Floor Panel Assembly Apparatus with Sensor-Guided Edge Alignment

Solution Overview

Problem

The manual assembly of multi-layered floor tiles is labor-intensive, time-consuming, and prone to errors due to the need for precise alignment of layers, which becomes increasingly challenging as panel sizes grow.

Innovation Solution

An assembly apparatus comprising a platform with walls that guide and align the edges of a base layer and a top layer, along with a sensor unit and a transfer mechanism with articulating vacuum arms to ensure accurate and repeatable alignment and placement of the layers.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of operation

If manual alignment and placement of layers is performed, then flexibility and simplicity are maintained, but labor intensity and time consumption increase significantly

Engineering Contradiction:

ImprovesimplicityVSAvoidassembly speed

Core Design Contradiction:

Ease of operationVSProductivity

Solution Approach 1:

The system uses sensor units to automatically detect alignment status and visual indicators to guide operators, enabling the assembly process to self-regulate without requiring highly skilled manual judgment. The apparatus serves itself by providing real-time feedback on alignment quality.

Inventive Principle:

Principle #25Self-service

Solution Approach 2:

The patent replaces manual visual alignment with automated sensor units that optically detect alignment status. The mechanical act of eyeballing and adjusting is substituted with sensor-based detection and automated feedback mechanisms.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

2Device complexity

If manual alignment is performed by operators eyeballing the layers, then no complex equipment is needed, but alignment precision deteriorates

Engineering Contradiction:

Improveequipment simplicityVSAvoidalignment accuracy

Core Design Contradiction:

Device complexityVSManufacturing precision

Solution Approach 1:

The patent replaces manual visual alignment with automated sensor units that optically detect alignment status. The mechanical act of eyeballing and adjusting is substituted with sensor-based detection and automated feedback mechanisms.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

Sensor units continuously monitor alignment status and provide real-time feedback through visual indicators. This closed-loop feedback system automatically guides the alignment process without requiring complex manual judgment or adjustment.

Inventive Principle:

Principle #23Feedback

3Device complexity

If manual placement is performed without automated guidance, then device complexity remains low, but reliability of alignment deteriorates

Engineering Contradiction:

Improvesystem simplicityVSAvoidalignment consistency

Core Design Contradiction:

Device complexityVSReliability

Solution Approach 1:

Sensor units continuously monitor alignment status and provide real-time feedback through visual indicators. This closed-loop feedback system automatically guides the alignment process without requiring complex manual judgment or adjustment.

Inventive Principle:

Principle #23Feedback

Solution Approach 2:

The system uses sensor units to automatically detect alignment status and visual indicators to guide operators, enabling the assembly process to self-regulate without requiring highly skilled manual judgment. The apparatus serves itself by providing real-time feedback on alignment quality.

Inventive Principle:

Principle #25Self-service

4Area of stationary object

If larger floor panels are assembled manually, then coverage area increases, but alignment difficulty and time consumption worsen

Engineering Contradiction:

Improvepanel coverage areaVSAvoidassembly time

Core Design Contradiction:

Area of stationary objectVSLoss of time

Solution Approach 1:

Sensor units continuously monitor alignment status and provide real-time feedback through visual indicators. This closed-loop feedback system automatically guides the alignment process without requiring complex manual judgment or adjustment.

Inventive Principle:

Principle #23Feedback

Solution Approach 2:

The patent replaces manual visual alignment with automated sensor units that optically detect alignment status. The mechanical act of eyeballing and adjusting is substituted with sensor-based detection and automated feedback mechanisms.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

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

The apparatus enables efficient, accurate, and repeatable assembly of multi-layered floor panels, reducing labor and time while minimizing errors, even for larger panels.

Implementation Method 1

The retention feature can include a plurality of suctioning couplers

Methodology Applied

Scientific EffectVacuum suction: Vacuum

Data Source

PatentUS12291879B2Method and apparatus for assembling a floor panel

Publication Date: 2025.05.06 SNAP LOCK INDS

AI summary

An assembly apparatus for assembling a floor panel can include a platform to support a base layer and a top layer of the floor panel. The platform can include a first wall configured to contact a first edge of the base layer and a first edge of the top layer. The platform can further include second wall adjacent to the first wall and configured to contact a second edge of the base layer and a second edge of the top layer. A sensor unit can determine whether the first edge of the base layer is aligned with the first edge of the top layer, and whether the second edge of the base layer is aligned with the second edge of the top layer.