Pallet Image Feedback for Reliable Workpiece Extraction
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Solution Overview
Problem
In jointless processing, the state of products and remaining materials on a pallet can change due to vibrations or other factors during movement, leading to inefficiencies in takeout and discharge, as existing systems do not account for these changes, potentially requiring machine stops and reducing efficiency.
Innovation Solution
A transport control system using an imager to capture pallet images and a processor to determine abnormalities, allowing for adjustments in extraction position and order to ensure proper removal of products and remaining materials, even in cases of deviation or overlap.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Extent of automation
If jointless processing is used to eliminate manual removal, then automation of machining and takeout is achieved, but positional deviation of products and remaining material occurs during pallet movement, causing extraction failures and efficiency decline
Solution Approach 1:
The system performs preliminary imaging of the pallet to detect positional deviations of products and remaining material before the extraction process begins. This advance detection allows the control unit to pre-calculate corrected extraction positions and adjust extraction parameters in advance, preventing extraction failures caused by positional deviations that occur during pallet movement after jointless processing
Solution Approach 2:
The system implements a feedback mechanism where the imager continuously monitors the pallet to detect actual positions of products and remaining material, and the control unit uses this feedback information to dynamically adjust extraction parameters. This closed-loop control ensures that extraction operations remain reliable even when positional deviations occur during pallet movement, maintaining the balance between automation and reliability
2Speed
If the pallet moves after machining, then transport and takeout can proceed, but vibrations cause positional changes that lead to overlap and extraction failure
Solution Approach 1:
The system captures an image of the pallet before extraction to detect positional deviations caused by vibrations during movement. By performing this detection in advance, the control unit can pre-calculate the corrected extraction position and adjust extraction parameters before the actual extraction operation, maintaining positioning precision despite transport-induced deviations
Solution Approach 2:
The control unit dynamically changes extraction parameters (such as extraction position and trajectory) based on the detected positional deviations from the captured image. This parameter adjustment compensates for the positioning errors introduced by pallet movement and vibrations, allowing the system to maintain manufacturing precision during high-speed transport operations
3Ease of operation
If product or remaining material position changes on the pallet, then normal extraction cannot be performed, but stopping the machining tool and transporter to remove the cause reduces machining efficiency
Solution Approach 1:
The system uses real-time feedback from the imager to detect positional changes of products and remaining material on the pallet. The control unit processes this feedback information and automatically adjusts extraction parameters to accommodate the changed positions, enabling smooth extraction operations to continue without stopping the machining tool or transporter, thereby maintaining high machining efficiency
Solution Approach 2:
By capturing the pallet image and detecting positional deviations before extraction, the system performs preliminary correction of extraction parameters. This advance preparation allows the extraction operation to proceed smoothly despite positional changes, eliminating the need to stop the machining process to remove causes of extraction failure and thus preserving productivity
Data Source
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AI summary
[Problem] To provide a transport control system and a normality determination method capable of suppressing a decline in machining efficiency. [Means to Solve Problem] Provided is a transport control system 8 comprising an imager 31 that captures an image of a pallet 6 on which machined workpieces, cut and separated by a machining tool 1, are placed, and a processor 32 that determines a presence or absence of an abnormality based a captured image captured by the imager 31, wherein the processor 32 acquires the captured image including a product Wa and a remaining material Wb as the machining target workpieces from the imager 31, and determines an abnormality if a position of one of the machining target workpieces in the captured image deviates from its proper position.