Object Sorting and Tray Mapping for Rapid Prototyping Efficiency
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Solution Overview
Problem
In mass production of customized items, such as orthodontic appliances, the inefficiency in arranging objects of varying sizes and shapes on trays leads to wasted material and increased fabrication time and cost due to the current random mapping process, which does not consider the heights or widths of the items.
Innovation Solution
A system and method for sorting objects by height and mapping them onto trays with fixed dimensions, using a queue-based approach that fills columns sequentially, optimizing the arrangement to minimize height diversity and maximize density, and employing column organization plans to ensure efficient use of space.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If objects are mapped randomly onto trays without considering their dimensions, then the mapping process is simple, but material waste increases and tray utilization decreases
Solution Approach 1:
The patent applies preliminary action by sorting objects by height before mapping them onto trays. This pre-arrangement ensures that when objects are placed on trays, they are organized in a way that maximizes vertical space utilization. The sorting step is performed in advance of the mapping process, allowing the system to achieve efficient tray utilization without complicating the actual mapping operation.
Solution Approach 2:
The patent changes the parameter of object arrangement by transitioning from random placement to height-based sequential placement. Objects are sorted by their height parameter and then mapped in ascending or descending order, which optimizes the vertical dimension of tray usage. This parameter change enables better space utilization and reduces material waste while maintaining process simplicity.
2Productivity
If objects are mapped without sorting by height, then the mapping process is faster, but the number of trays required increases
Solution Approach 1:
The patent applies preliminary action by sorting objects by height before mapping. This pre-sorting enables the mapping process to proceed efficiently with optimized tray utilization. The sorting is performed once before the mapping begins, and then objects are mapped sequentially in height order, which maximizes the use of vertical space on each tray and reduces the total number of trays needed.
Solution Approach 2:
The patent addresses the tray quantity issue by optimizing the vertical dimension (height) of tray utilization. By sorting objects by height and placing them in sequential order, the system effectively uses the vertical space on each tray more efficiently. This dimensional optimization allows more objects to be accommodated on fewer trays without sacrificing mapping speed.
3Device complexity
If objects are arranged without considering height diversity, then the arrangement process is simpler, but processing time per tray increases
Solution Approach 1:
The patent applies preliminary action by sorting objects by height before the arrangement process. This pre-sorting reduces height diversity within each tray batch, which in turn reduces the processing time required for each tray. The sorting is performed once in advance, and then objects are arranged sequentially, maintaining simplicity while reducing processing time.
Solution Approach 2:
The patent changes the arrangement parameter from random or sequence-based placement to height-based sequential placement. By organizing objects in ascending or descending height order, the system minimizes height diversity on each tray, which optimizes processing efficiency. This parameter change reduces processing time per tray while keeping the arrangement process relatively simple through automated sorting and sequential mapping.
Data Source
AI summary
A system and methods for batch sorting objects and mapping the objects on a tray having a fixed dimension along an x-axis and a fixed dimension along a y-axis. Certain aspects of the present embodiments include (a) storing the objects in a queue; (b) sorting the objects in the queue according to a dimension of the objects; (c) mapping the objects sequentially into a first column of a plurality of columns on the tray until the first column is filled; (d) mapping the objects into a subsequent column until the subsequent column is filled; (e) repeating step (d) until only a last column in the plurality of columns remains to be filled, or until no more objects remain in the queue; and (f) mapping the objects into the last column in accordance with a column organization plan. In certain embodiments, at least one of the columns, and not necessarily the last column, includes objects mapped in accordance with a column organization plan.