Panel Processing Assembly with Optical Profile Correction
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Solution Overview
Problem
The complexity of setting up processing systems for panel-shaped workpieces requires extensive time due to the empirical coordination of multiple processing units, leading to subjective and non-reproducible optimal results, and existing quality monitoring methods fail to detect undercuts and align cameras accurately, resulting in parallax errors and inability to correct active errors.
Innovation Solution
A method that determines deviations in the actual profile geometry compared to a target geometry, allowing for precise correction values to be applied to processing units, such as adjusting tool exchange and conveying speed, using non-contact measuring devices like cameras and lasers, or touch sensors to ensure high-quality production by aligning processing units and maintaining geometric accuracy.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If empirical coordination of multiple processing units is used, then processing units can be set up, but set-up time becomes excessively long and results are non-reproducible
Solution Approach 1:
The patent replaces the manual empirical coordination process with an automated optical measurement and control system. Cameras and lasers automatically measure workpiece geometry, and a control system automatically adjusts processing unit parameters based on measured data, eliminating subjective operator involvement and dramatically reducing set-up time while improving reproducibility
Solution Approach 2:
The processing system performs self-adjustment through automated feedback loops. The measurement system continuously monitors workpiece geometry, and the control system automatically modifies processing unit parameters to maintain optimal settings, enabling the system to self-correct without manual intervention during operation
2Ease of operation
If cameras are aligned for quality monitoring, then monitoring can be performed, but parallax errors occur and undercuts cannot be detected
Solution Approach 1:
The patent employs multiple cameras positioned at different spatial locations and angles to capture workpiece geometry. By using triangulation from multiple viewpoints and incorporating depth information from laser scanning, the system eliminates parallax errors and can detect undercut features that would be hidden from a single camera viewpoint
Solution Approach 2:
The patent introduces laser projection as an intermediary to create known reference patterns on the workpiece surface. These projected patterns serve as measurement references that enable accurate geometric determination without requiring precise camera alignment, as the laser patterns provide built-in spatial references for the measurement system
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 method enables precise detection and correction of profile geometry deviations, ensuring high-quality production by aligning processing units and maintaining geometric accuracy, thereby increasing throughput and the useful life of processing devices.
Implementation Method 1
with at least one laser for irradiating the profile and at least one camera for detecting the irradiated profile
Data Source
Figure 1
Figure 2a~2b
Figure 3
AI summary
The invention relates to a method for operating at least one processing device and a processing system with at least one processing device. Such a processing device can be a processing device for machining, in particular plate-shaped, workpieces, which is used, for example, in the furniture and building component industries.