Golf Ball Shuttle Routing for High-Speed Multi-Station Printing
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Solution Overview
Problem
Conventional automation tools have limited applicability in golf ball manufacturing, particularly in printing processes due to the variety of markings and small quantities, requiring manual handling and inefficient movement between processing stations.
Innovation Solution
A high-speed golf ball handling and management system with a control system that orchestrates the movement of shuttles through an interconnected track system, enabling simultaneous processing of golf balls at multiple stations, including orientation, printing, and offloading, using shuttles with specialized holders to maintain precise orientation and interaction with processing stations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If conventional automation tools are used for golf ball printing, then device complexity is reduced, but productivity and manufacturing precision deteriorate due to limited applicability to variety of markings and small quantities
Solution Approach 1:
The system employs a single printing station equipped with multiple printing heads, each capable of applying different markings. The control system can direct any printing head to any position on the golf ball, enabling one station to perform the work of multiple specialized stations. This universal approach handles variety of markings and small quantities efficiently while maintaining high productivity through automated shuttle-based transport.
Solution Approach 2:
The system uses dynamic routing where shuttles are selectively directed to different stations based on real-time processing requirements. The control system dynamically assigns shuttles to printing stations or offloading stations depending on the specific marking needs and quantity requirements, optimizing resource utilization and maintaining high productivity without requiring dedicated stations for each marking type.
2Productivity
If manual movement between processing stations is used, then device complexity is reduced, but productivity and loss of time worsen due to inefficient handling
Solution Approach 1:
The system introduces automated shuttles as intermediary carriers between the golf ball storage area and processing stations. These shuttles automatically transport golf balls, eliminating manual handling. The control system manages shuttle routing dynamically, directing them to printing stations for marking or to offloading stations for removal, thereby achieving high throughput through automation while managing complexity through centralized control.
Solution Approach 2:
The system divides the manufacturing process into distinct functional stations (printing stations with different marking capabilities and offloading stations) connected by a shared transport system. Each station is specialized for its function, but the segmented architecture allows flexible routing of shuttles based on real-time needs, enabling high productivity without requiring every station to be constantly occupied.
3Manufacturing precision
If individual printing stations are prepared for different markings, then manufacturing precision is improved, but productivity and loss of time worsen due to preparation and turnover requirements
Solution Approach 1:
Each printing station is designed as a universal station with multiple printing heads capable of producing different markings. The control system selects which printing head to use based on the required marking, eliminating the need for physical reconfiguration or preparation of stations for different products. This maintains marking accuracy through precise positioning and selection while achieving high productivity by avoiding setup time and turnover between different marking types.
Data Source
AI summary
A golf ball printing system has a plurality of stations and a plurality of station tracks. The plurality of stations have an orienting station, a printing station, and a offloading station, and each of the plurality of station tracks have an orienting station track, a printing station track, and an offloading station track. The golf ball printing system also has a primary track connecting each of the plurality of station tracks and a plurality of shuttles configured to traverse the primary track and the plurality of station tracks. The golf ball printing system further has a control system configured to control the movement of the plurality of shuttles to print a marking on a golf ball on each of the plurality of shuttles at the printing station.