Sheet Metal Gripping With Laser Scan Detachment Detection
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Solution Overview
Problem
Existing detection systems for checking the complete detachment of finished pieces from sheet metal after cutting and/or punching in automatic machines suffer from low resolution, slow scanning times, or are expensive and difficult to set up, leading to inefficient and unreliable piece removal.
Innovation Solution
A method and system utilizing a laser scanner sensor with a polarized retro-reflective amplified photosensor and a brushless electric motor to quickly and accurately scan the work surface for residual connections between pieces and the sheet metal, ensuring precise detection and efficient piece removal.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If a rotating head laser scanner is positioned at a distance from the work surface to avoid hindering piece picking, then the detection range is sufficient, but the resolution becomes low and sometimes lower than the thickness of pieces and sheet metal
Solution Approach 1:
The detection system uses a movable carriage that can dynamically adjust its position along the first direction to change the scanning distance from the work surface. This allows the system to optimize resolution by moving closer to pieces requiring detailed inspection while maintaining adequate range for overall surface scanning, thereby resolving the contradiction between detection range and resolution.
2Productivity
If multiple laser sensors are spaced apart and moved together to reduce scanning time, then the scanning speed increases, but the system complexity increases
Solution Approach 1:
The work surface scanning is divided into multiple segments, each scanned by a single laser sensor positioned at different locations along the first direction. The controller coordinates these segmented scanning operations to occur in parallel or sequence, achieving high scanning speed equivalent to multiple sensors while maintaining system simplicity through the use of fewer physical components.
3Reliability
If vision systems are used to detect piece geometry and identify gaps, then detection capability is enhanced, but the system becomes expensive and difficult to set up and adjust
Solution Approach 1:
The system replaces complex vision systems with a simplified optical detection approach using laser sensors that emit laser beams and receive reflections. This substitution maintains reliable detection capability for identifying piece geometry and gaps while dramatically reducing system complexity, cost, and setup requirements by using straightforward optical components rather than sophisticated vision processing systems.
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
Enables rapid and precise detection of complete detachment, reducing scanning time to a few tenths of a second per piece, enhancing the reliability and efficiency of the gripping and moving process.
Implementation Method 1
laser sensors capable of emitting a laser beam and receiving its reflection
Implementation Method 2
a laser scanner sensor with a polarized retro-reflective amplified photosensor
Implementation Method 3
a laser scanner sensor with a polarized retro-reflective amplified photosensor
Data Source
AI summary
A method for gripping and moving worked pieces obtained by cutting and/or punching at least one sheet metal and arranged on a work surface includes positioning a gripping assembly at a piece to be picked up and at the same time positioning a sensor device by moving it along a first direction in a first position in which the sensor device is aligned with a projection of a peripheral edge of the piece along a second direction orthogonal to first direction, and grasping and lifting the piece at a defined height with respect to the work surface by the gripping assembly. The method also includes activating the sensor device and moving it to a second position to scan a settled portion of work surface that is below the lifted piece in order to detect a gap or a residual connection between lifted piece and the sheet metal.