Manufacturing Resource Layout Using 2D Operating Zone Combination
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Solution Overview
Problem
Current 3D computer graphic modeling and simulation systems face inefficiencies in defining and optimizing resource layouts for manufacturing environments, particularly in combining complex and irregular operating zones, which leads to suboptimal use of factory floor space and safety concerns due to reliance on heuristic methods and prior engineering knowledge.
Innovation Solution
The implementation of a computer-implemented method that projects solid models of kinematic chains onto a plane, applies Boolean set operations, and uses Hausdorff distance with dilation and erosion to define and combine operating zones based on proximity and user-defined criteria, resulting in a compact, intuitive, and efficient representation of resource layouts.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If heuristic methods and prior engineering knowledge are used to define operating zones, then the process is simple and intuitive, but the factory floor space utilization is suboptimal and safety concerns arise
Solution Approach 1:
The patent replaces heuristic human judgment with automated computational geometry algorithms. The system uses Boolean set operations and Hausdorff distance calculations to automatically determine operating zones, substituting the mechanical process of manual layout planning with an automated digital system that optimizes space utilization while maintaining simplicity through algorithmic objectivity.
Solution Approach 2:
The patent transforms the subjective parameter of 'engineering knowledge' into objective mathematical parameters. By using Hausdorff distance as a quantifiable metric and Boolean operations as deterministic rules, the system changes the nature of the parameters from qualitative heuristics to quantitative geometric properties, enabling optimal space utilization without sacrificing operational simplicity.
2Manufacturing precision
If complex Boolean set operations are applied to combine irregular operating zones, then the precision of zone definition improves, but the computational complexity increases
Solution Approach 1:
The patent extracts the essential geometric properties needed for zone combination, focusing only on the boundary representations and spatial relationships. By taking out only the necessary geometric elements (contours, vertices, edges) and applying Boolean operations specifically to these extracted features rather than entire 3D models, the system achieves precise zone definition while reducing computational complexity.
Solution Approach 2:
The patent simplifies the computational problem by projecting 3D operating zones onto 2D planes for the Boolean combination operations. This dimensionality reduction allows complex 3D zone intersections to be handled through 2D contour operations, maintaining precision in the essential spatial relationships while significantly reducing computational complexity.
3Ease of manufacture
If traditional layout planning methods are used, then the process is straightforward, but the ergonomics and safety of manufacturing environments deteriorate
Solution Approach 1:
The patent incorporates safety and ergonomics criteria as feedback parameters in the automated layout optimization process. The system evaluates proposed operating zone configurations against predefined safety distances and ergonomic requirements, providing feedback that guides the Boolean operations and Hausdorff distance calculations to produce layouts that are both simple to implement and safe for workers.
Data Source
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AI summary
Embodiments are directed to methods and systems for automatically determining a resource layout. An example embodiment begins by obtaining data indicating a position and a task performed by each resource of a plurality of resources. Then, for each resource of the plurality, a respective zone on a plane of interest occupied by the resource is automatically determined using the obtained data indicating the position and the task performed by the resource. In turn, determined zones of two or more resources of the plurality of resources are automatically combined into a combined zone based upon criteria and a file, e.g., a CAD/CAM file, indicating a layout of the plurality of resources on the plane of interest is automatically created based upon the determined zones and the combined zone.