Manufacturing Resource Operating Zones for Compact Factory Layouts
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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 uses geometric operators, such as Hausdorff distance, dilation, and erosion, to automatically determine and combine operating zones based on proximity information and user-defined criteria, creating a compact and intuitive 2D representation of operating zones, which can be used to optimize resource layouts and include safety zones.
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 layout design process is simplified, but the use of factory floor space becomes suboptimal and safety concerns arise
Solution Approach 1:
The patent replaces heuristic manual layout design with an automated computer-implemented method that uses geometric operators (Hausdorff distance, dilation, erosion) to calculate and optimize operating zones. This substitution of manual mechanical design processes with automated computational methods enables optimal space utilization while maintaining ease of operation through software automation.
Solution Approach 2:
The patent transforms the layout design process by changing parameters from fixed heuristic-based zones to dynamically calculated zones using geometric operations. The operating zones are defined through parameterized geometric transformations (dilation with radius r1, erosion with radius r2) that optimize space utilization while ensuring safety distances between resources.
2Measurement precision
If complex geometric operations are performed in three-dimensions, then accurate operating zones are obtained, but computational efficiency decreases
Solution Approach 1:
The patent projects three-dimensional operating zones onto a two-dimensional factory floor plane, performing geometric operations in 2D space rather than 3D. This dimensionality reduction maintains measurement precision for layout purposes while significantly improving computational efficiency. The projection approach calculates operating zones on the relevant 2D plane where resources are actually positioned.
Solution Approach 2:
The patent extracts the essential geometric operations needed for operating zone definition and performs only those specific operations (projection, dilation, erosion, Boolean set operations) required for accurate zone calculation. By taking out and isolating the critical computational steps from full 3D modeling, the system achieves accurate results with reduced computation time.
3Adaptability or versatility
If manual editing of operating zones is allowed, then user flexibility is improved, but the complexity of zone definition increases
Solution Approach 1:
The patent creates virtual copies of operating zones that can be manipulated and edited without affecting the underlying resource configurations. Users can copy, move, and modify zone definitions through graphical interface operations, providing flexibility while keeping the system complexity managed through virtual representation rather than direct resource modification.
Solution Approach 2:
The patent introduces an intermediary graphical user interface layer between users and the complex geometric operations. This intermediary provides intuitive tools for zone editing (selection, movement, resizing) that hide the underlying computational complexity while maintaining user flexibility. The GUI acts as a mediator that simplifies interaction with the sophisticated geometric algorithms.
Data Source
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.