Tool Magazine Occupancy Optimization for Minimal Tool Relocation
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Solution Overview
Problem
Machine tools face inefficiencies due to waiting times caused by the unavailability of successor tools during machining, leading to reduced machine efficiency and increased production times, especially when producing a variety of workpieces that require different tools, and the complex task of allocating tools in large magazines considering their space requirements and restrictions.
Innovation Solution
A computer-aided method for optimizing tool magazine location occupancy using mixed-integer linear optimization to minimize tool relocations by identifying permissible pairs of magazine locations for each tool, ensuring collision-free placement and minimizing free spaces between tools, thereby achieving a compact and efficient tool arrangement.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If tools are stored in fixed magazine positions in large capacity magazines, then the machine can handle a wide variety of workpieces requiring different tools, but the constant removal and addition of tools reduces machine efficiency and increases production time
Solution Approach 1:
The system performs preliminary actions by predicting future tool requirements based on the workpiece sequence and proactively relocating tools to optimal magazine positions before they are needed. This advance preparation eliminates waiting periods and ensures tools are readily available when required, maintaining both versatility and productivity
2Ease of manufacture
If tools are placed arbitrarily in magazine positions, then tool allocation is simple, but space requirements and magazine constraints cannot be satisfied leading to collisions and improper placement
Solution Approach 1:
The system transforms the tool allocation problem from a simple placement task into an optimized parameter arrangement problem. By considering tool dimensions, magazine constraints, and accessibility requirements as parameters, the system determines optimal positions that satisfy all spatial and operational constraints while minimizing relocations
3Quantity of substance
If tools are relocated frequently to accommodate new tools in large magazines, then all tools can be accommodated, but the number of repositionings increases complexity and time
Solution Approach 1:
The system performs preliminary analysis of the tool requirements and magazine state to identify optimal placement positions before any physical relocation occurs. This advance planning minimizes the number of repositionings needed and reduces operational complexity
Solution Approach 2:
The system continuously monitors the magazine state and tool usage patterns, using this feedback to dynamically adjust tool positions. This feedback mechanism ensures that tools are relocated only when necessary and placed in positions that optimize future accessibility, reducing overall repositioning complexity
Data Source
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Figure 4A~4C
AI summary
The invention relates to a method for optimizing the occupancy of magazine spaces (P) by tools within at least one tool magazine (R) for a machine tool in a computer-supported manner, having the following steps: a) detecting a quantity of magazine spaces (P) in at least one tool magazine (R), b) detecting a first quantity of tools which occupy at least one magazine space and the magazine spaces occupied by said tools, c) detecting a second quantity of tools which are to be additionally received in the at least one tool magazine, d) detecting the required space and optionally at least one other property for each tool, e) detecting a quantity of allowed magazines spaces for each tool, an allowed magazine space depending on the required space, at least one other property of the tool, and/or a property of the magazine space, f) detecting a quantity of allowed magazine space pairs, wherein a first tool can be placed on a first magazine space of the magazine space pair, said first magazine space being allowed for the first tool, and a second tool can be placed on the second magazine space of the magazine space pair, said second magazine space being allowed for the second tool, in a collision-free manner with respect to the respective required space for each tool, and detecting the size of the free intermediate space between the placed first tool and the placed second tool, and g) optimizing the occupancy of the magazine spaces by tools of the first quantity and at least one tool to be received of the second quantity such that the number of relocations, which are required for receiving the aforementioned tool, of the tools of the first quantity is minimized, and the required relocations and (initial) placements of the tools of the second quantity are carried out in such a compact manner that the sum of the sizes of the free intermediate spaces of two adjacently placed tools is minimized, and the magazine space pair for said adjacently placed tools is a magazine space pair of the quantity of the magazine space pairs allowed for said tool pair.