Encoder-Based Product Status Synchronization for Asynchronous Inspection
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Solution Overview
Problem
In manufacturing environments with multiple process stations, existing systems face challenges in correlating and synchronizing inspection data from asynchronous machine vision systems and other inspection devices to determine the status of products moving through the processing line, leading to inefficiencies in tracking and disposition.
Innovation Solution
A product status synchronization device that receives signals from various process stations, aligns the status data temporally, and provides a control signal for downstream stations, allowing for the synchronization and combination of outputs from multiple inspection systems to determine a final product status, such as pass or reject, based on physical distances and movement signals.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If multiple asynchronous inspection systems operate independently at different positions along the processing line, then each system can perform its inspection function, but the systems cannot correlate inspection data to particular products moving through the line
Solution Approach 1:
The patent introduces a mediator system comprising a encoder that generates position signals and a processor that uses these signals to correlate inspection data from multiple asynchronous systems to specific product positions. The encoder acts as an intermediary that provides a common reference frame, allowing the processor to synchronize status data from different inspection stations to the actual physical position of products on the conveyor, thereby resolving the information loss problem while maintaining independent inspection operations.
2Adaptability or versatility
If inspection systems are distributed at arbitrary positions along the manufacturing line, then comprehensive product inspection is achieved, but synchronizing and combining outputs from these systems becomes complex
Solution Approach 1:
The patent replaces complex mechanical synchronization mechanisms with an electronic encoder-based position signaling system. Instead of using mechanical linkages or complex timing mechanisms to synchronize distributed inspection systems, the encoder generates electronic position signals that are processed to correlate inspection data with product positions. This substitution of mechanical synchronization with electronic position tracking simplifies the overall system architecture while maintaining adaptability to arbitrary inspection station positions along the manufacturing line.
3Productivity
If multiple process stations process products asynchronously, then processing throughput is maintained, but tracking and correlating product statuses becomes difficult
Solution Approach 1:
The patent applies preliminary action by having the encoder continuously generate position signals before inspection data needs to be correlated. The processor uses these pre-existing position signals to immediately correlate inspection status with product position as data becomes available, rather than waiting for synchronization events. This preliminary generation of position reference data enables rapid correlation of asynchronous inspection results, maintaining processing throughput while minimizing status tracking time.
Data Source
AI summary
Systems and methods are directed to a device comprising a product status synchronization device. Examples of the product status synchronization device comprise a plurality of input ports and an encoder input, each of the input ports coupled to one of a plurality of registers and configured to receive a signal indicative of a status assigned to a product by one of a plurality of process stations, and to register the status assigned to the product into the one of the plurality of registers coupled to the input port, wherein one or more of the plurality of process stations are located at different distances from a predetermined location along a processing line and are configured to asynchronously process one or more products moving through the processing line.