Broken Needle Fragment Handling With Magnetic Alignment and Imaging
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Solution Overview
Problem
Existing methods for handling needle fragments after a breakage are inefficient, leading to potential remnants in textile materials and lack effective documentation and recycling processes.
Innovation Solution
A device and method involving a container with a holding magnet to align needle fragments, captured by a camera for imaging and analysis, which is then evaluated using geometric data to ensure all fragments are present, and the image is stored for documentation and inventory management.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If needle fragments are manually collected and documented using adhesive film, then documentation is achieved, but the process is time-consuming and fragments may be lost
Solution Approach 1:
The patent replaces manual mechanical documentation (adhesive film attachment) with an automated optical system. A camera captures images of needle fragments automatically, and image processing algorithms analyze the fragments without manual intervention, eliminating the time-consuming manual documentation process while maintaining reliable fragment recovery.
Solution Approach 2:
The system enables self-service documentation where the needle fragments themselves are documented through automatic image capture and analysis. The fragments are automatically detected, imaged, and analyzed by the system without requiring human operators to manually handle or document each fragment, reducing time loss while ensuring complete recovery.
2Reliability
If all needle fragments are manually inspected and verified, then complete recovery is ensured, but the process is labor-intensive and error-prone
Solution Approach 1:
The patent replaces manual visual inspection with an automated optical inspection system. A camera captures images of the needle fragments, and image processing algorithms automatically analyze whether all fragments are present and complete, eliminating labor-intensive manual inspection while providing reliable verification through systematic automated analysis.
3Productivity
If needle inventory is manually tracked and reordering is initiated, then inventory control is achieved, but the process is inefficient and delays timely reordering
Solution Approach 1:
The system implements automated feedback loops where needle fragment data captured by the camera and processed through image analysis is automatically fed into inventory management systems. This triggers automatic reordering processes when inventory thresholds are reached, eliminating manual tracking delays and ensuring timely reordering through continuous automated monitoring and feedback.
Solution Approach 2:
The inventory management system performs self-service tracking and reordering initiation. The system automatically monitors needle usage and inventory levels, and autonomously triggers reordering processes without requiring manual intervention, significantly improving productivity while reducing the time loss associated with manual inventory management.
4Loss of information
If adhesive film is used to attach fragments for documentation, then documentation is achieved, but recycling is hindered due to foreign material contamination
Solution Approach 1:
The patent replaces the mechanical attachment method (adhesive film) with a non-contact optical documentation system. The camera captures images of the needle fragments without physical contact, eliminating foreign material contamination while maintaining high-quality documentation. This allows needle fragments to remain pure and suitable for recycling.
Solution Approach 2:
The system creates digital copies (images) of the needle fragments instead of physically attaching them to adhesive film for documentation. These digital copies retain all necessary information for documentation and analysis while leaving the physical needle fragments uncontaminated and pure, enabling efficient recycling without loss of substance.
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
Ensures complete recovery of needle fragments, improves recycling, and automates inventory updates, enabling timely reordering and accurate tracking of needle usage.
Implementation Method 1
A holding magnet is arranged on the base body and generates a magnetic field for holding the fragments on the upper side of the base body
Data Source
Figure 1
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AI summary
The invention relates to a device (40) and a method for handling fragments (10) of a broken needle (11), for example in the context of a needle exchange of a broken needle (11) for a new needle (17). The fragments (10) of the broken needle (11) are arranged in a container (16) in a predetermined position. An image (32) of the fragments (10) of the broken needle (11) is then recorded with the aid of a camera (23). The recorded image (32) is stored for documentation (32) at at least one storage location and/or analysed as to whether all the fragments (10) of the broken needle (11) are present. After recording the image (32), the container (16) is closed in order to avoid the fragments (10) of the needle (11) being lost away from the sewing workstation.