Optical Projection Guidance for Workpiece Orientation in Machining
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Solution Overview
Problem
Manual handling of work pieces during machining, such as in press brakes, drilling, and welding machines, often results in errors due to the operator's difficulty in correctly orienting the piece for the next machining step, which can be exacerbated by the need to interpret graphical representations on control screens, leading to misinterpretation and loss of focus from the machine.
Innovation Solution
A method that involves reading a predetermined work plan, detecting the work piece's orientation, comparing it to the required orientation, and projecting indications directly onto the work piece or machine to guide correct positioning and orientation, using cameras and projectors to provide real-time feedback without requiring the operator to look away.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of information
If graphical representation is shown on control screen to help operator, then operator receives guidance information, but operator must take eyes off press brake and interpret graphical representation which can lead to errors
Solution Approach 1:
The patent introduces an optical projection system as an intermediary between the control system and the workpiece. Instead of requiring the operator to look at a screen, the system projects guidance information directly onto the workpiece or press brake, allowing the operator to maintain visual contact with the machine while receiving orientation guidance.
Solution Approach 2:
The patent transitions from two-dimensional graphical representation on a screen to three-dimensional projection directly on the workpiece or machine surface. This spatial transformation allows guidance information to be viewed from multiple angles and maintains the operator's focus on the physical workspace.
2Productivity
If operator relies on spatial awareness to orient work piece, then operator can perform machining, but errors occur due to difficulty in determining correct orientation
Solution Approach 1:
The patent implements a feedback mechanism where the control system continuously monitors the workpiece orientation through camera or sensor detection, compares it with the required orientation from the work plan, and provides real-time projection feedback to guide the operator in correcting the orientation. This closed-loop system reduces errors while maintaining productivity.
Solution Approach 2:
The system performs preliminary detection and comparison of workpiece orientation before the machining step is executed. The projection guidance is provided in advance, allowing the operator to correct orientation issues before they result in machining errors, thus preventing rather than correcting mistakes.
3Adaptability or versatility
If multiple tools are provided for different machining steps, then machine capability is enhanced, but operator confusion increases regarding which tool to use and how to orient work piece
Solution Approach 1:
The patent applies local quality by providing specific, localized projection guidance for each tool position and workpiece orientation. Instead of requiring the operator to understand the entire system, the projection system highlights only the relevant tool and orientation needed for the current step, simplifying the operator's decision-making process while maintaining full machine versatility.
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 approach significantly reduces errors by providing clear, real-time guidance on the correct orientation and positioning of the work piece, enhancing the operator's spatial awareness and reducing the need to interpret graphical representations, thus improving machining accuracy and efficiency.
Implementation Method 1
the indications are projected on the work piece by a laser
Data Source
AI summary
Disclosed is a method for aiding in manual handling of a work piece during machining, which method comprises the steps of: reading a predetermined work plan, comprising a required orientation of the work piece for each machining step of the work plan; detecting the orientation of the work piece; comparing the detected orientation of the work piece with the required orientation; and projecting an indication on the work piece for aiding to manually orient the work piece to the required orientation for the machining step to be performed. Al disclosed is a device for performing the method.