Workpiece Display Alignment for Faster Conveyor Sorting
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Solution Overview
Problem
In industrial metal and sheet metal processing, sorting workpieces manufactured by flatbed machine tools is inefficient due to the lack of effective visualization of workpiece information, leading to errors and increased operator workload, especially when dealing with numerous differently sized and shaped pieces.
Innovation Solution
A method and system that displays workpiece image data and order information on a monitor positioned near the conveyor system, synchronized with the sequence and arrangement of workpieces, allowing operators to sort workpieces efficiently by providing geometry-based illustrations and order data in real-time, using a machine-readable processing plan and a display unit with a processor.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If workpiece information is not visualized during sorting, then the sorting process can proceed without additional equipment, but operator efficiency decreases and errors increase
Solution Approach 1:
The patent creates a visual copy of the workpiece arrangement and order information on a display device. The control system generates a graphical representation showing the positions, shapes, and order data of all workpieces on the conveyor belt, allowing operators to see workpiece information without physically inspecting each piece during high-speed sorting
Solution Approach 2:
The display device acts as an intermediary between the machine tool control system and the human operator. It translates machine-readable workpiece data into visual information that operators can quickly interpret, bridging the gap between automated manufacturing and manual sorting processes
2Ease of operation
If projection technology is used to display workpiece information, then information can be projected onto workpieces, but the system becomes complex and less reliable in varying lighting conditions
Solution Approach 1:
Instead of projecting information onto physical workpieces, the patent creates a separate visual copy on a display device. This eliminates the need for projection equipment and complex optical systems while providing the same information access functionality in a simpler, more reliable manner
Solution Approach 2:
The patent replaces the mechanical/optical projection system with an electronic display system. The control system electronically generates and displays workpiece information, substituting complex projection hardware with a simpler software-based solution that is not affected by lighting conditions
3Reliability
If operators manually sort workpieces without visual aid, then no additional equipment is needed, but operator workload increases and sorting accuracy decreases
Solution Approach 1:
The display device provides real-time feedback to operators about workpiece positions, shapes, and order information. This visual feedback allows operators to quickly identify and sort the correct workpieces without increasing physical workload, thereby improving sorting accuracy and reducing errors
Data Source
AI summary
A method for displaying a sequence of workpiece-illustrations and/or order information for supporting a sorting process during manufacturing of workpieces with a manufacturing system includes transporting manufactured workpieces with the conveyor system to the sorting point according to a sequence and arrangement specified by the processing plan. The method further includes receiving, in the processor of the display unit, workpiece image data and/or order data provided by the machine tool control system for the workpieces transported to the sorting point. The method additionally includes displaying the workpiece image data and/or the order data on the monitor of the display unit in a sequence and/or an arrangement such that the sequence and/or the arrangement of the workpiece image data and/or the order data corresponds to the sequence and/or the arrangement of the workpieces transported from the conveyor system to the sorting point.