Dynamic Workpiece Positioning With Sensor-Guided Cut Optimization
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Solution Overview
Problem
Traditional machine centers lack efficient and cost-effective optimization methods for workpiece positioning, requiring expensive upgrades and significant downtime due to the need for new scanners and control system upgrades.
Innovation Solution
A dynamically directed workpiece positioning system that uses sensors and computer systems to detect and reposition workpieces based on actual and desired positions, allowing for continuous optimization and cut solution calculation, reducing the need for costly hardware upgrades by integrating with existing systems.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional optimization methods are implemented in machine centers, then positioning precision and productivity are improved, but device complexity and cost increase significantly
Solution Approach 1:
The scanner is integrated into the existing infeed system, allowing it to serve multiple functions: detecting workpiece position, providing data for optimization calculations, and coordinating with the machine center controls. This multi-functionality reduces the need for separate dedicated optimization hardware.
Solution Approach 2:
The optimization system merges the scanner, infeed system, and machine center controls into a unified coordinated system. The scanner data is integrated with the existing controls to dynamically adjust workpiece positioning, combining multiple subsystems into a cohesive optimization solution.
2Manufacturing precision
If scanner and control system upgrades are implemented, then workpiece positioning optimization is achieved, but loss of time due to installation and downtime increases
Solution Approach 1:
The scanner is positioned to detect workpiece characteristics before the workpiece enters the machine center processing area. This preliminary detection allows optimization calculations to be performed in advance, so that positioning adjustments can be made without delaying the actual processing operation.
Solution Approach 2:
The system maintains continuous operation by performing optimization calculations and positioning adjustments without interrupting the workpiece flow. The scanner operates continuously to track workpiece position, and the controls continuously adjust positioning while the workpiece is being conveyed, ensuring uninterrupted processing.
3Productivity
If expensive scanner and control upgrades are purchased, then optimization capability is improved, but cost increases significantly
Solution Approach 1:
The system uses the existing infeed system and controls to perform optimization functions. The scanner provides workpiece position data, and the existing controls automatically adjust positioning based on this data, allowing the system to optimize its own operation without requiring expensive dedicated optimization hardware.
Solution Approach 2:
The system replaces complex mechanical positioning mechanisms with a sensor-based detection and control-based adjustment approach. Instead of using expensive mechanical optimization devices, the system uses scanner detection combined with software-based optimization calculations and electronic control signals to achieve precise positioning.
Data Source
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AI summary
In various embodiments, a dynamically directed workpiece positioning system may include a transport, a sensor positioned to detect a workpiece on the transport, a cutting member positioned along or downstream of the transport, and a computer system. The sensor may scan the workpiece as the workpiece is moved relative to the transport by a human operator or a positioning device. Based on the scan data, the computer system may generate commands to guide the human operator or positioning device in moving the workpiece to a desired position corresponding to a cut solution for the workpiece. Optionally, the computer system may cause the cutting member to be repositioned while the workpiece is being moved relative to the transport. Once the workpiece is in the desired position, the transport may be used to move the workpiece toward the cutting member. Corresponding methods and apparatuses are also disclosed.