Robot Loading Interface for Small-Lot Sheet Handling
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Solution Overview
Problem
Existing sheet metal and wood working machines face inefficiencies in loading and unloading operations, particularly when small lot sizes require manual intervention, leading to high susceptibility to errors and significant setup and calibration costs.
Innovation Solution
A system utilizing a sensor interface, representation unit, user interface, evaluation unit, and planning unit to automate loading and unloading processes, allowing machine operators to provide user inputs for grasping and depositing positions, enabling a loading robot to execute these operations efficiently and accurately.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If automated loading and unloading systems are implemented, then productivity and efficiency are improved, but device complexity and setup costs increase significantly
Solution Approach 1:
The system uses a single camera that serves multiple functions: capturing images of workpieces, determining their positions, and providing data for both loading and unloading operations. This multi-functional approach eliminates the need for separate sensor systems for each function, reducing overall device complexity while maintaining high productivity
Solution Approach 2:
The system creates a digital representation (image) of the physical workpiece arrangement and uses this copy to plan and execute loading/unloading operations. By working with the digital model rather than direct physical measurement, the system simplifies the control architecture and reduces the complexity of real-time sensing requirements
2Measurement precision
If full automation with complex sensor systems is implemented, then measurement precision and reliability are improved, but device complexity and cost increase
Solution Approach 1:
The camera creates a visual copy of the workpiece arrangement, which is then processed to extract position information. This optical copying method achieves sufficient measurement precision without requiring complex coordinate measurement systems or multiple specialized sensors, thereby simplifying the overall device architecture
Solution Approach 2:
The system replaces complex mechanical measurement systems with an optical sensing approach using a camera. This substitution maintains adequate measurement precision for workpiece positioning while significantly reducing mechanical complexity and the number of moving parts required
3Productivity
If automated systems are implemented without manual intervention, then productivity is improved, but susceptibility to errors increases due to setup and calibration requirements
Solution Approach 1:
The system captures images of the actual workpiece arrangement and uses this feedback to adjust the loading plan. By comparing the captured image with the planned arrangement, the system can identify and correct positioning errors, reducing error susceptibility while maintaining high throughput
Solution Approach 2:
The system determines the positions of all workpieces before the loading operation begins, using captured images to create a complete overview. This preliminary assessment allows for error-free planning and execution, avoiding errors that would occur during manual setup and calibration
Data Source
AI summary
A device for loading or unloading sheet metal processing or wood working machine, including: sensor interface that receives information on workpieces in a loading area; representation unit for creating representation of workpieces and loading area, based on sensor signal; user interface for providing representation to machine operator and for receiving user input from machine operator including information on position of workpieces in representation; evaluation unit for determining revised representation of workpieces and loading area, based on sensor signal and user input, interface being designed for providing revised representation to machine operator and for receiving further user input including information on workpiece loading operation carried out; planning unit for determining control instructions enabling loading robot to execute loading operation being carried out based on signal and on further user input; and control interface for activating and controlling loading robot to execute loading operation based on control instructions.