Sheet Sorting Handler Control for Uneven Transfer Grid Wear
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Solution Overview
Problem
In metal sheet handling during laser cutting, the variable and uneven wear of the transfer board grid due to repeated interactions with the laser beam causes issues in accurately adjusting the gripping height of handlers, leading to potential errors in drawing cut pieces and scrap, with existing solutions either being costly or burdensome in terms of equipment replacement or additional sensor installation.
Innovation Solution
The control logic of the sorting machine is interfaced with the cutting centre's control logic to utilize altitude data from the cutting head's distance sensor, creating a map of the metal sheet surface altitude and underlying grid wear, allowing the handlers to adjust their position accurately and adapt to local wear patterns without additional sensors or premature grid replacement.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the gripping height of handlers is fixed, then the device complexity is reduced, but the reliability of gripping decreases due to uneven grid wear
Solution Approach 1:
The system dynamically changes the gripping height parameter based on detected grid wear. The control unit receives wear information from the detection device and adjusts the gripping height accordingly, allowing the handler to adapt to uneven grid wear without requiring complex mechanical adjustments or multiple sensors throughout the system.
Solution Approach 2:
A feedback loop is established where the detection device continuously monitors grid wear, sends this information to the control unit, which then adjusts the gripping height in real-time. This feedback mechanism ensures reliable gripping while maintaining relatively simple device architecture by using centralized control rather than distributed adjustment mechanisms.
2Measurement precision
If additional height detectors are installed on each handler, then the measurement precision of grid wear is improved, but the device complexity and cost increase
Solution Approach 1:
The detection device serves multiple functions: it detects grid wear at various positions, provides data for height adjustment, and can potentially monitor overall grid condition. By using a single multi-functional detection system rather than multiple specialized sensors, the measurement precision is maintained while device complexity is reduced.
Solution Approach 2:
The control unit acts as an intermediary that processes detection data and translates it into appropriate gripping height adjustments. This mediator approach allows one detection device to serve multiple measurement needs without requiring direct sensor-to-actuator connections for each measurement point, thereby reducing system complexity while maintaining precision.
3Reliability
If the transfer board grid is replaced frequently, then the reliability of gripping is maintained, but the productivity and cost of the system decrease
Solution Approach 1:
The detection device performs preliminary assessment of grid wear before it reaches critical levels. By detecting wear early and adjusting gripping parameters proactively, the system maintains reliable gripping without needing to replace the grid frequently, thus avoiding productivity losses from shutdowns and replacements.
Solution Approach 2:
Instead of a static grid replacement schedule, the system dynamically adapts to grid wear conditions by adjusting gripping height in real-time. This dynamic approach extends the usable life of the grid while maintaining gripping reliability, thereby improving overall system productivity by reducing unnecessary replacements and downtime.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This solution enables accurate and efficient gripping of metal sheets and scrap, avoiding errors and extending the life of the transfer board by allowing precise adjustment to uneven grid wear, reducing the need for frequent replacements and additional sensor installations.
Implementation Method 1
a distance sensor, mounted on the cutting head, for detecting, position by position, the altitude of a surface of the metal sheet
Data Source
Figure 1
Figure 2~3
Figure 4A~4B
AI summary
A method and a cutting system for sheets comprising at least a cutting centre (L), a sorting apparatus (S) provided with handlers (1-4) for gripping pieces cut by said cutting centre and a transfer board (5), movable between an area where said handlers (1-4) operate and the inside of the cutting centre (L), apt to support said sheets, said cutting centre (L) comprising at least a cutting head (L1), which is mounted movable above said transfer board (5) and is provided with a distance detection sensor which detects distance data with respect to a sheet to be cut resting on said transfer board (5), said transfer board (5) comprising a resting grid (5c) which is partly worn by said cutting head (L), said cutting centre (L) and said sorting apparatus (S) have respective first and second control logics, and wherein data interface means are furthermore provided, between said first control logic of the cutting centre (L) and said second control logic of the sorting apparatus (S), by which said distance data, acquired by said distance detection sensor, are transferred and said second control logic has processing means for defining, periodically during operation cycles, an altitude map based on said distance data detected in a number of positions, and for controlling a gripping step of said handlers (1-4) based on said altitude map.