Adaptive Shoe Upper Tool Paths for Precise Bite Line Bonding
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Solution Overview
Problem
The automated processing of shoe parts in footwear manufacturing is challenging due to the pliable 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 result in inefficiencies and waste.
Innovation Solution
The system generates tool paths for processing shoe parts by demarcating a 'bite line' to define surface regions on the shoe upper, allowing for precise application of adhesives and other treatments, using conditionally visible or virtual markings and three-dimensional scanning to ensure accurate bonding without manual intervention.
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
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 enables automated and efficient processing of shoe parts, reducing waste and ensuring strong bonds while maintaining aesthetic quality by accurately defining treatment areas on the shoe upper.
Implementation Method 1
a first camera that records a first series of images representing a plurality of points at which the light intersects with the marked bite line and representing the reflection of the light off of the at least part of the portion of the shoe upper
Data Source
Figure 1~2
Figure 3~4
Figure 5~6A
AI summary
A system for processing partially assembled parts of an article of footwear, the system including: a marking mechanism for marking physical indicia on a shoe upper at a bite line, the bite line defining, on the shoe upper, an interface between the shoe upper and a corresponding bottom unit upon assembly of the shoe; a light source that projects light across at least a portion of the marked bite line at an angle non-parallel to the marked bite line; a first camera that records a first series of images representing a plurality of points at which the light intersects with the marked bite line and representing the reflection of the light off of the at least part of the portion of the shoe upper to be covered by the corresponding bottom unit upon assembly of the shoe; a second camera that records a second series of images representing the plurality of points at which the light intersects with the marked bite line; and a computing system that processes the first and second series of images to generate bite line data and three-dimensional profile data and utilizes the bite line data and the three-dimensional profile data to generate a tool path for processing.