Continuous Laying Line Camera Positioning for Press Embossing
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Solution Overview
Problem
Existing methods for congruent laying of workpiece layers in a press face challenges in achieving precise positioning and embossing on both sides due to imprecise recording of arcuate lower coating material positions, leading to slipping and frequent interruptions, resulting in slow and inefficient production.
Innovation Solution
A device with transfer devices having multiple spatial degrees of freedom and camera systems for precise positioning of workpiece layers on a continuously running laying line, allowing for accurate alignment and simultaneous embossing on both sides by merging position data from multiple camera systems, and using vacuum plates for secure and directional placement of coating materials.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If the laying line is stopped frequently for positioning workpiece layers, then positioning accuracy is improved, but production efficiency deteriorates
Solution Approach 1:
The camera systems detect and record the positions of workpiece layers and carrier plates before they reach the pressing position. Transfer devices pre-position components on the moving laying line, ensuring alignment is achieved during motion rather than requiring stops. This preliminary detection and positioning during transport resolves the contradiction by maintaining accuracy without sacrificing continuous production.
2Manufacturing precision
If the laying line accelerates and decelerates frequently, then positioning precision is improved, but workpiece layer stability deteriorates due to slipping
Solution Approach 1:
Camera systems continuously monitor the positions of workpiece layers and carrier plates during transport on the laying line. This feedback information is used to calculate and adjust the positions of subsequent components, compensating for any slipping or position deviations that occur during acceleration and deceleration. The real-time monitoring ensures positioning precision is maintained without requiring frequent stops that would disrupt workflow.
3Measurement precision
If camera systems are added to detect both upper and lower coating material positions, then measurement precision is improved, but device complexity deteriorates
Solution Approach 1:
The camera systems serve multiple functions: they detect the positions of both upper and lower coating materials, track carrier plates, monitor workpiece stack positions during transport, and provide data for calculating optimal deposit positions. By making the camera systems multi-functional rather than adding separate detection devices for each function, the solution improves measurement precision while minimizing the increase in device complexity.
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 solution enables continuous, uninterrupted process acceleration with enhanced accuracy and reliability, preventing slipping and allowing for synchronized embossing on both sides of the press plates, significantly improving production efficiency.
Implementation Method 1
the pickup for the workpiece layer is a vacuum plate or a suction frame with a large number of individual suction cups
Data Source
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AI summary
Disclosed are a method and an apparatus for congruently laying workpiece layers which are to be pressed together in a press, said apparatus consisting of a laying line (17), at least one laying station (1-4; 11-14) for a bottom sheet-type coating material (5), a support plate (6), a top sheet-type coating material (7; 8), and camera systems (19; 20) for ascertaining the positions of the individual workpiece layers and the individual stacks of workpieces. In order to allow said method and apparatus to increase accuracy during simultaneous two-sided congruent embossing at an increased process speed, at least one transfer device (15) is assigned to each laying station (1-4; 11-16), said at least one transfer device (15) having a plurality of degrees of freedom in different spatial directions and being equipped with a receiving device (16) for a workpiece layer to be transferred and with a camera system (9); furthermore, the laying line (17) is driven continuously, and the workpiece layers are designed such that they can be continuously laid on the laying line (17) or on workpieces previously laid on the laying line (17) and move therewith in a properly oriented manner.