Optical Service Cart Centering for Textile Machine Operating Units
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Solution Overview
Problem
Existing positioning and centring systems for service carts in textile machines face issues such as mechanical wear, dirt accumulation, inaccuracy due to elastic deformation, need for dedicated drives, and sensitivity to orientation, which compromise the precision and reliability of the positioning and centring process.
Innovation Solution
A positioning and centring device using a QR code cryptogram on each operating unit, combined with an optical scanner and control unit, to accurately identify and align the service cart with the operating unit, reducing mechanical wear and sensitivity to dirt, and improving centring precision.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a mechanical centring system with retractable levers and seats is used, then the service cart can be positioned and centred, but mechanical wear and dirt accumulation compromise the kinematics of the centring unit over time
Solution Approach 1:
The patent replaces the mechanical centring system with an optical system. A camera captures an image of the operating unit, and image processing algorithms determine the centring position. This substitution eliminates mechanical wear and dirt accumulation issues, as the optical system has no moving parts that contact the operating unit.
Solution Approach 2:
The patent creates an optical copy (image) of the operating unit using a camera. Instead of direct mechanical contact, the system captures visual information and processes it to determine positioning. This copying approach allows the service cart to be centred accurately without physical interaction that would cause wear.
2Measurement precision
If a mechanical centring system is used, then the service cart can be positioned, but elastic deformation of the structure subjected to the weight of the service cart causes inaccuracy
Solution Approach 1:
The patent replaces mechanical positioning systems that are susceptible to elastic deformation with an optical measurement system. The camera and image processing capture the position of the operating unit without applying mechanical load, thereby eliminating errors caused by structural deformation under the service cart's weight.
3Reliability
If a reflection system using a reflector is used to replace mechanical centring, then the service cart can be centred, but dirt from fibrils deposited on the reflector partially or completely obscures it, compromising functionality
Solution Approach 1:
The patent replaces the reflection system with a direct optical capture system using a camera. Instead of relying on light reflection from a reflector surface that accumulates dirt, the system directly captures an image of the operating unit. This eliminates the problem of dirt obscuring the reflector and compromising functionality.
4Measurement precision
If optical positioning and centring systems using laser pointers and barcodes are used, then the unit number can be identified and centring achieved, but several sub-codes are required to ensure accurate positioning, increasing the code footprint
Solution Approach 1:
The patent merges the identification and centring functions into a single visual code system. Instead of requiring separate barcodes for identification and multiple sub-codes for centring, the system uses one visual code that contains both pieces of information. The image processing algorithm extracts both the unit number and centring position from this single code, reducing the overall footprint.
Solution Approach 2:
The patent transitions from one-dimensional linear barcodes to two-dimensional visual codes. This dimensional change allows more information to be encoded in a smaller space. The visual code can simultaneously encode the unit number, centring position, and other parameters in a compact format that requires less space than traditional barcode systems.
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 QR code system enhances positioning accuracy, reduces mechanical wear and dirt sensitivity, and improves system reliability by enabling precise alignment and real-time operational information, thus enhancing machine performance and user interface accessibility.
Implementation Method 1
an optical scanner (24), provided on the service cart (16), suitable for scanning the cryptogram (22)
Data Source
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AI summary
An industrial textile machine (12) comprising at least two operating units (14) and at least a service cart (16) for the operating units (14). The industrial textile machine (12) further comprising a positioning and centring device (20) for said service cart with respect to said operating units (14). The positioning and centring device (20) comprises: a cryptogram (22) provided on each of the operating units (14), an optical reader (24) provided on the service cart (16) adapted to read the cryptogram (22), and a control unit (26) operatively connected to the optical reader (24) and to the drive means (18). The cryptogram (22) comprising a centring reference (28) for said optical reader (24) with respect to the cryptogram (22), and an identification code (30) of the operating unit (14) on which it is provided. The control unit (26), following a service request signal from an operating unit (14), being adapted to operate the drive means (18) to move the at least one service cart (16) to the operating unit (14) the cryptogram (22) contains the identification code (30) of the operating unit (14) that requested the service; and centring the service cart (16) relative to the operating unit (14) based on the centring reference (28) of the cryptogram (22).