Window Frame Flash Cleaning With Profile Inspection Compensation
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Solution Overview
Problem
Existing window frame welding processes often result in weld flash, which requires further processing to remove, but variations in profile dimensions and misalignment complicate consistent removal, affecting the appearance and assembly of window frames.
Innovation Solution
A window processing system with sensors and controllers that inspect the frame profiles, adjust cleaning tools to match specific configurations, and dynamically control the removal of weld flash, ensuring precise cleaning based on sensed dimensions and alignment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If multiple types of tools are used to remove weld flash, then the ability to handle different profile types is improved, but the machine complexity increases
Solution Approach 1:
The patent implements a universal cleaning machine that can process multiple profile types (square, rectangular, circular, oval) using a single tool carrier assembly. The tool carrier accommodates various cutting tools (milling cutters, contouring cutters, end mills) that can be selectively positioned and activated based on the profile type being processed, eliminating the need for multiple dedicated machines for different profile configurations.
Solution Approach 2:
The patent employs dynamic adjustment mechanisms that allow the tool carrier and cutting tools to be repositioned and reconfigured during operation. The tool carrier can move along the profile, and the cutting tools can be selectively engaged or disengaged based on the detected profile geometry, enabling the same machine to adapt to different profile types without manual reassembly or tool changes.
2Adaptability or versatility
If profile dimensions are allowed to vary, then manufacturing flexibility is improved, but cleaning precision deteriorates
Solution Approach 1:
The patent incorporates a scanning mechanism that performs preliminary measurement of the profile dimensions and geometry before the cleaning operation begins. The system scans the profile to detect its specific dimensions, shape, and characteristics, then uses this information to pre-program or pre-adjust the cleaning tool paths and parameters, ensuring precise cleaning despite variations in profile dimensions.
Solution Approach 2:
The patent implements a feedback control system where the scanning mechanism continuously monitors the profile dimensions during processing. The detected dimensional information is fed back to the control system, which dynamically adjusts the cleaning tool positions, speeds, and engagement forces to maintain consistent cleaning precision across profiles with varying dimensions.
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
The system effectively removes weld flash with precision, improving the appearance of window frames and ensuring accurate assembly by adapting to variations in profile dimensions and misalignment.
Implementation Method 1
a monitor for inspecting a profile of the window frame or sash
Data Source
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AI summary
A window processing system is disclosed for fabricating window frames. A welding station has welding heads to weld or fuse vinyl frame parts together. The frames are taken to a cleaning station having a number of cleaning heads that are independently actuated to move into a position relative selected portions of the window frame to clean off burrs, weld beads etc from the welded window frame. The cleaning process involves both training of a controller to recognize certain frame profiles and a compensation process for adjusting the cleaning process for individual variations in the frame that occur during fabrication. Real-time cleaning involves coupling a visual sensor to a moving support that also supports a cleaning tool.