Panel Machining Profile Feedback for Faster Setup Accuracy
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Solution Overview
Problem
The existing machining systems for panel-shaped workpieces face significant setup challenges due to the complexity of adjusting multiple machining units, leading to lengthy setup times and subjective quality control, with issues like tool wear and temperature stabilization affecting dimensional accuracy and reproducibility.
Innovation Solution
A method involving machining a workpiece to determine its actual profile geometry, comparing it to a target geometry, and outputting corrective values for machining units to adjust their settings, using contactless or contact sensors to ensure precise alignment and quality control, allowing for continuous improvement during the manufacturing process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If empirical adjustment of multiple machining units is performed manually, then the machining system can be set up, but the setup time becomes excessively long and the results are not reproducible
Solution Approach 1:
The patent replaces manual empirical adjustment with an optical measurement system (lasers and cameras) that automatically detects profile geometry. This substitution of mechanical/manual adjustment with optical measurement and automated feedback eliminates subjective aspects and dramatically reduces setup time while maintaining high precision.
Solution Approach 2:
The patent implements a feedback loop where the actual profile geometry is measured by lasers and cameras, compared to target geometry, and corrective values are automatically generated to adjust machining units. This closed-loop feedback system ensures reproducible results and eliminates the need for lengthy manual trial-and-error adjustment.
2Reliability
If multiple machining units are adjusted manually based on user experience, then the system can operate, but the quality control becomes subjective and non-reproducible
Solution Approach 1:
The patent replaces subjective manual judgment with objective optical measurement systems. Lasers and cameras provide quantifiable data about profile geometry, eliminating variability between different operators and ensuring reproducible quality control across different production runs.
Solution Approach 2:
The measurement system automatically compares actual profile geometry with target geometry and generates corrective values without human intervention. The system self-corrects by providing adjustment instructions to machining units, eliminating dependence on operator experience and ensuring consistent quality.
3Measurement precision
If traditional measurement methods with cameras are used, then workpiece quality can be monitored, but parallax errors occur and undercuts cannot be detected
Solution Approach 1:
The patent uses multiple lasers positioned at different locations to illuminate the workpiece profile from various angles. This segmentation of the measurement function across multiple light sources enables detection of complex profile features including undercuts that would be invisible from a single viewpoint.
Solution Approach 2:
The patent transitions from 2D camera-based measurement to 3D optical measurement using multiple lasers and triangulation. This dimensional enhancement eliminates parallax errors by creating direct geometrical relations between measured results and actual contour through three-dimensional spatial measurement.
Data Source
AI summary
The invention relates to a method for operating at least one machining apparatus as well as a machining system with at least one machining apparatus. Such a machining apparatus can be a machining apparatus for machining workpieces, in particular panel-shaped workpieces, which are used, for example, in the furniture and component industry.