Machining Device Visual Sensor Pallet Contaminant Detection

Solution Overview

Problem

Existing machining devices lack the ability to monitor contaminant adhesion on pallets, leading to unnecessary cleaning and the potential for jamming due to undetected contaminants.

Innovation Solution

A machining device equipped with a visual sensor that captures images of the pallet to detect contaminants, suspends workpiece supply if contaminants are present, and only performs cleaning when necessary, using a contaminant removing unit to ensure removal of contaminants and prevent jamming.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If cleaning is performed continuously or frequently without monitoring, then contaminants are removed from the pallet, but cleaning time increases and cleaning fluid is wasted

Engineering Contradiction:

Improveprevention of jammingVSAvoidcleaning time

Core Design Contradiction:

ReliabilityVSLoss of time

Solution Approach 1:

The visual sensor performs preliminary detection of contaminants on the pallet before workpiece supply. The system only initiates cleaning operations when contaminants are actually detected, rather than performing cleaning continuously or on a fixed schedule. This preliminary action approach prevents unnecessary cleaning operations while ensuring contaminants are removed when present, resolving the contradiction between preventing jamming and reducing cleaning time

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The system implements a feedback loop where the visual sensor continuously monitors the pallet for contaminants, and the control unit adjusts cleaning operations based on actual contaminant presence. When contaminants are detected, cleaning is activated; when no contaminants are present, cleaning is suspended. This feedback mechanism ensures cleaning is performed only when necessary, eliminating waste of time and cleaning fluid while maintaining reliable operation

Inventive Principle:

Principle #23Feedback

2Reliability

If cleaning is performed without monitoring contaminant adhesion, then contaminants may be removed, but cleaning is performed unnecessarily when no contaminants are present

Engineering Contradiction:

Improveprevention of jammingVSAvoidcleaning fluid

Core Design Contradiction:

ReliabilityVSLoss of substance

Solution Approach 1:

The visual sensor performs preliminary detection of contaminants on the pallet before workpiece supply. The system only initiates cleaning operations when contaminants are actually detected, rather than performing cleaning continuously or on a fixed schedule. This preliminary action approach prevents unnecessary cleaning operations while ensuring contaminants are removed when present, resolving the contradiction between preventing jamming and reducing cleaning time

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The system implements a feedback loop where the visual sensor continuously monitors the pallet for contaminants, and the control unit adjusts cleaning operations based on actual contaminant presence. When contaminants are detected, cleaning is activated; when no contaminants are present, cleaning is suspended. This feedback mechanism ensures cleaning is performed only when necessary, eliminating waste of time and cleaning fluid while maintaining reliable operation

Inventive Principle:

Principle #23Feedback

3Loss of time

If visual monitoring of contaminants is implemented, then unnecessary cleaning is reduced, but device complexity increases

Engineering Contradiction:

Improvecleaning timeVSAvoidmonitoring system complexity

Core Design Contradiction:

Loss of timeVSDevice complexity

Solution Approach 1:

A visual sensor serves as an intermediary component between the pallet and the control system. The sensor captures images of the pallet surface, and the control unit processes these images to detect contaminants. This intermediary approach provides intelligent monitoring without requiring complex mechanical or manual inspection systems, achieving contaminant detection with relatively simple added components

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

The patent replaces potential complex mechanical inspection systems or manual visual inspection with an optical/image-based detection system. The visual sensor uses image capture and processing to detect contaminants, substituting mechanical complexity with optical sensing and computational analysis, which simplifies the overall monitoring mechanism while maintaining effective contaminant detection

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

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

This solution reduces cleaning time and fluid usage while effectively preventing jamming by ensuring only necessary cleaning and continuous monitoring of contaminant adhesion.

Implementation Method 1

a visual sensor configured to capture an image of the pallet outside a machining chamber of the machine tool

Methodology Applied

Scientific EffectLight reflection: Reflection

Data Source

PatentUS9676072B2Machining device with visual sensor for locating contaminants

Publication Date: 2017.06.13 FANUC LTD

AI summary

A machining device is provided with a machine tool, a pallet to which a workpiece is secured, a pallet changer configured to move and change the pallet, and a workpiece attaching unit configured to attach and detach the workpiece to and from the pallet. Further, the machining device is provided with a visual sensor configured to capture an image of the pallet, and contaminants that may possibly cause jamming as the workpiece is supplied to the pallet are detected from the image captured by the visual sensor. A workpiece supply operation for the pallet is suspended if the contaminants are detected.