Actuator Interference Matrix for Automatic Machine Recovery
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Solution Overview
Problem
Automatic packaging machines for tobacco industry articles face challenges in restoring functional state due to actuator collisions, requiring manual intervention by expert operators, which is time-consuming and complex, especially when multiple actuators are involved, leading to potential mechanical damage and system deadlocks.
Innovation Solution
A method using an optimization algorithm to define a path for restoring the functional state by creating an interference matrix that maps actuator positions to determine collision-free movements, allowing the automatic machine to recover from non-functional states without human intervention, utilizing a control unit to execute these movements based on calculated paths.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If manual actuation of actuators is used to restore functional state, then collision risk is reduced, but restoration time increases significantly
Solution Approach 1:
The patent replaces manual mechanical actuation with an automated control system that calculates optimal actuator sequences using interference matrices. The control unit automatically determines collision-free paths and actuates actuators in the calculated sequence, eliminating the need for manual intervention while maintaining safety.
Solution Approach 2:
The patent pre-calculates interference matrices that map all possible actuator position combinations and identifies collision-free paths in advance. This preliminary analysis allows the control unit to quickly restore functional state without real-time manual evaluation, significantly reducing restoration time while ensuring safety.
2Reliability
If expert operators manually control actuators, then collision detection is possible, but system complexity increases and expert dependency arises
Solution Approach 1:
The patent implements a self-service system where the control unit automatically calculates interference matrices and determines collision-free actuator sequences without human intervention. The system manages its own restoration process, eliminating the need for expert operators and reducing system management complexity.
Solution Approach 2:
The patent introduces an interference matrix as an intermediary data structure that systematically represents all actuator position combinations and their collision risks. This matrix serves as a mediator between the control unit and physical actuators, automating the complex evaluation process that previously required expert human judgment.
3Productivity
If actuators are moved rapidly to restore functional state, then productivity is maintained, but collision risk increases
Solution Approach 1:
The patent pre-calculates interference matrices that identify all collision-free paths between actuator positions. By having this information prepared in advance, the control unit can rapidly move actuators along predetermined safe paths without real-time collision detection, maintaining high restoration speed while ensuring safety.
Solution Approach 2:
The system uses the pre-calculated interference matrix as feedback guidance to control actuator movements. The control unit references the matrix to verify each movement step is collision-free, enabling rapid automated restoration with guaranteed safety through continuous reference to the pre-analyzed safe paths.
Data Source
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AI summary
A method and an automatic machine for tobacco and/or cigarette production is disclosed, wherein an interference matrix (10) is determined, in which all the possible combinations of positions (11,n8,n9) of two or more actuators (8,9) are defined, wherein the interferences between the actuators (8,9) of the machine are marked (X), and the interference matrix (10) is used for recovery or restoring after failure to a defined operational/functional state. In particular, the automatic machine has a plurality of actuators, each of which is capable of assuming a plurality of different positions. The method comprises the steps of: determining, once, an interference matrix, which indicates, for each position of an actuator, the presence or absence of interference with respect to all the possible positions of the other actuators; and using the interference matrix for carrying out restoration of the automatic machine from a non-functional state to a functional state.