Remote Tele-Programming for Real-Time Manufacturing Equipment Control
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Solution Overview
Problem
Industrial welding faces challenges due to a decreasing number of skilled users, hazards, and inaccessible manufacturing facilities, necessitating systems that allow experienced users to operate remotely and safely.
Innovation Solution
A tele-programming system that uses sensors to gather data, a processor to transform motion inputs into commands, and a manual controller to program manufacturing equipment remotely, with real-time execution and haptic feedback.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If manual controller is positioned physically remote from equipment, then operational safety is improved and accessibility to hazardous areas is reduced, but control precision and real-time responsiveness deteriorate
Solution Approach 1:
A computer serves as an intermediary between the manual controller and manufacturing equipment. The controller sends commands to the computer, which processes them and sends instructions to the equipment. This mediator enables physical separation while maintaining precise control through digital communication channels.
Solution Approach 2:
The patent replaces direct mechanical control connections with electronic/digital communication systems. Motion inputs from the manual controller are converted to digital signals, processed by software, and transmitted electronically to control the equipment, eliminating the need for direct mechanical coupling.
2Productivity
If manufacturing facilities are designed to optimize weight and space, then productivity and resource efficiency are improved, but human accessibility and ease of programming deteriorate
Solution Approach 1:
The computer acts as a mediator that enables operators to program and control equipment from remote locations. This allows manufacturing facilities to be designed with optimized space utilization while maintaining operator accessibility through remote interfaces rather than requiring physical presence in cramped or hazardous areas.
3Adaptability or versatility
If motion input is transformed through mathematical transformation, then control adaptability and coordination accuracy are improved, but system complexity increases
Solution Approach 1:
The patent employs mathematical transformations to convert motion input parameters into equipment control parameters. This allows the system to adapt to different equipment types and motion requirements by transforming coordinates, velocities, and accelerations appropriately, providing versatility without requiring hardware changes.
4Manufacturing precision
If teachpoints are saved frequently during programming, then program accuracy and repeatability are improved, but data processing time and storage requirements increase
Solution Approach 1:
The system automatically determines when to save teachpoints based on predefined criteria such as minimum distance thresholds or time intervals, without requiring manual intervention. This self-service approach balances program accuracy with efficient data processing by saving points only when necessary.
Data Source
AI summary
Systems and methods for programming equipment used for or related to a manufacturing process, comprising installing equipment in a manufacturing environment; positioning a plurality of sensors within the manufacturing environment in proximity to the equipment, wherein the plurality of sensors are configured to gather data from the manufacturing environment; connecting at least one processor to the plurality of sensors, wherein the at least one processor includes software for receiving data from the plurality of sensors and the equipment; wherein the software on the processor mathematically transforms the motion input into corresponding motion commands, wherein the equipment, which is physically remote from the at least one controller, executes the motion commands in real-time; and by the software, saving a teachpoint in a program file.