Sheet Metal Bending with Image-Guided Workpiece Positioning

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Solution Overview

Problem

Existing sheet metal workpiece processing machines require significant operator attention and concentration for multiple bending operations, with manual repositioning of stops and initiation of bending processes, leading to potential errors and reduced productivity.

Innovation Solution

A method utilizing a production device with two press beams and a control device with an image recognition program that automatically positions stops, initiates bending deformation, and manages production steps, allowing the operator to focus on workpiece alignment and insertion, with cameras capturing images to determine the workpiece's position and orientation for automated control.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Extent of automation

If automated control with foot switch activation is used, then bending operations can be automated, but operator attention and concentration are still required for timely workpiece handling and repositioning

Engineering Contradiction:

Improvebending operation automationVSAvoidoperator workload

Core Design Contradiction:

Extent of automationVSEase of operation

Solution Approach 1:

The system uses image recognition technology to automatically detect workpiece presence, positioning, and deformation state. The control device autonomously determines when to initiate bending operations and when to transition between production steps, allowing the machine to serve itself rather than requiring continuous operator monitoring and manual activation.

Inventive Principle:

Principle #25Self-service

2Adaptability or versatility

If manual positioning of stops and workpiece insertion is required, then flexibility in workpiece handling is maintained, but productivity is reduced due to repeated manual interventions

Engineering Contradiction:

Improveworkpiece handling flexibilityVSAvoidproduction speed

Core Design Contradiction:

Adaptability or versatilityVSProductivity

Solution Approach 1:

The image recognition system continuously monitors the workpiece and machine state, providing real-time feedback to the control device. This enables automatic adjustment of production timing and stop positioning while maintaining adaptability to different workpiece types and production requirements, thereby increasing productivity without sacrificing flexibility.

Inventive Principle:

Principle #23Feedback

3Reliability

If operator concentration is required for safe operation, then collision prevention is possible, but risk of operator error and injury increases during automatic changes

Engineering Contradiction:

Improvecollision preventionVSAvoidoperator injury risk

Core Design Contradiction:

ReliabilityVSObject-affected harmful factors

Solution Approach 1:

The system replaces manual operator monitoring and decision-making with an automated image recognition and control system. The control device autonomously manages machine operations based on visual feedback, eliminating the need for operator concentration while maintaining safety through automated collision prevention mechanisms and reducing operator exposure to harmful factors.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

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 approach simplifies the operation, reduces operator workload, enhances safety by minimizing manual intervention during bending, and increases productivity by optimizing stop repositioning and ensuring accurate deformation, thus improving overall operational reliability and efficiency.

Implementation Method 1

at least one camera (17) is provided to capture images of the processing area (16), with a control device (10) having an image recognition program (15) for determining the position and alignment of the workpiece (5) from the images captured by the camera (17)

Methodology Applied

Scientific EffectImage recognition: Image Processing

Implementation Method 2

Carrying out the bending deformation by pressing an upper tool against the workpiece and the lower tool by moving the press beams towards one another

Methodology Applied

Scientific EffectMechanical force: Mechanical Force

Data Source

PatentEP3790678B1Method using a manufacturing device for shaping sheet metal

Publication Date: 2022.03.16 TRUMPF MASCHEN AUSTRIA

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AI summary

The invention relates to a method for producing a component by shaping a workpiece (5) made of sheet metal using a manufacturing device (1) comprising bending tools (6, 7) fastened to crossheads (2, 3) and comprising a control means (10) having a manufacturing program (14) for semi-automatic operation of the manufacturing device (1), at least two manufacturing steps (F1, F2) being performed, each comprising shaping by means of bending, and a manufacturing step (F1, F2) comprising: positioning stops (8, 9) for orienting the workpiece (5); placement of the workpiece (5) in the working region (16) by an operator; performing the shaping by means of bending; moving the crossheads (2, 3) away from one another and removal of the workpiece (5) by the operator. After a first manufacturing step (F1), execution of a subsequent second manufacturing step (F2) of the manufacturing program (14) is started, by the working region (16) being captured by a camera (17, 18) and the position and orientation of the workpiece (5) being determined by an image recognition program (15) and, based on the position of the workpiece (5) determined by the image recognition program (15), the subsequent second manufacturing step (F2) being started by the manufacturing program (14).