Molded Product Take-Out Teaching With Single-Camera Alignment
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Solution Overview
Problem
The conventional teaching method for taking out molded products requires multiple imaging devices and relies on operator skill to adjust the take-out head in the lateral direction, making the process difficult and prone to errors, including the risk of falls and extended operation times.
Innovation Solution
A teaching method that uses a single imaging device positioned above or obliquely above the die, capturing images of the die and surrounding structures, with reference symmetric structures displayed to help align the take-out head's center with the die's center, allowing for precise lateral positioning without direct downward visualization.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Area of stationary object
If multiple imaging devices are used to capture images for teaching, then the imaging coverage is improved, but the device complexity and cost increase
Solution Approach 1:
The patent positions the single imaging device to capture images from an oblique angle rather than directly from above, utilizing the lateral dimension to achieve both wide coverage and accurate lateral positioning. The device is mounted on the movable frame at a position that allows it to image both the die and the approach frame simultaneously in one view.
2Measurement precision
If the imaging device is positioned directly above the die, then the lateral positioning is improved, but the imaging device cannot capture both the die and approach frame in one view
Solution Approach 1:
The imaging device is positioned obliquely rather than directly above, utilizing the lateral dimension to expand imaging coverage while maintaining sufficient lateral positioning accuracy through proper optical axis orientation toward the die center.
Solution Approach 2:
The patent uses symmetric reference structures (tie bars or guide pins) as intermediary visual cues to help the operator achieve accurate lateral positioning. These reference structures provide a visual basis for alignment without requiring direct overhead viewing.
3Measurement precision
If the operator climbs on top of the molding apparatus to make alignment, then the lateral positioning is improved, but the safety risk increases
Solution Approach 1:
The patent replaces the mechanical approach of physically climbing onto the apparatus with an optical system. The imaging device mounted on the movable frame provides visual feedback that enables accurate lateral positioning from a safe distance, eliminating the need for the operator to climb on the apparatus.
4Ease of operation
If conventional teaching method is used, then the operator can make adjustments, but the operation time is extended
Solution Approach 1:
The imaging device provides real-time visual feedback to the operator during teaching operations. By displaying the captured image on a monitor, the operator can immediately see the effect of positioning adjustments and make corrections quickly, significantly reducing the time required compared to conventional trial-and-error methods.
Solution Approach 2:
The patent introduces symmetric reference structures as visual intermediaries that simplify the alignment process. These reference structures provide clear visual cues that enable rapid and accurate positioning without requiring complex measurements or repeated adjustments.
Data Source
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AI summary
An image display device displays an image such that a pair of reference symmetric structure portions, e.g. a pair of guide pins, are included in a captured image displayed on a display section, the pair of reference symmetric structure portions being located symmetrically with respect to a second virtual plane which extends in the opening direction and the vertical direction and includes a virtual center line of the molding apparatus which extends in the opening direction. A teaching execution section is used to determine the lateral position of an approach frame in the take-out operation by changing the position of the approach frame such that the center of an imaging range is located at a middle position between the pair of reference symmetric structure portions included in the captured image.