Elastic Material Alignment Using Vision-Guided Deflection Correction
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Solution Overview
Problem
The manual lamination process of elastic materials like sponge mattresses is inefficient, labor-intensive, and prone to inaccuracies due to the large size and softness of the materials, which are affected by temperature, humidity, and external forces.
Innovation Solution
A system comprising an image recognition device, a control unit, a motion robot, and a correction device that automates the handling and correction of elastic materials by photographing images, calculating adjustment data, and controlling robotic movements to align and correct the materials with high precision.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If manual operations are used for lamination, then workers can directly observe and adjust the sponge layers, but the labor intensity is high and production efficiency is low
Solution Approach 1:
The patent replaces manual mechanical operations with an automated system comprising image recognition devices, control units, and motion robots. The image recognition device captures images of the base and upper piece, the control unit processes the images to determine positioning information, and the motion robot executes automated lamination operations, thereby substituting human labor with an automated mechanical-electronic system.
Solution Approach 2:
The system enables self-service through automated image recognition and processing. The image recognition device automatically captures and analyzes the sponge layer positions, the control unit autonomously calculates positioning data, and the motion robot self-executes the lamination without continuous human intervention, making the process self-sufficient.
2Device complexity
If manual operations are used for lamination, then workers can perform the task with simple equipment, but the accuracy and quality stability of the lamination are poor
Solution Approach 1:
The patent implements a feedback mechanism where the image recognition device continuously monitors the position of the base and upper piece, captures real-time images, and feeds this information back to the control unit. The control unit processes the feedback data to calculate accurate positioning information, which is then used by the motion robot to adjust and execute precise lamination operations.
Solution Approach 2:
The patent replaces simple manual tools with an automated system comprising image recognition devices, control units, and motion robots. The image recognition device captures precise positional data, the control unit processes this data to determine exact lamination parameters, and the motion robot executes the lamination with high precision, thereby achieving superior manufacturing accuracy.
3Ease of operation
If workers manually handle the sponge layers, then they can directly feel the material properties, but the labor intensity is high due to the large size and weight of the products
Solution Approach 1:
The patent replaces manual handling of heavy sponge layers with an automated motion robot system. The motion robot is equipped with end effectors that can grasp and manipulate the sponge layers, eliminating the need for workers to physically handle the heavy materials while maintaining full control over the lamination process.
Solution Approach 2:
The patent introduces an intermediary mechanism between the operator and the heavy sponge layers. The motion robot acts as an intermediary that receives control signals from the control unit and executes the handling operations, thereby mediating the interaction between the control system and the heavy materials without requiring direct human contact.
4Productivity
If automated equipment is used for lamination, then production efficiency increases and labor intensity decreases, but the system complexity increases
Solution Approach 1:
The patent segments the automated lamination system into distinct functional modules: an image recognition device for capturing images, a control unit for processing images and calculating positioning data, and a motion robot for executing lamination operations. This segmentation allows each module to perform its specific function independently, simplifying the overall system architecture while maintaining high productivity.
Solution Approach 2:
The patent designs the automated system with multi-functional components. The image recognition device serves both for capturing images and for quality inspection, the control unit handles both image processing and motion control, and the motion robot performs both positioning and lamination operations, thereby reducing overall system complexity through functional integration.
Data Source
AI summary
Embodiments provide a system suitable for handling and correcting elastic materials and a method thereof. In the embodiments, a system for handling and correcting elastic materials includes a workbench, and also includes: an image recognition device, a control unit, a motion robot and a correction device.