Automated Scrap Removal for Window Frame Production
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Solution Overview
Problem
Insulating glass units (IGUs) face issues with atmospheric water vapor infiltration due to discontinuities at frame corners and inefficiencies in manual operations, leading to production delays and scrap generation during the fabrication of elongated window components.
Innovation Solution
An automated system for removing scrap elongated window component stock from a conveyor using a path of travel altering mechanism, a translating mechanism, and a controller, which facilitates rapid changeover between different widths of strip material, reducing waste and operator-dependent errors.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If manual operations are used for scrap removal and frame fabrication, then operator flexibility is maintained, but production efficiency decreases and scrap generation increases
Solution Approach 1:
The automated scrap removal system operates autonomously without requiring manual intervention. The pusher mechanism automatically detects, grasps, and removes scrap frames from the production line, enabling the system to service itself and maintain continuous operation without operator dependency
Solution Approach 2:
Manual mechanical operations for scrap removal are replaced with an automated mechanical system comprising a pusher mechanism with gripper fingers actuated by pneumatic or electric actuators. This substitution eliminates manual labor while maintaining precise control over the scrap removal process
2Loss of substance
If continuous production is maintained without scrap removal, then production flow is uninterrupted, but waste accumulation increases and production space is consumed
Solution Approach 1:
The pusher mechanism extracts scrap frames from the continuous production flow at designated removal points. By taking out the scrap material immediately after formation and before it accumulates, the system prevents waste buildup while maintaining uninterrupted production of valid frames
Solution Approach 2:
The automated scrap removal system operates continuously alongside the frame production process. The pusher mechanism cycles automatically to remove scrap frames without interrupting the formation of new frames, ensuring continuous useful action in both production and waste removal
3Reliability
If corner keys are used to connect frame elements, then assembly flexibility is improved, but vapor infiltration paths are created at junctures
Solution Approach 1:
The corner key components that create infiltration paths are completely removed from the design. Instead of using separate corner keys to connect frame elements, the system uses continuous corner structures formed directly from the roll-formed frame, eliminating the junctures where vapor infiltration occurs
Solution Approach 2:
The corner connection structures are merged with the main frame elements to create a continuous, integrated corner structure. This merging eliminates the separate junctures between corner keys and frame elements, providing an unbroken sealant barrier while maintaining ease of manufacture through roll-forming
4Shape
If V-shaped notches are cut in tubes for corner joints, then bending capability is improved, but infiltration paths extend along corner parting lines
Solution Approach 1:
The V-shaped notches that create infiltration paths are completely removed from the corner joint design. The system uses alternative corner configurations formed through roll-forming processes that do not require notch cutting, thereby eliminating the parting lines where vapor infiltration occurs
Solution Approach 2:
The mechanical notch-cutting process is replaced with a roll-forming process that creates corner joints without discontinuities. The roll-forming mechanism shapes the tube into corner configurations through controlled deformation, eliminating the need for post-forming notch cutting and the associated infiltration paths
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 significantly reduces waste and production time by enabling rapid changeover between strip materials, improving manufacturing throughput and allowing for real-time response to customer orders, while minimizing operator errors and inefficiencies.
Implementation Method 1
a pusher for contacting and moving the scrap piece off the conveyor
Data Source
AI summary
An apparatus for automatic removal of scrap elongated window component stock from a conveyor includes a path of travel altering mechanism, a translating mechanism, and a controller. The path of travel altering mechanism is positioned along the path of travel that selectively facilitates movement of scrap elongated window component stock off the path of travel. The translating mechanism is in communication with the path of travel altering mechanism for moving the scrap elongated window component stock off of the path of travel.