Laser Marking for Automated Structure Alignment
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Solution Overview
Problem
Automated manufacturing processes face challenges in achieving high accuracy for part location and orientation, especially when parts are manufactured in different locations and at different times, leading to manufacturing inaccuracies that can result in mismatched components.
Innovation Solution
A laser-marking system that applies permanent markings to structures, allowing working equipment to align its coordinate system with the structure by using markings, and includes a computer system, steering assembly, and cameras to determine the precise location and orientation of the structure, enabling accurate alignment and operation of tools for precise manufacturing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If standard part positioning is used, then ease of operation is improved, but manufacturing precision deteriorates
Solution Approach 1:
The system applies markings to the part in advance during manufacturing, so that when the part is later positioned in the automated machine, the markings are already present and can be used for precise location and orientation determination without requiring additional setup or positioning actions
2Manufacturing precision
If part location and orientation information is improved, then manufacturing precision is improved, but device complexity increases
Solution Approach 1:
The part itself carries the location and orientation information through markings applied during manufacturing, eliminating the need for external fixtures, jigs, or complex positioning devices. The part essentially serves its own positioning function by containing the necessary geometric information directly on it
3Manufacturing precision
If markings are applied to structures, then manufacturing precision is improved, but ease of manufacture deteriorates
Solution Approach 1:
The marking application process is merged with the existing manufacturing process, so that markings are applied during normal production operations rather than as a separate post-processing step. This integration ensures that the additional marking step does not significantly increase overall manufacturing complexity or time
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
The system enables precise alignment and operation of tools, improving the accuracy of manufacturing processes, especially for large or irregular structures, and ensures that components meet tight tolerances, even when manufactured separately.
Implementation Method 1
a laser source configured to emit a laser beam
Data Source
AI summary
Working equipment includes a tool configured to work a structure at a working location thereon, with the structure having an applied marking at a known location with a known relationship with the working location. A computer system is configured to determine placement of the structure, and accordingly position the tool into at least partial alignment with the working location, and which in at least one instance, the tool is aligned with a second, offset location. A camera is configured to capture an image of the structure and including the marking, and further including the second location with which the tool is aligned. And the computer system is configured to process the image to locate the working location, reposition the tool from the second location and into greater alignment with the located working location, and control the repositioned tool to work the structure at the located working location.