Optical Part Centering and Press Loading for Irregular Flat Parts
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Solution Overview
Problem
Existing methods for centering and loading flat format parts in a press often result in inaccurate placement, leading to suboptimal shaping and increased production line downtime, particularly when handling parts with irregular shapes or multiple parts simultaneously, as they require multiple mechanical stops or optical measuring devices with separate centering and loading devices, which can be cumbersome and prone to errors.
Innovation Solution
A device comprising a conveyor, an optical measuring device, and at least two transfer devices, with a control unit that corrects the position of parts based on real-time measurements, allowing simultaneous loading and centering of multiple parts without the need for extensive mechanical stops, reducing production line length and improving efficiency by enabling continuous operation even if one transfer device fails.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If mechanical stops are used to correct part position, then centering is achieved, but parts may be damaged and device complexity increases
Solution Approach 1:
The patent replaces mechanical stops with a robotic arm equipped with sensors and vision systems. The robotic arm uses optical measurement to detect part positions and then applies gentle mechanical correction forces, eliminating the need for rigid mechanical stops that cause damage. This substitution of mechanical measurement and correction systems reduces harmful contact forces while maintaining centering precision.
Solution Approach 2:
The patent introduces a robotic arm as an intermediary between the conveyor system and the press. This intermediary device gently guides parts into correct positions without the harsh mechanical stops, acting as a buffer that reduces impact forces and prevents part damage while achieving accurate centering.
2Manufacturing precision
If multiple mechanical stops are used for irregular shapes or multiple parts, then positioning is ensured, but device complexity and quantity of components increase
Solution Approach 1:
The robotic arm serves multiple functions: it positions single parts, handles multiple parts simultaneously, adapts to various irregular shapes, and performs both measurement and correction tasks. This multi-functional device replaces numerous specialized mechanical stops, significantly reducing system complexity while maintaining positioning accuracy across different part configurations.
Solution Approach 2:
The robotic arm is a dynamic system that can adjust its position, orientation, and movement patterns in real-time based on part geometry and required positioning. Unlike fixed mechanical stops, the robotic arm adapts its configuration for each part, eliminating the need for multiple static stops and reducing overall device complexity.
3Manufacturing precision
If separate centering and loading devices are used, then centering precision is improved, but production line length and time increase
Solution Approach 1:
The patent combines centering and loading operations into a single robotic arm system. The robotic arm performs both functions sequentially in one location, eliminating the need for separate centering devices and loading devices. This merging reduces the physical length of the production line and minimizes transfer time between devices, maintaining precision while reducing cycle time.
Solution Approach 2:
The robotic arm performs preliminary centering measurements and corrections before the loading operation. By preparing parts in advance with precise positioning, the actual loading process is accelerated, reducing overall cycle time while maintaining high precision standards.
4Measurement precision
If optical measuring devices with separate centering and loading devices are used, then measurement precision is improved, but device complexity and production line length increase
Solution Approach 1:
The patent integrates the optical measuring device, centering system, and loading mechanism into a single robotic workcell. The vision system is mounted on or integrated with the robotic arm, allowing measurement, calculation, and correction to occur in one location. This consolidation reduces the number of separate devices while maintaining high measurement precision through the robotic system's coordinated operation.
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 ensures precise and efficient centering and loading of flat format parts, reducing production line downtime and allowing for simultaneous processing of multiple parts, while minimizing the risk of damage and optimizing floor space, thus enhancing overall production performance.
Implementation Method 1
an optical measuring device (4) to determine the real position of the parts (1) on the first conveyor (3)
Data Source
AI summary
Apparatus and methods for loading parts in a press wherein a conveyor transports the parts in a forward movement direction towards the press. An optical measuring device determines the real position of the parts on the conveyor. At least two transfer devices are configured to grab the parts off the conveyor and place them directly on a first surface of the press. A control unit is configured to receive the real position of the parts determined by the optical measuring device, and to compare the real position with a theoretical loading position of the parts on the first surface of the press. The control unit determines a deviation between the real and theoretical loading positions and uses the calculated deviation to command the transfer devices to correct the deviation and to place the parts on the first surface of the press in the theoretical position.