Processing Machine Mode Switching Control
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Solution Overview
Problem
Machine tools face challenges in optimizing switching between operator-attended and non-operator-attended workpiece processing modes, leading to suboptimal performance and reduced flexibility due to conflicting settings and additional adjustment requirements during frequent changes.
Innovation Solution
A method and system that allow switching between different workpiece processing operating modes by looking up stored settings specific to each mode, adjusting machine components accordingly, and providing feedback to operators on the completion of the switch, enabling seamless transitions between modes with defined processing parameters and strategies, including material handling, maintenance, and process safety measures.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the machine is optimized for non-operator-attended operation, then productivity is improved, but flexibility is reduced because the machine operator cannot leave even for a short time
Solution Approach 1:
The system dynamically switches between different operating modes (operator-attended and non-operator-attended) based on real-time requirements. The control system can adaptively adjust machine parameters and monitoring levels depending on whether an operator is present, allowing the machine to optimize for productivity during unmanned operation while maintaining flexibility when operators are available.
Solution Approach 2:
The patent implements different operational parameter sets for different modes. When switching from operator-attended to non-operator-attended mode, the system changes parameters such as monitoring frequency, alarm thresholds, and automated intervention levels. This allows the machine to be optimized for each specific operating condition, achieving high productivity during unmanned operation while maintaining the ability to adapt when operators are present.
2Adaptability or versatility
If the machine operator leaves the machine during operation, then flexibility is improved, but reliability deteriorates because optimum settings cannot be maintained during frequent mode changes
Solution Approach 1:
The control system stores pre-configured optimal settings for different operating modes (operator-attended and non-operator-attended). When a mode change is initiated, the system automatically retrieves and applies the appropriate pre-stored settings, ensuring that optimum operation parameters are maintained without requiring manual adjustment by the operator. This preliminary preparation of settings ensures reliability during mode transitions.
Solution Approach 2:
The system provides feedback to the operator about the status of mode switching and whether operator intervention is required. This feedback mechanism ensures that the machine maintains reliable operation by alerting operators to situations where their intervention is needed to preserve optimum settings, while also enabling flexible unmanned operation when conditions permit.
3Reliability
If the machine operator remains present during operation, then reliability is improved, but productivity is reduced due to additional adjustment work required during mode changes
Solution Approach 1:
The control system automatically performs the adjustment work that would otherwise require operator intervention. When switching between operating modes, the system self-adjusts machine parameters by retrieving pre-stored optimal settings and automatically reconfiguring the machine components. This eliminates the need for manual adjustment work, maintaining reliability through automatic optimization while improving productivity by freeing the operator from repetitive adjustment tasks.
4Adaptability or versatility
If frequent switching between operating modes occurs, then flexibility is improved, but device complexity increases due to additional adjustment requirements
Solution Approach 1:
All possible operating mode configurations are pre-configured and stored in the control system before runtime. This preliminary preparation eliminates the need for complex real-time adjustment mechanisms during mode switching. The system simply retrieves and applies the appropriate pre-stored configuration, enabling frequent mode changes without increasing device complexity.
Solution Approach 2:
The control system serves multiple functions: it stores configurations, manages mode switching, adjusts machine parameters, and provides operator feedback. By consolidating these functions into a single multi-functional control system, the patent enables flexible frequent mode switching without proportionally increasing overall device complexity. The universal control system handles all adjustment requirements through a unified interface and logic.
Data Source
AI summary
Methods, systems, and apparatus, including computer programs encoded on computer storage media, for switching between different operating modes on a processing machine. The operating modes are different from one another in respect of operator intervention requirements of an operator of the processing machine, One of the methods includes switching from a first operating mode to a second operating mode, looking up stored operating settings specific to the second operating mode and related to one or more potential operator interventions, changing operation of the processing machine in accordance of the stored operating settings specific to the second operating mode, and providing feedback to the operator of the machine, indicating whether a switch to the second operating mode is complete or whether at least one of the potential operator interventions is required.