Robotic Edge Forming with Profile Sensing for Gypsum Board Lines
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Gypsum board manufacturing is inefficient due to long wait times for manual adjustment of forming shoes, wear and tear, and debris accumulation, leading to inefficiencies and waste.
Innovation Solution
An automated edge forming system with robotic devices and sensing technology to detect profiles, adjust edge forming devices, and clean them automatically, ensuring precise positioning and maintenance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If manual adjustment of forming shoes is used, then device complexity is reduced, but productivity decreases due to long wait times
Solution Approach 1:
The forming shoe system performs self-adjustment through the robotic device automatically positioning and adjusting the forming shoes based on profile data, eliminating the need for manual intervention and reducing wait times while maintaining precise positioning
Solution Approach 2:
The patent replaces manual mechanical adjustment with an automated robotic system that uses sensors to detect board profiles and automatically positions forming shoes, substituting human-operated mechanical systems with automated electromechanical systems
2Reliability
If forming shoes are made static, then device complexity is reduced, but reliability decreases due to wear and deterioration
Solution Approach 1:
The forming shoes are made dynamically adjustable rather than static, allowing the robotic device to reposition and reorient them as needed, which extends their operational life and maintains forming quality throughout their service period
Solution Approach 2:
The system continuously monitors board profiles using sensors and uses this feedback to automatically adjust forming shoe positions, ensuring optimal performance and extending the operational life of the forming shoes by adapting to wear and changing conditions
3Manufacturing precision
If continuous contact is maintained, then manufacturing precision is improved, but loss of substance increases due to friction wear
Solution Approach 1:
The forming shoes are dynamically repositioned and reoriented by the robotic device to distribute wear across different surfaces, maintaining precise edge forming while reducing overall material consumption through extended component life
Solution Approach 2:
The system performs preliminary detection of board profiles and pre-adjusts forming shoe positions before contact is made, ensuring optimal positioning that minimizes unnecessary friction and material wear while maintaining precision
4Productivity
If manual cleaning is performed, then device complexity is reduced, but productivity decreases due to downtime
Solution Approach 1:
The forming shoe system performs self-cleaning through the robotic device, which automatically removes debris and contaminants, eliminating the need for manual cleaning interventions and maintaining continuous production
Data Source
AI summary
Methods, apparatuses, systems, computing devices, and/or the like are provided. An example edge forming system may include includes a sensing device configured to detect one or more profiles of one or more objects disposed on a production line. The system may include a robotic device. The robotic device may include a first end and a second end, one or more articulating segments disposed between the first and second ends, and a joint disposed at the first end of the robotic device. The system may include an edge forming device fixedly connected to the joint of the robotic device. The robotic device may be configured to position the edge forming device between an engaged position and a disengaged position. The edge forming device may be configured to engage the one or more objects on the production line when the edge forming device is in the engaged position.