Automated Grinding Wheel Mesh Piece Forming and Inspection
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Solution Overview
Problem
Current grinding wheel mesh piece manufacturing processes are inefficient due to manual picking and incomplete inspection, leading to low overall efficiency and high labor intensity, with existing automatic systems only partially addressing the issue.
Innovation Solution
An integrated system for automatic forming, picking, and inspection of grinding wheel mesh pieces, incorporating a visual inspection system, conveying system, and cutting system, which uses line scanning cameras and servo motors for precise positioning and defect recognition, enabling high-precision cutting and picking.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If manual picking is used, then labor flexibility is maintained, but picking efficiency is low and labor intensity is high
Solution Approach 1:
The patent replaces manual mechanical picking with an automated picking device that uses a picking head with multiple picking elements. The device mechanically picks up punched mesh pieces from the conveyor belt and places them onto acquisition sticks, eliminating manual labor while maintaining high picking efficiency through automated mechanical operations.
Solution Approach 2:
The picking device is designed to automatically perform the picking operation without human intervention. The conveyor belt feeds mesh pieces automatically, the picking head picks them up automatically, and the placement onto acquisition sticks is automatic, creating a self-service system that improves productivity while reducing manual operation.
2Measurement precision
If sampling inspection is used, then inspection cost is reduced, but defect detection completeness is insufficient
Solution Approach 1:
The patent implements continuous full inspection of every mesh piece as it passes through the inspection station on the conveyor belt. The inspection device captures images of each mesh piece and automatically analyzes them for defects, ensuring 100% inspection coverage rather than sampling, while maintaining continuous production flow without interrupting the manufacturing process.
Solution Approach 2:
The patent replaces manual inspection with an automated optical inspection system that uses cameras and image processing algorithms to detect defects. This substitution enables comprehensive inspection of every mesh piece without the time constraints of manual inspection, improving defect detection completeness while maintaining production efficiency.
3Productivity
If separate picking and inspection processes are used, then each process can be optimized independently, but overall process efficiency is reduced due to turnaround and waiting times
Solution Approach 1:
The patent merges the picking process and inspection process into a single integrated production line. The conveyor belt simultaneously transports mesh pieces through both the picking station and inspection station in sequence, eliminating the need to stop or transfer between separate processes. This integration reduces turnaround time and waiting time while improving overall production efficiency.
Solution Approach 2:
The integrated system maintains continuous motion of mesh pieces through the conveyor belt, with picking and inspection operations performed sequentially without interruption. The automated coordination of picking and inspection operations ensures that mesh pieces flow continuously through the system, minimizing idle time and maximizing productivity.
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 system achieves high production efficiency by reducing turnaround and waiting times, improving detection accuracy, and lowering costs through automated logic control of cutting, picking, and inspection processes.
Implementation Method 1
a line scanning camera and an LED light source are mounted in front of the cutting section conveying platform
Implementation Method 2
a line scanning camera and an LED light source are mounted in front of the cutting section conveying platform
Implementation Method 3
uses line scanning cameras and servo motors for precise positioning and defect recognition
Data Source
AI summary
An integrated system for automatic forming, picking, and inspection of a grinding wheel mesh piece and a method thereof, including a visual inspection system (1), a conveying system (2), a cutting system (3), and a picking system (4); the conveying system (2) is used to precisely control a conveying action of a cutting section conveying platform (51) and a picking section conveying platform (52), and the visual inspection system (1) is used to acquire an image of a grinding wheel mesh cloth, establish virtual origin coordinates of a cutting layout and center coordinates of the grinding wheel mesh piece after cutting, recognize defects of the grinding wheel mesh cloth, and calibrate qualified center coordinates and unqualified center coordinates; the cutting system (3) is used to cut the grinding wheel mesh cloth moved to the cutting section conveying platform (51) to obtain a circular grinding wheel mesh piece.