Press Brake Part Positioning With Orientation Pre-Check
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional laser-vision positioning systems in the machining industry do not adequately inform operators about the correct orientation or identity of raw parts before final placement in machines like press brakes, leading to misplacement and increased scrap rates, especially for non-symmetrical parts.
Innovation Solution
A machine-integrated positioning system that uses a light positioning device and vision system to pre-check the orientation and identity of raw parts at an advanced placement position before allowing them to be moved to the initial forming position, preventing the machine from cycling until correct alignment and orientation are confirmed, and providing feedback to operators through displays or lights.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of information
If conventional laser-vision positioning systems are used to direct operators where to place raw parts, then operators are informed about placement location, but operators are not informed about correct orientation or identity of parts, leading to misplacement and increased scrap rates
Solution Approach 1:
The system performs preliminary verification of part orientation and identity before the forming operation begins. The light positioning device projects reference marks that operators use to correctly orient parts before placement, preventing misplacement and scrap generation in advance
Solution Approach 2:
The system provides visual feedback through projected light patterns and reference marks that indicate to operators whether parts are correctly oriented and positioned. This real-time feedback enables operators to correct placement errors before they result in defective parts
2Productivity
If the machine allows cycling without pre-checking part orientation, then productivity is maintained, but defective finished parts are produced and scrap increases
Solution Approach 1:
The system performs preliminary verification of part orientation and identity before the forming operation begins. The light positioning device projects reference marks that operators use to correctly orient parts before placement, preventing misplacement and scrap generation in advance
Solution Approach 2:
The system provides visual feedback through projected light patterns and reference marks that indicate to operators whether parts are correctly oriented and positioned. This real-time feedback enables operators to correct placement errors before they result in defective parts
3Manufacturing precision
If the positioning system provides detailed orientation guidance, then part placement accuracy is improved, but system complexity increases
Solution Approach 1:
The system uses optical projection to create light-based copies or representations of reference marks and alignment patterns. This optical copying approach provides detailed positioning guidance without requiring complex mechanical measurement or adjustment mechanisms
Solution Approach 2:
The system replaces complex mechanical positioning and measurement devices with optical projection technology. The light positioning device uses projected patterns and visual references to guide operators, eliminating the need for intricate mechanical alignment systems
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 solution minimizes the production of defective finished parts and associated scrap by ensuring correct part orientation and identity before forming, optimizing efficiency and safety in the manufacturing process.
Implementation Method 1
projecting, by the light positioning device, a light beam to the advanced placement position
Implementation Method 2
an alignment of the register mark of the raw part with the light beam projected to the advanced placement position is then detected by the vision system
Data Source
Figure 1
Figure 2~3
Figure 4~5
AI summary
A machine integrated positioning system (10) shows an operator where to place a raw part (20) in the press brake or other machinery (12). Further, the operator is informed if the dimensions associated with the raw part (20) are, or are not, correct to produce the planned finished part (22). The operator is visually shown how the raw part (20) is to be oriented. The operator is informed if the raw part (22) is right-side-up, along with other pre-final placement information. If these and other conditions are not met, the machine integrated positioning system (10) may prevent the press brake and other machinery (12) from cycling.