Sensor-Guided Workpiece Loading Without Safety Hatches

Solution Overview

Problem

Existing workpiece processing systems face inefficiencies due to time-consuming and maintenance-intensive operations related to opening and closing hatches for safety, which can be improved by enhancing the safety device to reduce time requirements and maintenance costs.

Innovation Solution

A method for operating a workpiece machining system that employs a safety device with a control unit and sensors to monitor the safety area, allowing the gripper arm of the loading and unloading device to be moved between positions based on detected safety events, eliminating the need for a hatch and enabling compact design and optimized operations.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If a hatch is used to mechanically close or open the loading and unloading opening for safety, then operator safety is ensured, but the system becomes time-consuming and maintenance-intensive

Engineering Contradiction:

Improveoperator safetyVSAvoidtime for opening and closing hatch

Core Design Contradiction:

ReliabilityVSLoss of time

Solution Approach 1:

The patent removes the hatch component entirely from the system and replaces it with a sensor-based safety monitoring system. The first sensor means detects safety-relevant events in the safety area, and the control unit responds by blocking or returning the gripper arm, eliminating the mechanical hatch while maintaining safety functionality.

Inventive Principle:

Principle #2Taking out (Extraction)

Solution Approach 2:

The mechanical hatch system is replaced with an optical/electronic sensing system. Instead of using a physical barrier (hatch) to prevent access, the system uses sensor means to detect intrusions and control unit logic to prevent the gripper arm from operating when safety conditions are not met, substituting mechanical protection with electronic control.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

2Reliability

If a hatch is used to mechanically close or open the loading and unloading opening for safety, then operator safety is ensured, but maintenance costs increase

Engineering Contradiction:

Improveoperator safetyVSAvoidmaintenance of hatch mechanism

Core Design Contradiction:

ReliabilityVSEase of repair

Solution Approach 1:

The patent removes the hatch component entirely from the system and replaces it with a sensor-based safety monitoring system. The first sensor means detects safety-relevant events in the safety area, and the control unit responds by blocking or returning the gripper arm, eliminating the mechanical hatch while maintaining safety functionality.

Inventive Principle:

Principle #2Taking out (Extraction)

Solution Approach 2:

The mechanical hatch system is replaced with an optical/electronic sensing system. Instead of using a physical barrier (hatch) to prevent access, the system uses sensor means to detect intrusions and control unit logic to prevent the gripper arm from operating when safety conditions are not met, substituting mechanical protection with electronic control.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

3Reliability

If a hatch is installed on the machine tool for safety, then operator protection is provided, but the machine tool design becomes more complex

Engineering Contradiction:

Improveoperator protectionVSAvoidmachine tool structure

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The patent removes the hatch component entirely from the system and replaces it with a sensor-based safety monitoring system. The first sensor means detects safety-relevant events in the safety area, and the control unit responds by blocking or returning the gripper arm, eliminating the mechanical hatch while maintaining safety functionality.

Inventive Principle:

Principle #2Taking out (Extraction)

Solution Approach 2:

The mechanical hatch system is replaced with an optical/electronic sensing system. Instead of using a physical barrier (hatch) to prevent access, the system uses sensor means to detect intrusions and control unit logic to prevent the gripper arm from operating when safety conditions are not met, substituting mechanical protection with electronic control.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Data Source

PatentEP3428749B1Method for operating a workpiece machining system and workpiece machining system

Publication Date: 2021.07.28 SW AUTOMATION GMBH

Figure 1~2
Figure 3~4
Figure 5

AI summary

The invention relates to a workpiece machining system (2), which is particularly operable according to a method of claims 1 to 7, with at least one machine tool (4) comprising at least one loading and unloading opening and at least one safety area (8), with at least one loading and unloading device (10) comprising at least one support (12) and at least one loading and unloading device (14) movable along the support (12) and, in particular, multi-axis, wherein the loading and unloading device (14) can be arranged in a loading and unloading position in front of at least one of the at least one machine tool (4) and at least one gripper arm of the loading and unloading device (14) can be moved from a travel position, in which the gripper arm (28) is arranged substantially above the support (12), into an engagement position.in which the gripper arm (28) projects laterally beyond the support (12) and is arranged in or above the loading and unloading opening (6) of the machine tool (4), and with at least one safety device (24) for monitoring the safety area (8) of the at least one machine tool (4), which has at least one control unit (26) that is functionally assignable to or associated with the loading and unloading device (10) and at least one first sensor means (22) arranged in or on the safety area (8).