Portioning Apparatus Calibration Using Scanned Workpiece Geometry
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Solution Overview
Problem
Current calibration methods for high-speed portioning machines are time-consuming, requiring up to three hours and involving numerous test cuts with simulated workpieces, leading to significant downtime, especially when routine calibration or maintenance is needed.
Innovation Solution
A method involving loading targets on a conveyor, scanning, marking, and rescanning to calibrate the position of cutters relative to the scanner, using specific cutting patterns and shapes to accurately determine and adjust the cutter positions, reducing the number of calibration cycles and time required.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If traditional calibration methods using simulated workpieces with multiple test cuts are used, then manufacturing precision of cutter positioning is improved, but loss of time increases significantly (up to three hours)
Solution Approach 1:
The system performs preliminary scanning of the workpiece to obtain its three-dimensional characteristics before calibration. This preliminary information about the workpiece geometry is stored and used during the calibration process to guide the cutter positioning, eliminating the need for multiple iterative test cuts with simulated workpieces.
Solution Approach 2:
The invention creates a digital copy or model of the workpiece through scanning, which is then used for calibration purposes. Instead of using physical simulated workpieces that require multiple cuts and measurements, the system uses the scanned digital representation to determine accurate cutter positions, dramatically reducing calibration time while maintaining precision.
2Manufacturing precision
If multiple iterative calibration cycles are performed to achieve accurate positioning, then manufacturing precision is improved, but productivity decreases due to repeated calibration cycles
Solution Approach 1:
The invention replaces the mechanical iterative trial-and-error calibration process with an information-based system. By using scanning technology to capture workpiece geometry and computationally determining cutter positions based on this data, the system eliminates the need for repeated mechanical test cuts and physical adjustments, thereby improving productivity while maintaining portioning accuracy.
Solution Approach 2:
The system introduces an intermediary computational process that translates scanned workpiece geometry into precise cutter positioning instructions. This intermediary step allows the system to determine accurate positions without requiring multiple physical calibration cycles, thus resolving the contradiction between precision and productivity.
3Measurement precision
If detailed scanning and multiple measurement points are used, then measurement precision of workpiece characteristics is improved, but device complexity increases
Solution Approach 1:
The scanning system is designed to perform multiple functions: it scans the workpiece geometry for calibration purposes, stores the three-dimensional characteristics, and provides the data for determining cutter positions. This multi-functional approach eliminates the need for separate measurement devices and complex calibration apparatus, reducing overall system complexity while maintaining high measurement precision.
Data Source
AI summary
The calibrating system 100 includes a conveyance system 102 for carrying work products 104 arranged in multiple lanes extending along the conveyor to be trimmed and/or cut into portions P. A scanner 110 scans the work product and a cutter system 120 consisting of one or more cutters are arranged in an array or series of cutter assemblies for cutting the work products into end pieces P of desired sizes or other physical parameters. A processor/computer 150, using a scanning program or portioning program, determines how the work product may be portioned into one or more end piece product sets. The processor/computer using the portioning software then functions as a controller to control the cutter system 120 to portion the workpiece 104 according to the selected end product/pieces P.