Shaping Process Simulation Alignment Using Distinguishing Points

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Solution Overview

Problem

Current simulation methods for shaping machines, such as injection-molding processes, often result in significant deviations between simulated and actual processes, making it difficult to achieve accurate alignment and requiring numerous parameter studies to correct discrepancies.

Innovation Solution

A method that calculates modification parameters from distinguishing points in both simulation and measurement progressions to adjust the simulation or process, allowing for targeted alignment by mapping these points and applying modifications to reduce deviations, thereby improving the correspondence between simulation and real process results.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If simulations are carried out to model the injection process, then the process can be planned and optimized, but the simulation results often differ significantly from the actual process

Engineering Contradiction:

Improvesimulation accuracyVSAvoidalignment precision

Core Design Contradiction:

ReliabilityVSMeasurement precision

Solution Approach 1:

The patent transforms the simulation progression and/or measurement progression to obtain a quantification of deviation. This involves changing parameters such as time scaling factors and progression transformations to align the simulation curve with the measurement curve, thereby resolving the discrepancy between simulation accuracy and measurement precision

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The patent uses the quantified deviation between simulation and measurement as feedback to iteratively adjust the simulation parameters. By continuously comparing and adjusting based on the deviation measurement, the simulation accuracy is improved while maintaining precise alignment with actual process measurements

Inventive Principle:

Principle #23Feedback

2Reliability

If manual alignment methods are used between simulation and measurement, then alignment can be achieved, but the process is not fully automatable and requires significant manual effort

Engineering Contradiction:

Improvealignment reliabilityVSAvoidautomation capability

Core Design Contradiction:

ReliabilityVSExtent of automation

Solution Approach 1:

The patent replaces manual mechanical alignment processes with an automated computational system. The method automatically transforms progressions, determines distinguishing points, calculates deviations, and generates adjustment parameters without requiring manual intervention, thereby achieving full automation while maintaining alignment reliability

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The simulation system performs self-alignment by automatically comparing its own progression with measurement data and generating its own correction parameters. The system serves itself by identifying deviations and implementing corrections without external manual assistance

Inventive Principle:

Principle #25Self-service

3Manufacturing precision

If multiple parameter studies are conducted to correct simulation discrepancies, then accuracy can be improved, but the time and computational resources required increase significantly

Engineering Contradiction:

Improveprocess alignment precisionVSAvoidalignment time

Core Design Contradiction:

Manufacturing precisionVSLoss of time

Solution Approach 1:

The patent performs preliminary transformation of the simulation and/or measurement progression before detailed comparison. By pre-processing the data to establish a transformed progression that approximates the target progression, the method reduces the time required for subsequent detailed alignment and parameter adjustment

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The patent segments the alignment process into distinct steps: transforming progression, determining distinguishing points, calculating deviation, and generating adjustment parameters. This segmentation allows each step to be optimized independently and executed efficiently, reducing overall alignment time while maintaining precision

Inventive Principle:

Principle #1Segmentation

Data Source

PatentUS20210326498A1Method and computer program product for comparing a simulation with the real carried out process

Publication Date: 2021.10.21 ENGEL AUSTRIA

AI summary

A method for aligning a simulation of a process to be carried out with a shaping machine with the process really carried out, includes calculating a simulation progression of a variable characteristic of the process, measuring in the process really carried out a measurement progression of the characteristic variable, determining first distinguishing points of the curve of the simulation progression and second distinguishing points of the curve of the measurement progression, mapping the first distinguishing points and the second distinguishing points, calculating a modification parameter for the simulation and/or the process from coordinates of the first distinguishing points and second distinguishing points mapped to each other, and modifying the simulation and/or the process based on the modification parameter and carrying it out again.