Robotic Curve Folding of 2D Sheets Into Complex 3D Forms
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Solution Overview
Problem
Conventional methods for bending or folding two-dimensional sheet materials into three-dimensional shapes are limited, requiring multiple parts and welding, and cannot incorporate complex volumes without additional folds, restricting design and material usage.
Innovation Solution
A method using a computer device to define primary and secondary surfaces and their geometrical relationship, enabling digital instructions for curve folding by industrial robots, allowing for fully developed spreading and folding of two-dimensional sheets into three-dimensional objects without piecing together multiple parts, and enabling the creation of complex volumes without additional folds.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If conventional bending methods using dies are used, then bending force can be controlled, but the design is constrained by tool dimensions and requires multiple parts to be pieced together
Solution Approach 1:
The invention segments the bending process into discrete digital instructions that can be executed sequentially by robotic systems, allowing complex three-dimensional shapes to be formed from single continuous sheet pieces without requiring physical segmentation into multiple parts
Solution Approach 2:
The invention replaces conventional mechanical die-based bending systems with a digital instruction system that guides robotic actuators, substituting physical tool constraints with software-controlled processes that can form complex geometries without additional parts or welding
2Adaptability or versatility
If sequential folding in one dimension is used, then construction of three dimensional objects is possible, but material usage and design flexibility are constrained
Solution Approach 1:
The invention transitions from sequential one-dimensional folding to simultaneous multi-dimensional folding by defining fold lines across multiple dimensions in digital space, enabling the formation of complex three-dimensional shapes from single two-dimensional sheets with improved material utilization
Solution Approach 2:
The invention performs preliminary digital development and simulation of the folding process before physical manufacturing, allowing optimization of fold patterns and material layout to minimize waste and achieve complex geometries without trial-and-error physical prototyping
3Productivity
If complex volumes are incorporated without additional folds, then manufacturing efficiency improves, but conventional methods cannot achieve this
Solution Approach 1:
The invention creates accurate digital copies and simulations of the folding process and final three-dimensional geometry, allowing verification and optimization of complex volume formations before physical execution, ensuring both efficiency and precision
Solution Approach 2:
The invention introduces dynamic control of the folding process through real-time adjustment of digital instructions based on material feedback, enabling complex volumes to be formed with high precision while maintaining manufacturing efficiency through adaptive process control
Data Source
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AI summary
The present disclosure generally relates to material processing of a two dimensional sheet like material into a desired three dimensional shape object. In more detail, this disclosure inter alia presents carriers (500) comprising computer programs. The computer programs comprise instructions (510) and are for use in computer devices and industrial robots used in material processing of a two dimensional sheet like material.