Workpiece Trim Optimization Using Sensor-Guided Cutting Control
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Solution Overview
Problem
Existing workpiece processing systems struggle to optimize trim production and use, particularly in food products, leading to inefficiencies in portioning, trimming, and waste minimization.
Innovation Solution
A workpiece processing optimization system that includes a first cutting assembly, sensor assembly, sorting assembly, and computing device to analyze sensor data and adjust cutting settings, divert trim for optimal use, and generate a trim optimization plan.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If high-speed processing machines are used for portioning and trimming workpieces, then productivity is improved, but trim waste increases and trim optimization becomes difficult
Solution Approach 1:
The system employs sensor assemblies to detect workpiece characteristics and trim generation in real-time, feeding this information to a computing device that dynamically adjusts cutting parameters. This closed-loop feedback mechanism enables the high-speed cutting assembly to optimize trim production continuously, resolving the contradiction between maintaining high productivity and reducing trim waste.
Solution Approach 2:
The cutting assembly parameters are made dynamic rather than fixed, allowing real-time adjustment of cutting depth, speed, and positioning based on actual workpiece variations and trim accumulation. This dynamic adaptation enables the system to maintain optimal cutting conditions at high speeds while minimizing unnecessary trim generation.
2Manufacturing precision
If uniform portioning and trimming is implemented to meet customer specifications, then manufacturing precision is improved, but device complexity increases due to multiple assemblies
Solution Approach 1:
The cutting assembly is designed with multi-functionality, capable of performing both portioning and trimming operations with a single integrated unit. The sensor assembly and computing device serve multiple purposes: detecting workpiece characteristics, monitoring trim generation, and controlling cutting parameters. This universality reduces the need for separate specialized assemblies while maintaining precise uniform portioning.
Solution Approach 2:
Multiple functions are merged into integrated assemblies: the sensor assembly combines detection capabilities, the cutting assembly integrates both portioning and trimming functions, and the computing device unifies data processing and control. This merging reduces overall system complexity while achieving the required manufacturing precision for uniform portions.
3Loss of substance
If real-time sensor data analysis is used to optimize cutting settings, then trim production optimization is improved, but use of energy increases due to computing requirements
Solution Approach 1:
The system applies partial processing in terms of data analysis, focusing computational resources on the most critical parameters that directly influence trim generation. Rather than analyzing all possible sensor data, the computing device targets specific measurements (cutting depth, workpiece dimensions, trim accumulation) that provide the highest optimization return, thereby reducing energy consumption while maintaining effective trim control.
Data Source
AI summary
A trim optimization system may include a first cutting assembly configured to generate workpiece trim and trimmed workpieces, a sensor assembly configured to generate at least one of trimmed workpiece and trim sensor data, and a sorting assembly configured to divert trim from the first cutting assembly to a trim use assembly. The trim optimization system may include memory storing instructions that, when executed by a processor, cause a computing device of the workpiece processing optimization system to: process input data including at least one of trimmed workpiece sensor data, trim sensor data, trim demand for the trim use assembly, workpiece supply data, and workpiece processing requirements; and, output a trim optimization plan including at least one of: a trim designation location in the trim use assembly for an amount of trim; and instructions for adjusting settings to change an amount of workpiece trim generated by the first cutting assembly.