Press Brake Part Positioning With Orientation Verification
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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, leading to potential misplacement and defective finished parts, especially for non-symmetrical parts.
Innovation Solution
A machine-integrated positioning system that includes a vision device and a controller, which detects the alignment of a register mark on the raw part using a light positioning device, preventing the machine from operating unless the part is correctly oriented and positioned, and providing feedback to the operator through digital displays or alarms.
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 provided with basic positioning guidance, but the systems fail to inform operators about correct orientation or identity of raw parts, leading to potential misplacement and defective finished parts
Solution Approach 1:
The vision device performs detection of register mark alignment before the forming operation commences. The controller evaluates the alignment data and determines whether the raw part is correctly oriented and positioned prior to machine operation, preventing defective parts from being produced in the first place
Solution Approach 2:
The vision device provides real-time feedback to the controller about the alignment status of the register mark. The controller uses this feedback to either permit or prevent machine operation, creating a closed-loop control system that ensures only correctly oriented parts are processed
2Manufacturing precision
If the machine operates without integrated positioning verification, then manufacturing productivity is maintained, but defective parts are produced due to incorrect part orientation or placement
Solution Approach 1:
The alignment verification is performed in advance of the forming operation, allowing defective parts to be identified and corrected before they consume machine cycle time. This preliminary check prevents waste of productivity on incorrect parts
Solution Approach 2:
The integrated positioning system automatically verifies part orientation and provides feedback without requiring manual inspection or intervention. The system self-regulates by preventing machine operation when misalignment is detected, ensuring precision without sacrificing productivity
3Reliability
If laser sensors are used for safety purposes to detect persons in dangerous areas, then operator safety is improved, but the system cannot verify correct part orientation or prevent defective part formation
Solution Approach 1:
The vision device serves multiple functions: it provides safety monitoring similar to laser sensors while simultaneously performing precise measurement of register mark alignment to verify correct part orientation and identity. One device accomplishes both safety and quality verification tasks
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 system ensures correct orientation and identity verification of raw parts before forming, minimizing scrap and defective parts by preventing machine operation until alignment is confirmed, thus enhancing manufacturing efficiency and safety.
Implementation Method 1
The light positioning device is configured to project a light beam to at least one of the raw parts station, the initial forming position, and the finished parts station
Implementation Method 2
The vision device is configured to detect an alignment of the register mark of the raw part with the light beam projected by the laser device
Data Source
AI summary
A machine integrated positioning system shows an operator where to place a raw part in the press brake or other machinery. Further, the operator is informed if the dimensions associated with the raw part are, or are not, correct to produce the planned finished part. The operator is visually shown how the raw part is to be oriented. The operator is informed if the raw part is right-side-up, along with other pre-final placement information. If these and other conditions are not met, the machine integrated positioning system may prevent the press brake and other machinery from cycling.