Mobile Workpiece Identification for Real-Time Collection Tracking
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Solution Overview
Problem
Existing methods for marking workpieces in production are time-consuming, prone to errors, and inefficient, especially for small batch sizes, leading to production delays and increased manual effort in tracking and managing production orders.
Innovation Solution
Integrate a staging device with the automation device to handle marking elements, allowing the automation device to transport and sort marking elements alongside workpieces, using existing automation components to assign unique identifiers to workpiece collection units, and utilize indoor positioning systems for precise localization.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If manual marking and tracking methods are used, then flexibility and simplicity are maintained, but time consumption and error rates increase
Solution Approach 1:
The system prepares marking elements in advance with all necessary information (routing slips, barcodes, RFID tags) before workpieces arrive at collection units. This preliminary preparation eliminates the need for time-consuming manual marking operations at the collection points, directly resolving the contradiction between marking speed and time consumption.
Solution Approach 2:
The automation device performs marking operations autonomously by retrieving pre-prepared marking elements from storage and applying them to workpieces without human intervention. The system self-manages the entire marking process from element retrieval to application, eliminating manual labor while maintaining high marking speed.
2Reliability
If manual attachment of routing slips is used, then adaptability to different workpieces is maintained, but reliability and accuracy decrease
Solution Approach 1:
The system introduces marking elements (barcodes, RFID tags, data carriers) as intermediaries between the workpieces and the production control system. These standardized intermediaries carry all necessary information reliably and can be automatically read and processed, eliminating human errors in part declaration while maintaining adaptability through programmable data storage.
Solution Approach 2:
The marking elements serve multiple functions: identification, tracking, routing information storage, and data communication. This multi-functionality allows a single standardized system to handle diverse workpiece types and production scenarios, maintaining reliability across different applications without requiring complex specialized systems for each case.
3Productivity
If automated marking systems are implemented, then productivity increases, but device complexity increases
Solution Approach 1:
The system combines multiple functions into the existing automation device: workpiece transport, marking element retrieval, marking element application, and data management all occur through a single integrated automation system. This merging eliminates the need for separate dedicated marking machines and reduces overall system complexity while maintaining high productivity.
Solution Approach 2:
Instead of complex physical marking operations, the system uses information copying through standardized data carriers (barcodes, RFID tags). The marking elements are created as digital copies of workpiece information and applied through simple physical attachment or printing processes, dramatically reducing the complexity of the automation required while maintaining high productivity.
4Reliability
If permanent marking methods like engraving are used, then reliability of identification is improved, but flexibility and speed decrease
Solution Approach 1:
The system uses inexpensive, easily replaceable marking elements (stickers, printed labels, RFID tags) instead of permanent modifications. These marking elements can be quickly applied and changed without affecting the workpiece itself, enabling high marking speeds while maintaining reliable identification through the durability of the data carriers.
Solution Approach 2:
The system replaces mechanical marking processes (engraving, punching) with non-contact or minimal-contact methods such as barcode printing, RFID tag attachment, or magnetic labeling. This substitution eliminates the time-consuming mechanical operations while maintaining reliable and permanent identification through the inherent durability of the electronic or printed data carriers.
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
Enables efficient, cost-effective marking and tracking of workpieces, reducing manual effort, minimizing mix-ups, and enhancing production control, with real-time monitoring and accurate localization of workpieces and orders, optimizing manufacturing processes.
Implementation Method 1
mobile units for sending and receiving electromagnetic signals to and from the workpiece collection units
Implementation Method 2
the position of the marking elements is determined from the propagation times of the electromagnetic signals between the transmit-receive units and the marking elements
Data Source
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AI summary
The invention relates to a method for identifying workpieces (20, 20a-20e), wherein: a production machine (2) produces a plurality of workpieces (20, 20a-20e), and the produced workpieces (20, 20a-20e) are distributed in a sorted manner to multiple workpiece collection units (17a-17e); the produced workpieces (20, 20a-20e) are brought to the workpiece collection units (17a-17e) using an automation device (13); and identifying elements (24, 24a-24e) in the form of mobile units for emitting and receiving electromagnetic signals to and from transceiver units (89) are situated on the workpiece collection units (17a-17e) in order to be able to determine the position of the identifying elements (24, 24a-e) from transit times of the electromagnetic signals between the transceiver units (89) and the identifying elements (24, 24a-e). The identifying elements (24, 24a-e) each directly and/or indirectly bear information (60) regarding the workpieces (20, 20a-20e) on the workpiece collection units (17a-17e). The identifying elements (24, 24a-24e), which are provided by a delivery device (23) and each directly and/or indirectly bear information (60) regarding the workpieces (20, 20a-20e) on the workpiece collection units (17a-17e), are brought from the location of a delivery device (23) to a transfer zone (27) in the working area (29) of the automation device (13). The automation device (13) brings each provided identifying element (24, 24a-24e) from the transfer zone (27) to the associated workpiece collection unit (17a-17e).The invention makes it possible to identify workpieces in a simple and cost-effective manner in order to be able to locate them in real time.