Raw Stock Sheet Alignment Using Sensors and Air Jets
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional methods for aligning raw stock sheets in aircraft production are prone to damage the sheets, especially thinner ones, and are often laborious and error-prone, leading to inconsistencies in the manufacturing process.
Innovation Solution
An automated racking system using color detection sensors, proximity sensors, a lifting mechanism, and compressed air jets to accurately position and align raw stock sheets without physical contact, ensuring precise placement on worktables.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If manual alignment methods are used for raw stock sheets, then flexibility in handling is maintained, but the risk of damage to sheets increases and manufacturing precision deteriorates
Solution Approach 1:
The patent replaces manual mechanical alignment operations with an automated system using sensors (optical, capacitive, inductive) and computer-controlled positioning mechanisms. This substitution eliminates human error and physical contact that could damage sheets, while achieving higher alignment precision through automated detection and adjustment
Solution Approach 2:
The patent introduces sensors and computer control systems as intermediaries between the operator and the sheet alignment process. These intermediaries detect sheet position, orientation, and dimensions without physical contact, then transmit this information to positioning mechanisms that make precise adjustments, thereby protecting sheets from damage while improving alignment accuracy
2Manufacturing precision
If automated sensing systems are implemented for sheet alignment, then manufacturing precision is improved, but device complexity increases
Solution Approach 1:
The patent employs multi-functional sensors that can detect multiple parameters (position, orientation, dimensions) simultaneously, and a computer control system that manages sensing, calculation, and actuation functions. This multi-functionality reduces the number of separate components needed, thereby managing device complexity while achieving high alignment precision
Solution Approach 2:
The automated system performs self-measurement and self-adjustment of sheet alignment without requiring external intervention. The sensors automatically detect sheet parameters, the computer calculates required adjustments, and the positioning mechanisms execute corrections, creating a self-service system that improves precision while containing complexity through integration
3Productivity
If traditional handling equipment is used for raw stock sheets, then ease of operation is maintained, but productivity decreases due to labor-intensive processes
Solution Approach 1:
The patent replaces labor-intensive manual handling and alignment operations with automated mechanical systems controlled by computers. This substitution eliminates the need for operators to manually position and measure sheets, significantly improving productivity while the system maintains ease of operation through automated decision-making and execution
Solution Approach 2:
The automated system enables continuous operation by eliminating the intermittent manual intervention required in traditional processes. Sheets can be processed continuously through automated sensing, calculation, and positioning operations, improving manufacturing efficiency while the integrated control system maintains operational simplicity
Data Source
AI summary
This disclosure provides methods, components, devices, and systems for providing positioning and alignment of raw stock sheets during the manufacturing process. Some aspects, more specifically, relate to detecting a position of a raw stock sheet lifted from an initial position using proximity sensors and realigning the sheet to a desired position. Current techniques can cause misalignment or damage to sheets during placement. In some aspects, a raw stock sheet can be analyzed by a plurality of sensors to accurately and consistently place raw stock sheets from an initial position to a desire position for downstream manufacturing processes.