Robotic Gate Cutting Without Jigs Using Sensor Feedback
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Solution Overview
Problem
Existing methods for cutting gates from molded articles require a jig for each type, increasing manufacturing costs and cycle time due to the need for specific setups for different molded articles.
Innovation Solution
A method and system that uses a cutting device movable in an automatic control coordinate system, equipped with sensors to detect the shape of the molded article and determine the position of the gate for precise cutting without the need for jigs, allowing for automated cutting and subsequent handling of the material passage parts.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a jig is prepared for every type of molded article for gate cutting, then cutting precision is maintained, but manufacturing cost increases and cycle time increases
Solution Approach 1:
The patent applies universality by replacing dedicated jigs for each molded article type with a single robotic system equipped with vision sensors and force sensors. This universal system can adapt to different article types through sensor-based positioning and compliance control, eliminating the need for multiple specialized jigs while maintaining cutting precision across various product geometries
Solution Approach 2:
The patent replaces the mechanical jig-based positioning system with a sensor-based detection and control system. Vision sensors capture article geometry and position the gate location, while force sensors provide compliance control during cutting. This substitution eliminates complex mechanical jigs while achieving comparable or superior positioning accuracy through software-based adaptation
2Manufacturing precision
If a jig is prepared for every type of molded article for gate cutting, then stable cutting position is achieved, but manufacturing cycle time increases
Solution Approach 1:
The patent applies preliminary action by using vision sensors to detect and pre-position the molded article and identify gate location before cutting begins. The system captures article geometry in advance, calculates the optimal cutting position, and pre-aligns the cutting tool, eliminating the time-consuming jig setup and positioning operations required in traditional methods
Solution Approach 2:
The patent applies dynamics by implementing a flexible, adaptive positioning system that can quickly adjust to different article types and orientations. The robotic system dynamically adapts its cutting path and positioning strategy based on real-time sensor feedback, allowing rapid changeover between product types without the inertia and setup time associated with fixed jig-based systems
3Manufacturing precision
If multiple jigs are prepared for different molded article types, then cutting accuracy is maintained, but manufacturing cost increases
Solution Approach 1:
The patent applies universality by designing a single robotic cutting system with vision and force sensors that can handle multiple molded article types. This universal system eliminates the need to manufacture, store, and maintain multiple dedicated jigs, significantly reducing tooling costs while maintaining cutting accuracy through sensor-based positioning and adaptive control
Solution Approach 2:
The patent applies copying by using vision sensors to create a digital representation or model of the molded article's geometry and gate location. This virtual copy guides the robotic cutting system, eliminating the need for physical duplicate jigs for each article type while maintaining precise cutting accuracy through digital templating and coordinate mapping
Data Source
AI summary
A method for automatically cutting off a material passage part while reducing manufacturing cost and cycle time. This method includes preparing a cutting device capable of moving in an automatic control coordinate system, placing the molded article without fixing the molded article, detecting a shape of the molded article by a sensor, acquiring a position of the material passage part in the coordinate system, determining a position of a cut spot in the material passage part as a target position in the coordinate system, moving the cutting device in the coordinate system and disposing the cutting device on a work position for cutting the cut spot, and cutting the cut spot by the cutting device arranged on the work position.