Light-Based Position Control for Manual Picking Consistency
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Solution Overview
Problem
Manual picking processes in manufacturing are prone to variance among operators and over time, leading to inconsistencies in the picking sequence and efficiency.
Innovation Solution
A light-based position control system that projects light beams in a 2D grid over component bins, detecting beam interruptions to guide operators through a calibrated picking sequence using audio, visual, and tactile cues to ensure correct bin access and track efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If manual picking processes are used with simple workstation layouts, then ease of operation is improved, but manufacturing precision deteriorates due to operator variance and inconsistency in picking sequences
Solution Approach 1:
The system uses light beams to detect the operator's hand position and provides real-time feedback through visual indicators (LEDs) and audio cues. When the operator reaches for the correct component bin, the system detects the beam interruption and provides confirmation feedback, guiding the operator to follow the calibrated picking sequence consistently
Solution Approach 2:
The patent replaces mechanical position control systems (used in automated picking) with an optical detection system using light beams. This substitution allows manual operators to achieve precision comparable to automated systems while maintaining the flexibility and ease of operation of manual processes
2Manufacturing precision
If fully-automated picking processes are used with close control of robot movement, then manufacturing precision is improved, but device complexity increases
Solution Approach 1:
The patent replaces complex mechanical position control systems required for automated robots with a simpler optical detection system using light beams and photodetectors. This maintains manufacturing precision while significantly reducing device complexity and allowing manual operation
Solution Approach 2:
The system allows manual operators to perform picking tasks without requiring complex automated control systems. The light-based detection system enables operators to self-guide through the picking sequence using simple visual and audio feedback, eliminating the need for sophisticated mechanical control infrastructure
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 provides a highly repeatable quality level in manual picking processes by ensuring operators follow a correct sequence, reducing errors and improving efficiency through real-time feedback and training data.
Implementation Method 1
Whenever the operator interrupts or breaks one or more of the light beams in the plane while reaching for a component in one of the component bins, the coordinates of the broken light beam(s) are automatically detected via the light device and process controller
Data Source
AI summary
A position control system for a manual picking workstation having a plurality of component bins includes a light device and a process controller. The light device projects a light beam along a plane. The process controller includes a processor and memory containing a calibrated assembly sequence and predetermined bin coordinates for each of the component bins. The process controller executes a method to detect, via the light device, an instance of beam breakage wherein the light beam is interrupted or broken, and to determine two-dimensional (2D) coordinates of the beam breakage. The process controller also determines corresponding bin coordinates of an expected bin via the calibrated assembly sequence, compares the determined 2D coordinates to the corresponding bin coordinates, and executes a control action when the determined coordinates do not match the corresponding bin coordinates. The light device may be an oscillating laser scanner or fixed lasers.