Robotic Trimming of Contoured Polymeric Panels From 3D CAD
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Solution Overview
Problem
Existing methods for producing contoured architectural panels, particularly double-curved ones, face inefficiencies due to the need for unique molds for each shape, and there is a need for further improvements in panel trimming processes.
Innovation Solution
A method involving a robotic arm that attaches to a thermoformed panel, removes it from the mold, trims its edges using a cutting router controlled by 3D drawing software, and deposits it at a collection station, enabling efficient trimming of contoured polymeric panels.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If traditional wooden or foam molds are used for panel forming, then each panel shape can be produced with high precision, but different tools are required for each shape which reduces manufacturing efficiency
Solution Approach 1:
The patent applies universality by using a single programmable robotic arm to perform multiple trimming operations on different panel shapes. The robotic arm can be reprogrammed via 3D CAD software to accommodate various panel geometries, replacing the need for multiple dedicated wooden or foam molds. This multi-functional approach maintains precision while significantly improving manufacturing efficiency.
2Manufacturing precision
If multiple unique molds are created for different panel shapes, then each shape can be produced accurately, but the complexity and cost of tooling increases
Solution Approach 1:
The patent applies parameter changes by using 3D CAD software to programmatically control the robotic arm's movement parameters. Instead of creating physically different molds for each panel shape, the system changes the digital parameters (coordinates, paths, speeds) of the single robotic arm to accommodate various shapes. This dramatically reduces tooling complexity while maintaining manufacturing precision.
3Adaptability or versatility
If manual trimming methods are used for contoured panels, then flexibility in handling different shapes is maintained, but trimming precision and consistency deteriorates
Solution Approach 1:
The patent applies mechanics substitution by replacing manual trimming operations with an automated robotic arm system. The robotic arm, controlled by 3D CAD software, substitutes human operators to perform trimming operations. This maintains adaptability to different shapes through programmable control while significantly improving edge trimming precision and consistency through automated, repeatable movements.
4Productivity
If a single tool is used to produce various panel components, then manufacturing efficiency improves, but the precision and quality of each specific shape may deteriorate
Solution Approach 1:
The patent applies copying by using 3D CAD software to create digital models of the final panel shapes. These digital copies serve as precise templates that guide the robotic arm's trimming operations. The robotic arm effectively copies the desired geometry from the digital model, ensuring that even though a single tool is used for various panels, the precision and quality of each specific shape are maintained through accurate digital replication.
Data Source
AI summary
A method for trimming a thermoformed panel comprises the steps of opening a thermoforming mold to reveal the thermoformed panel, attaching a robotic arm holding means to the thermoformed panel, removing the thermoformed panel from the thermoforming mold by the robotic arm holding means, repositioning the robotic arm holding means over a trimming table, the table comprising a cutting router affixed to the table bed, moving the robotic arm holding means relative to the cutting router in directions to trim all edges of the panel to required panel dimensions, moving the robotic arm and trimmed panel to a panel collection station, and depositing the trimmed panel at the collection station, wherein the directional movement of the robotic arm is controlled by input from 3-dimensional drawing software of the final shape of the thermoformed panel, and wherein the thermoformed panel is of a polymeric material.