Cube-Shaped Mosaic Pieces Vibratory Tray Orientation
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Solution Overview
Problem
The existing methods for assembling mosaic pieces are complex and inefficient due to the need for precise orientation and handling of irregularly shaped pieces, which limits production output and quality, and restricts the size of usable pieces to above 1 cm due to sensor limitations.
Innovation Solution
The method involves using cube-shaped mosaic pieces that can be easily and accurately positioned on trays with vibratory and rotational motion, eliminating the need for orientation and overturning systems, and allowing pieces as small as 5 mm to be used, simplifying the manufacturing process and enabling smaller sizes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If irregular parallelepiped mosaic pieces are used with orientation sensors and overturning mechanisms, then proper orientation can be achieved, but the manufacturing process becomes complex and costly
Solution Approach 1:
The patent applies asymmetry in reverse by making the pieces symmetric (cube-shaped with identical faces). This eliminates the need for orientation detection and overturning mechanisms, as any face can be positioned upward. The symmetric geometry allows pieces to be randomly oriented during conveyance without requiring complex control systems.
Solution Approach 2:
The patent extracts and eliminates the orientation control system (sensors, blowers, overturning mechanisms) from the manufacturing process. By designing pieces that don't require orientation control, the complex subsystem is completely removed, simplifying the overall system while maintaining manufacturing precision.
2Manufacturing precision
If optical sensors and overturning mechanisms are used for piece orientation, then proper positioning can be ensured, but manufacturing time increases and productivity decreases
Solution Approach 1:
By making pieces symmetric with identical faces, the patent eliminates the need for time-consuming orientation detection and overturning operations. Pieces can be conveyed and positioned directly without waiting for sensor verification or mechanical overturning, significantly increasing production speed while maintaining positioning accuracy.
Solution Approach 2:
The piece geometry is pre-designed to be self-orienting through its symmetric cube shape. This preliminary design feature ensures that orientation is inherently satisfied without requiring real-time control actions during manufacturing, thereby eliminating time delays associated with sensor verification and mechanical adjustment.
3Measurement precision
If electronic sensors are used for detecting piece position, then orientation control is possible, but pieces smaller than 1 cm cannot be detected
Solution Approach 1:
The patent removes the dependency on electronic sensors for piece detection and orientation verification. By using symmetric cube-shaped pieces that self-orient during conveyance, the system no longer requires sensor-based measurement, thereby eliminating the 1 cm minimum size limitation and enabling the use of much smaller pieces (e.g., 5 mm or less).
Solution Approach 2:
The piece geometry itself serves the detection and orientation function that previously required external sensors. The symmetric cube shape inherently provides orientation information through its physical behavior during conveyance, making external sensing systems obsolete and enabling detection of pieces regardless of size.
4Manufacturing precision
If orientation means with sensors and blowers are implemented, then piece orientation can be controlled, but manufacturing costs increase
Solution Approach 1:
The patent extracts and eliminates the expensive orientation control subsystem (optical sensors, blowers, overturning mechanisms) by redesigning the piece geometry. The symmetric cube-shaped pieces require no active orientation control, removing the need for costly equipment while maintaining precise orientation through passive geometric properties.
Solution Approach 2:
By making pieces symmetric with identical faces, the patent eliminates the need for expensive orientation detection and control equipment. The symmetric geometry allows any face to be positioned upward without requiring verification or correction, thereby eliminating capital and operational costs associated with orientation control systems.
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
This approach simplifies the manufacturing process, increases productivity, reduces costs by eliminating sensor and blower systems, and allows for the creation of mosaics with smaller pieces, enhancing aesthetic value and versatility.
Implementation Method 1
laying said pieces on suitable trays that are provided with grid and subjected to vibratory and rotational motion in order to allow the pieces to be evenly distributed within the seats provided by said grid
Implementation Method 2
laying said pieces on suitable trays that are provided with grid and subjected to vibratory and rotational motion in order to allow the pieces to be evenly distributed within the seats provided by said grid
Data Source
AI summary
A method for preparing tiles or sheets consisting of mosaic pieces. More particularly, the invention relates to a method allowing the assembly of mosaic pieces to be greatly facilitated within suitable supports for producing tiles or sheets of mosaic pieces that are ready to be laid down. The method provides a step of providing cube-shaped pieces and laying the latter on trays that are subjected to a vibratory and rotational motion.