Window Frame Cleaning Station with Sensor-Driven Weld Flash Removal
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing window frame and sash welding processes result in weld flash, which requires additional processing to remove, but variances in profile dimensions and misalignment complicate consistent removal, affecting the appearance and assembly of windows.
Innovation Solution
A window processing system that includes a cleaning station with sensors and controllers to inspect the profile of window frames or sashes, dynamically adjusting the movement of cleaning tools to accurately remove weld flash based on sensed dimensions and configurations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-generated harmful factors
If multiple types of cleaning tools are used to remove weld flash, then the weld flash can be removed, but the ability to consistently remove weld flash to controlled dimensions is hampered due to profile dimension variances and misalignment
Solution Approach 1:
The cleaning station incorporates adjustable cleaning tools that can dynamically adapt their position and orientation based on the detected profile of the window frame. The system uses sensors to detect the actual profile dimensions and misalignment, then adjusts the cleaning tool positions accordingly to maintain consistent removal dimensions despite variations in the welded profile.
Solution Approach 2:
The system employs sensors to detect the profile of the window frame before cleaning, and this detection information is fed back to the control system which then adjusts the cleaning tool positions and movements. This closed-loop feedback mechanism ensures that the cleaning process compensates for profile variances and misalignment, achieving controlled dimensions in weld flash removal.
2Shape
If cleaning tools are used to remove weld flash, then appearance can be improved, but too much or too little weld flash may be removed degrading the appearance
Solution Approach 1:
The cleaning tools are designed with adjustable positions and orientations that can be dynamically modified based on the detected profile. This allows the system to adapt to each specific profile configuration and remove the precise amount of weld flash needed to achieve uniform appearance without over- or under-removal.
Solution Approach 2:
The system changes operational parameters such as cleaning tool position, orientation, and movement path based on the detected profile parameters. By adjusting these parameters according to the actual profile dimensions and weld flash characteristics, the system achieves precise control over the amount of material removed, ensuring consistent appearance quality.
3Object-generated harmful factors
If a corner cleaner machine is used to remove weld flash, then weld flash can be removed, but the process is hampered by profile dimensions changing in the frame extrusion
Solution Approach 1:
The cleaning station is designed as a universal system that can handle multiple profile types and dimensions. The cleaning tools are adjustable and reconfigurable, allowing the same machine to effectively clean different frame extrusion profiles by modifying tool positions and orientations based on the detected profile characteristics.
Solution Approach 2:
The system uses sensors to detect the actual profile dimensions of each frame piece, and this information is used to dynamically adjust the cleaning tool parameters. This feedback mechanism enables the system to adapt to varying profile dimensions and maintain effective weld flash removal across different profile types.
Data Source
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.