Shoe Upper Tool Paths for Bite Line Adhesive Application
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Solution Overview
Problem
The automated processing of shoe parts in footwear manufacturing is challenging due to the pliable and bending nature of materials used, leading to variations in optimal tool paths for each shoe, and manual processes are often required to ensure accurate bonding, which can be wasteful and detrimental to the environment.
Innovation Solution
The generation of tool paths for automated manufacturing systems that demarcate a 'bite line' on the shoe upper to define regions for adhesive application, using conditionally visible or virtual markings, allowing for precise application of adhesives and other treatments, enabling accurate bonding while minimizing waste.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If adhesive application is performed manually to ensure precise coverage, then bonding reliability is improved, but productivity decreases and labor costs increase
Solution Approach 1:
The system uses vision sensors to automatically detect the actual position and shape of the shoe upper, and the controller automatically adjusts the tool path based on detected variations, enabling the system to self-correct without manual intervention while maintaining precision at automated speeds
Solution Approach 2:
The system dynamically changes processing parameters including tool path coordinates, adhesive application rate, and robot motion speed based on real-time detection of material variations, allowing automated processing to adapt to each workpiece's unique characteristics
2Reliability
If increased amount of adhesive is applied to prevent bonding failure, then bonding reliability is improved, but material waste increases and environmental harm worsens
Solution Approach 1:
The system applies adhesive with locally optimized quantity and distribution based on the detected actual geometry of each bonding area, ensuring sufficient coverage only where needed rather than uniform over-application across the entire surface
Solution Approach 2:
The vision system provides real-time feedback on the actual position and shape of the bonding surface, allowing the controller to adjust adhesive application parameters dynamically to achieve precise coverage without excess material
3Reliability
If increased amount of adhesive is applied to ensure coverage, then bonding reliability is improved, but harmful effects increase due to incomplete curing and discoloration
Solution Approach 1:
The system precisely controls adhesive application to match the exact boundaries of the bonding area detected by the vision system, preventing adhesive from reaching areas where it would cause discoloration or soiling
Solution Approach 2:
The vision system detects and maps the bonding area boundaries before adhesive application begins, allowing the controller to pre-calculate the optimal tool path that stays within acceptable boundaries and prevents harmful overflow
4Productivity
If automated processing is implemented without adaptive tool paths, then productivity is improved, but manufacturing precision decreases due to material variations
Solution Approach 1:
The system transitions from fixed static tool paths to dynamic adaptive tool paths that are generated in real-time based on vision detection of each workpiece's actual geometry, allowing automated processing to accommodate material variations
Solution Approach 2:
The controller dynamically changes tool path parameters including position coordinates, motion speed, and application rate based on detected variations in each shoe upper's shape and position, maintaining precision throughout automated high-speed processing
Data Source
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.