Robotic Table Tracking for Continuous Machining Part Exchange
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Solution Overview
Problem
Existing machining processes require stopping the machining tool and opening the enclosure door for part exchange, leading to production losses due to the time-consuming nature of these operations.
Innovation Solution
A robotic table tracking system is implemented inside the machining enclosure, allowing continuous operation by using dual vises and custom tracking software to monitor part positions, enabling the robot to exchange parts without stopping the machining process or opening the door.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If parts are exchanged by opening the enclosure door, then part exchange can be performed, but production time is lost due to stopping the machining process and door operations
Solution Approach 1:
The part exchange operation is segmented into two independent workstations (first workstation and second workstation) positioned on opposite sides of the enclosure. While the machining tool processes a part at one workstation, the robot can simultaneously exchange parts at the other workstation, eliminating the need to stop the machining process for part exchange.
Solution Approach 2:
The system maintains continuous machining operation by implementing parallel operations: the machining tool continuously processes parts at one workstation while the robot simultaneously performs part exchange at the other workstation. This ensures the machining tool never stops running, achieving continuous useful action.
2Extent of automation
If a robot is placed outside the enclosure for part exchange, then part loading and unloading can be performed, but the machining process must be stopped and the door must be opened and closed
Solution Approach 1:
Instead of positioning the robot outside the enclosure (external dimension), the robot is placed inside the enclosure (internal dimension). This allows the robot to access parts at both workstations without requiring door opening and closing, eliminating the time loss associated with door operations while maintaining automatic part loading and unloading.
3Ease of operation
If the machining tool stops for part exchange, then parts can be exchanged, but production efficiency decreases due to machining downtime
Solution Approach 1:
The system prepares part exchange in advance by positioning the robot and parts at the second workstation while the machining tool is still processing at the first workstation. This preliminary preparation allows the robot to immediately exchange parts when the machining cycle completes, eliminating idle time and maintaining continuous production.
Data Source
AI summary
A method and apparatus for controlling a continuous machining process includes a robot, a machining tool, a table, and a raw parts supply mounted inside a machining cell enclosure. The table has first and second vises for holding parts. The machining tool is operated to machine a raw part in one of the vises while the robot is operated to pick a machined part from the other vise and then place another raw part into the other vise. The table can be fixed or rotatable. The robot places the picked machined parts on an exit conveyor to remove the machined parts from the enclosure.