Mass Production Tool Cycle Recording via Machine-Tool Signal Matching
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Solution Overview
Problem
Existing methods for recording work cycles of mass production installations, such as injection-molding machines and tools, are inefficient in automatically monitoring and counting cycles, requiring manual intervention and lacking in precise identification of servicing needs.
Innovation Solution
A system using sensors on both the machine and tool to measure physical variables like acceleration and temperature, comparing time profiles to synchronize and count cycles, with a coupling unit to automate the detection of pairing and generate counting sequences, and a counting unit to store and analyze these sequences for servicing needs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If sensors are attached to both the machine and tool to measure physical variables, then the precision of cycle detection is improved, but the device complexity increases
Solution Approach 1:
A coupling unit is introduced as an intermediary component that receives data from multiple sensors on the machine and tool, processes the time profiles, and determines cycle coherence. This mediator consolidates the complexity of coordinating multiple sensors and processing their data, while the sensors themselves remain focused on their measurement function, thus improving measurement precision without proportionally increasing overall system complexity.
2Productivity
If manual monitoring and counting methods are used, then the device complexity is reduced, but the productivity decreases
Solution Approach 1:
The system enables self-service automation by having sensors automatically monitor physical variables, the coupling unit automatically process and compare time profiles to detect cycles, and the system automatically generate maintenance schedules without manual intervention. This self-service capability improves productivity by eliminating manual monitoring while the modular architecture keeps device complexity manageable through clear separation of functions.
3Ease of operation
If automated cycle counting is implemented, then the ease of operation is improved, but the loss of information increases due to potential synchronization errors
Solution Approach 1:
The coupling unit implements feedback by continuously comparing the time profiles from machine and tool sensors, detecting coherence between them, and using this feedback to accurately determine when cycles occur. This feedback mechanism ensures that cycle counting remains accurate despite the automation, as the system constantly verifies synchronization between machine and tool operations before registering a cycle.
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
Enables highly automated and simplified recording of work cycles, reducing manual labor and improving the identification of when tools or machines require servicing, allowing for more efficient maintenance scheduling.
Implementation Method 1
sensors on both the machine and tool to measure physical variables like acceleration and temperature
Implementation Method 2
sensors on both the machine and tool to measure physical variables like acceleration and temperature
Implementation Method 3
comparing time profiles to synchronize and count cycles
Data Source
AI summary
A method for recording mass production work cycles of a facility. The facility having a machine and a replaceable mass production tool which is secured to the machine and is moved by the machine. According to the method, number sequences are formed that indicate how many cycles have been carried out by a specific tool in cooperation with a specific machine. The required detection of the cooperation of the particular tool with the particular machine is carried out on the basis of a comparison between the time curves of the values of two measured physical variables, wherein one physical variable is measured on the tool, and the second physical variable is measured on the machine, the two physical variables being such that the values thereof change cyclically with the rhythm of the work cycle carried out by the tool and the machine together.