Metal Workpiece Reshaping Using Contour-Based Deformation Analysis
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Solution Overview
Problem
Manual reshaping of metal products based on visual inspection is labor-intensive and inefficient due to varying degrees of deformation in workpieces, leading to high labor costs and low reshaping efficiency.
Innovation Solution
A method involving the acquisition of position data from workpieces using a measurement system, conversion into coordinate information, fitting to obtain surface contour curves, comparison with standard curves to determine deformation, and automated reshaping based on generated reshaping information.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If manual reshaping based on visual inspection is used, then flexibility in handling varying deformation is achieved, but labor costs increase and reshaping efficiency decreases
Solution Approach 1:
The patent replaces the manual visual inspection and manual reshaping mechanical system with an automated optical measurement system (laser scanner or camera) and computer-controlled reshaping system. The measurement system captures workpiece geometry data, the computer processes this data to determine deformation, and the reshaping system automatically adjusts the workpiece, eliminating manual intervention while maintaining adaptability to varying deformation through software algorithms
Solution Approach 2:
The system enables the workpiece to be automatically measured, analyzed, and reshaped without human intervention. The measurement system self-captures the workpiece geometry, the computer self-determines the deformation and generates reshaping instructions, and the reshaping system self-executes the correction, creating a self-service automated workflow that improves efficiency while handling varying deformation cases
2Ease of operation
If manual reshaping based on visual inspection is used, then simplicity of operation is maintained, but labor costs increase and reshaping efficiency decreases
Solution Approach 1:
The patent replaces the simple manual operation of visual inspection and hand reshaping with an automated system where a computer executes measurement data processing and reshaping control algorithms. While the underlying system becomes more complex, the operator's task is simplified to initiating the automated process, and the overall productivity increases through automated execution
3Productivity
If automated measurement and reshaping systems are implemented, then reshaping efficiency improves and labor costs reduce, but system complexity increases
Solution Approach 1:
The patent employs a computer system that performs multiple functions: it receives and processes measurement data from different measurement systems (laser scanner or camera), executes deformation analysis algorithms, generates reshaping instructions, and controls the reshaping system. This multi-functional computer-based approach consolidates complexity into a single coordinating system rather than requiring separate complex systems for each function
Solution Approach 2:
The computer acts as an intermediary between the measurement system and the reshaping system. It receives measurement data, processes it through deformation analysis algorithms, generates appropriate reshaping instructions, and transmits these to the reshaping system. This intermediary role simplifies the overall system architecture by providing a central coordination point that manages the complexity of data processing and control logic
Data Source
AI summary
A reshaping method for metal product includes acquiring position data information of a workpiece; converting the position data information into coordinate information, and fitting the coordinate information to obtain a surface contour curve of the workpiece; comparing the surface contour curve with a standard contour curve to generate a comparison result; obtaining reshaping information of the workpiece based on the comparison result; and controlling the reshaping system to reshape the workpiece. The disclosure acquires position data information of the workpiece by measuring, converts the position data information into coordinate information, fits the coordinate information to obtain the surface contour curve of the workpiece, compares the surface contour curve with the standard contour curve to obtain deformation situation, and reshapes the workpiece according to the reshaping information based on the deformation situation, which improves efficiency of workpiece reshaping and reducing labor costs. An electronic device is also provided.