wherein the marking levels (3) differ in terms of spatial coordinates and/or parameters for the laser head (21); - selecting a first one of the marking levels (3); - positioning the laser head (21) and/or pivoting the support rail (1) in accordance with the spatial coordinates of the selected marking level (3); - applying markings (5) in accordance with the marking instructions of the selected marking level (3) with the parameters for the laser head (21); and - selecting a next one of the marking levels (3) for marking on the basis of those movements of the laser head (21) and of the support rail (1) which would be necessary to enable markings in accordance with the next one of the marking levels (3) to be applied. The invention further relates to a device for carrying out said method.