Shoe Upper Tool Paths Using 3D Bite Line Boundaries

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Solution Overview

Problem

The automated manufacturing of athletic shoes faces challenges due to the pliable nature of materials used, making optimal tool paths for processing shoe parts variable and difficult to achieve, leading to potential failures in bonding due to inadequate adhesive application, which can result in costly waste and environmental issues.

Innovation Solution

The system generates tool paths for the application of adhesives and other treatments by demarcating a bite line on the shoe upper, using conditionally visible or virtual markings, to ensure precise application within the first surface region, thereby guiding the processing tools to apply adhesives only where necessary, reducing waste and ensuring strong bonding.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If an increased amount of adhesive is applied to ensure adequate coverage, then bonding reliability is improved, but material waste increases and environmental harm worsens

Engineering Contradiction:

Improvebonding reliabilityVSAvoidadhesive waste

Core Design Contradiction:

ReliabilityVSLoss of substance

Solution Approach 1:

The system performs preliminary scanning and virtual modeling of the shoe parts before adhesive application. The tool path is planned and optimized in advance using digital twins and simulations, allowing the adhesive applicator to follow precise predetermined paths that ensure complete coverage without over-application, thereby reducing adhesive waste while maintaining bonding reliability

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The system incorporates real-time feedback mechanisms where sensors monitor the adhesive application process, and the control system adjusts the tool path and application parameters dynamically. This closed-loop control ensures that adhesive is applied only where needed and in the correct amount, preventing both inadequate coverage and excessive material usage

Inventive Principle:

Principle #23Feedback

2Reliability

If an increased amount of adhesive is applied to prevent bonding failure, then bonding reliability is improved, but harmful effects increase due to incomplete curing and environmental damage

Engineering Contradiction:

Improvebonding reliabilityVSAvoidenvironmental harm and incomplete curing

Core Design Contradiction:

ReliabilityVSObject-generated harmful factors

Solution Approach 1:

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The system dynamically adjusts adhesive application parameters such as flow rate, application speed, and layer thickness based on real-time feedback and pre-planned tool paths. By optimizing these parameters, the system ensures that adhesive is applied in the precise amount needed for complete curing, preventing harmful effects from over-application while maintaining bonding reliability

Inventive Principle:

Principle #35Parameter changes

3Reliability

If adhesive is applied to ensure complete coverage, then bonding reliability is improved, but adhesive material may extend beyond desired areas causing discoloration and soiling

Engineering Contradiction:

Improvebonding reliabilityVSAvoidadhesive application precision

Core Design Contradiction:

ReliabilityVSManufacturing precision

Solution Approach 1:

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The system replaces manual or less precise mechanical adhesive application methods with an automated robotic system that follows digitally generated tool paths. This substitution enables precise control over adhesive application, ensuring that adhesive is deposited only within the desired boundaries while maintaining complete coverage for reliable bonding

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

4Manufacturing precision

If manual processes are used for shoe manufacturing to maintain precision, then manufacturing precision is improved, but productivity decreases

Engineering Contradiction:

Improveadhesive application precisionVSAvoidmanufacturing productivity

Core Design Contradiction:

Manufacturing precisionVSProductivity

Solution Approach 1:

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

Inventive Principle:

Principle #35Parameter changes

Data Source

PatentUS11341291B2Generation of tool paths for shoe assembly

Publication Date: 2022.05.24 NIKE INC

AI summary

A tool path for treating a shoe upper may be generated to treat substantially only the surface of the shoe bounded by a bite line. The bite line may be defined to correspond to the junction of the shoe upper and a shoe bottom unit. Bite line data and three-dimensional profile data representing at least a portion of a surface of a shoe upper bounded by a bite line may be utilized in combination to generate a tool path for processing the surface of the upper, such as automated application of adhesive to the surface of a lasted upper bounded by a bite line.