Tool Magazine Slot Allocation Under Collision and Space Constraints
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Solution Overview
Problem
Machine tools experience inefficiencies due to waiting times when tools are not optimally allocated in tool magazines, leading to increased production time and reduced machine efficiency, particularly in scenarios where tools have varying space requirements and must be rearranged to avoid collisions and adhere to specific magazine constraints.
Innovation Solution
A method utilizing mixed integer linear optimization to optimize the allocation of tools in tool magazines, minimizing waiting times by placing tools in collision-free, permissible locations close to their original positions, while considering space requirements, weight, and load capacity, and using a control device to implement this optimization.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If tools are optimally allocated in tool magazines to minimize waiting times, then machine efficiency is improved, but tool rearrangement complexity increases due to collision avoidance and magazine constraints
Solution Approach 1:
The system performs preliminary optimization calculations for tool magazine allocation before production begins. The control device computes the optimal tool positions based on the sequence of operations and tool space requirements, allowing tools to be pre-positioned to minimize waiting times during spindle replenishment without causing collisions during actual production.
Solution Approach 2:
The optimization system dynamically adjusts tool allocation based on varying production requirements. When the sequence of operations or tool requirements change, the control device recalculates the optimal magazine configuration and automatically rearranges tools, making the system adaptable to different production scenarios while maintaining efficiency.
2Loss of time
If tools are placed close to their original positions to minimize travel distances, then rearrangement time is reduced, but optimization flexibility is limited
Solution Approach 1:
The optimization algorithm applies local quality by prioritizing tools that require frequent access or have critical timing requirements. Instead of uniformly moving all tools, the system identifies specific tools whose repositioning will have the greatest impact on reducing waiting times, and focuses optimization efforts on those local areas of the magazine while keeping other tools in place.
Solution Approach 2:
The system performs preliminary calculations to determine which tools should be moved and by how much, balancing the trade-off between travel distance and optimization flexibility. The control device computes optimal positions that minimize total rearrangement distance while still achieving significant reductions in waiting times, allowing flexible optimization without excessive movement.
3Loss of time
If extensive tool rearrangement is performed to optimize magazine occupancy, then waiting times are minimized, but production downtime increases
Solution Approach 1:
The system applies partial action by performing only the necessary tool repositioning required to achieve optimal waiting time reduction, rather than completely rearranging all tools. The control device identifies the minimum set of tool movements needed to improve magazine occupancy, thereby reducing waiting times while minimizing production downtime during rearrangement.
Solution Approach 2:
The optimization is performed preliminarily before production starts or during scheduled maintenance periods. The control device calculates the optimal tool allocation in advance, allowing tools to be arranged optimally before they are needed, thus minimizing waiting times during production without causing extensive downtime during the actual production run.
4Reliability
If tools are stored according to space requirements and magazine constraints, then collision-free operation is ensured, but magazine space utilization efficiency decreases
Solution Approach 1:
The system performs preliminary optimization calculations that simultaneously consider collision avoidance and space utilization. The control device computes tool positions that satisfy all space requirement constraints and prevent collisions while maximizing magazine occupancy efficiency, allowing both reliability and productivity goals to be achieved through pre-calculated optimal arrangements.
Solution Approach 2:
The optimization algorithm dynamically adjusts tool positions and magazine configuration parameters to achieve optimal space utilization. By varying parameters such as tool orientation, positioning, and magazine layer usage, the system maximizes the number of tools that can be stored safely without collisions while maintaining easy accessibility for frequently used tools.
Data Source
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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. One or more workpieces of one or more workpiece types is produced using the tools supplied by a magazine device at a supply area, having the following steps: a) detecting a number of workpieces to be produced, b) detecting a number of magazine spaces (P) in at least one tool magazine (R), c) detecting a number of tools, d) detecting the required space and optionally at least one other property for each tool, e) detecting allowable magazines spaces for each tool, an allowable magazine space depending on the required space, the other property of the tool, and/or a detected property of the magazine space, f) detecting an allowable starting magazine occupancy, a starting magazine space for each tool being detected, g) detecting a sequence of work steps to be carried out by the machine tool on a workpiece, wherein a tool provided for a work step of the sequence is used to produce the workpiece, h) detecting work step time periods required to carry out each individual work step on the workpiece, i) detecting one or more supply time periods depending on the sequence of the work steps to be carried out and depending on a magazine occupancy required for supplying the respective tool for the following work step at the supply area by means of the magazine tool, j) optimizing the occupancy of the magazine spaces by tools, each of which can occupy only one allowable magazine space in a collision-free manner such that the entire wait time is minimized, said entire wait time being composed of individual wait times resulting from the respective difference between the detected supply time period and the detected work step time period if the value of the difference is positive, otherwise the individual wait time assumes the value of null. The invention is characterized in that k) the occupancy of the magazine spaces by tools is optimized such that said tools are placed on the same magazine spaces of the starting magazine occupancy or on allowable magazine spaces near the magazine space previously occupied by said tools in a collision-free manner.