Optical Positioning for Fiber-Reinforced Plastics

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Solution Overview

Problem

Automated production and assembly systems face challenges in achieving precise positioning and orientation of fiber-reinforced plastics, leading to potential faulty products and increased production costs due to imprecise placement, which is time-consuming and requires low tolerances.

Innovation Solution

A system comprising a location-determining system with a movable arm and optical detection devices that detect the relative positions of the object, receiving apparatus, and production apparatus, allowing for precise placement without complex orientation of the production apparatus, using reference markings and a positioning robot to compensate for deviations.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Manufacturing precision

If the production apparatus is arranged relative to the system with very low tolerances, then positioning precision is improved, but the setup process becomes time-consuming and increases manufacturing costs

Engineering Contradiction:
Improvepositioning precisionVSAvoidsetup time
Core Design Contradiction:
Manufacturing precisionVSLoss of time

Solution Approach 1:

The patent replaces the mechanical alignment system with an optical measurement system. Instead of mechanically adjusting the production apparatus to achieve precise positioning, the system uses optical detection devices to measure the actual positions of both the positioning apparatus and production apparatus, then calculates and compensates for deviations computationally. This substitution of mechanical adjustment with optical-mechanical-computational methods resolves the contradiction by achieving high positioning precision without time-consuming manual alignment.

Inventive Principle:
Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The patent implements a feedback mechanism where the optical detection devices continuously monitor the positions of the positioning apparatus and production apparatus, and the control unit adjusts the positioning commands based on the measured deviations. This closed-loop feedback system ensures that even if the production apparatus is not initially positioned with very tight tolerances, the system can detect and compensate for the deviations, achieving precise placement without requiring time-consuming pre-alignment.

Inventive Principle:
Principle #23Feedback

2Manufacturing precision

If the production apparatus is arranged relative to the system with very low tolerances, then positioning precision is improved, but manufacturing costs increase

Engineering Contradiction:
Improvepositioning precisionVSAvoidmanufacturing cost
Core Design Contradiction:
Manufacturing precisionVSEase of manufacture

Solution Approach 1:

The patent replaces expensive mechanical precision alignment mechanisms with more cost-effective optical detection and computational compensation systems. Instead of requiring the production apparatus to be manufactured and installed with very tight mechanical tolerances (which is costly), the system uses optical devices to detect positions and computationally determines placement positions that account for any deviations, achieving the same precision outcome at lower manufacturing cost.

Inventive Principle:
Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The patent introduces an intermediary computational system that acts as a mediator between the positioning apparatus and the production apparatus. This control unit calculates the optimal placement position based on measured deviations, serving as an intermediary that compensates for imprecise mechanical alignment. This intermediary computational layer eliminates the need for expensive high-precision mechanical manufacturing while maintaining positioning accuracy.

Inventive Principle:
Principle #24Intermediary (Mediator)

3Measurement precision

If optical recognition system is used to ascertain relative position, then positioning capability is improved, but the system cannot recognize incorrect location of production apparatus

Engineering Contradiction:
Improvepositioning capabilityVSAvoiderror detection capability
Core Design Contradiction:
Measurement precisionVSReliability

Solution Approach 1:

The patent extends the optical detection system to serve multiple functions: it not only measures the position of the object to be processed but also measures the positions of both the positioning apparatus and the production apparatus. This multi-functional use of the optical detection devices enables the system to perform both positioning and error detection, resolving the contradiction by making the measurement system universal rather than specialized for a single function.

Inventive Principle:
Principle #6Universality (Multi-functionality)

Solution Approach 2:

The patent implements feedback by using the optical detection devices to continuously monitor the positions of all system components and feeding this information back to the control unit. The control unit then compares the actual positions with the ideal positions and adjusts the placement commands accordingly. This feedback mechanism enables the system to recognize and compensate for incorrect locations of the production apparatus, enhancing reliability while maintaining positioning precision.

Inventive Principle:
Principle #23Feedback

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 significantly reduces production stoppages and costs by enabling precise placement and orientation of fiber-reinforced components, enhancing process reliability and productivity by detecting and compensating for deviations in real-time.

Implementation Method 1

The location-detecting device is configured to detect a relative position of the receiving apparatus in relation to the location-detecting device and furthermore to detect a relative position of the production apparatus in relation to the location-detecting device

Methodology Applied
Scientific EffectOptical reflection: Reflection

Data Source

PatentUS10646992B2System and method for placing an object, which is to be processed, on a production apparatus in a precise position
Publication Date: 2020.05.12 NEW MEXICO TECH RES FOUND
  • US10646992B2 patent drawing

AI summary

A system and method for placing an object, which is to be processed on a production apparatus in a precise position, is provided. The system includes at least one location-determining system for determining a relative location of an object in relation to a production apparatus and a positioning apparatus for positioning the object on the production apparatus. The positioning apparatus has a receiving apparatus for receiving and discharging the object, and a movable arm for moving the object from one location to another. The location-determining system has at least one location-detecting device to detect a relative location of the receiving apparatus in relation to the location-detecting device. The location-detecting device is configured to detect a relative location of the object in relation to the location-detecting device and also a relative location of the production apparatus in relation to the location-detecting device.