Part Transfer Mechanism for Under-Gantry Cut Part Removal
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Solution Overview
Problem
Existing cutting machines require manual labor to remove cut parts from large metal plates, which is hazardous and inefficient, and the use of overhead cranes is slow and may disrupt other operations, while also posing challenges in distinguishing and separating parts with minor dimensional differences.
Innovation Solution
A part transfer apparatus that includes a cutting table with a cutting tool gantry and a part transfer apparatus capable of lifting, rotating, and moving cut parts vertically and horizontally, allowing for automated removal and sorting of parts, including the ability to pass underneath the cutting tool gantry for efficient operation and simultaneous processing of multiple plates.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If manual labor is used to remove cut parts from the cutting table, then the operation is simple and requires no complex equipment, but it poses safety risks due to climbing on the table and bending down, and is tedious and strenuous
Solution Approach 1:
The patent replaces manual mechanical operations with an automated part transfer apparatus that uses lifting mechanisms (such as magnets for ferrous materials, vacuum equipment, or mechanical grippers) to automatically remove cut parts from the cutting table. This eliminates the need for operators to climb on the table or bend down, thereby removing safety risks while maintaining operational simplicity through automation.
Solution Approach 2:
The part transfer apparatus is configured to autonomously identify, grasp, lift, and transport cut parts from the cutting table without human intervention. The system serves itself by automatically navigating to parts, determining their orientation, and placing them in designated storage areas, thereby eliminating manual labor and associated safety hazards.
2Adaptability or versatility
If an overhead crane is used to lift larger parts from the table, then parts that cannot be lifted manually can be removed, but the operation is slow and may disrupt other operations requiring the crane
Solution Approach 1:
The patent replaces the overhead crane system with a dedicated part transfer apparatus equipped with adaptable lifting mechanisms. This apparatus can handle both small and large parts using different lifting methods (magnetic, vacuum, or mechanical), and operates independently on the cutting table, thereby eliminating the bottleneck and disruption caused by shared crane usage while maintaining versatility in handling various part sizes.
Solution Approach 2:
The part transfer apparatus is designed as a separate, self-contained system that operates independently from the overhead crane. By segmenting the part removal function into a dedicated apparatus, the system achieves both versatility in handling different part sizes and high productivity through simultaneous, uninterrupted operation.
3Ease of operation
If manual identification and separation of parts is performed, then parts for different jobs or customers can be separated and stored together, but it requires time-consuming accurate measuring to ensure parts are not mixed up
Solution Approach 1:
The patent replaces manual visual inspection and measurement with automated sensing systems (such as optical scanners, cameras, or dimension sensors) integrated into the part transfer apparatus. These systems automatically identify part dimensions, characteristics, and job identifiers, enabling rapid and accurate sorting without time-consuming manual measurement, thereby maintaining ease of operation while eliminating time loss.
Solution Approach 2:
The system creates digital copies or records of part measurements and characteristics through automated sensing, storing this information for identification and sorting purposes. This eliminates the need for repeated manual measurement and verification, significantly reducing the time required for part identification and separation while ensuring accuracy through digital record-keeping.
4Productivity
If the cutting table is made long enough to support two or more plates for simultaneous processing, then high machine utilization is achieved, but the complexity of coordinating cutting and unloading operations increases
Solution Approach 1:
The part transfer apparatus is designed as a universal system that can operate in multiple zones along the extended cutting table simultaneously. It具备 the capability to service multiple cutting zones with a single apparatus through coordinated movement and multiple lifting mechanisms, thereby achieving high machine utilization across multiple plates without proportionally increasing system complexity.
Solution Approach 2:
The part transfer apparatus employs dynamic coordination where multiple lifting mechanisms can be independently controlled to service different zones simultaneously. The system adapts its operation dynamically based on the positions and needs of different cutting zones, enabling efficient multi-zone operation without requiring complex fixed infrastructure, thereby achieving high productivity with manageable complexity.
Data Source
AI summary
A cutting machine is provided, including: a cutting table having a first end and a second end aligned along an X-axis; a cutting tool gantry configured to cut parts from plate supported on the cutting table, the cutting tool gantry spanning the cutting table in a Y-axis perpendicular to the X-axis and being configured to travel along the X-axis between the first end and the second end; and a part transfer apparatus configured to remove cut parts from the cutting table, the part transfer apparatus being configured to travel along the X-axis between the first end and the second end, wherein the part transfer apparatus is able to pass underneath the cutting tool gantry while travelling along the X-axis. Methods of manufacturing and storing parts are also provided, along with a method of identifying when a part is in contact with a finishing apparatus.