Optical Spool Profile Detection and Sorting for Automatic Spooling
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing automatic spooling systems struggle with processing spools with irregular shapes and orientations, leading to reduced productivity as they cannot handle spools with anomalous geometries efficiently, resulting in decreased overall efficiency and increased downtime.
Innovation Solution
A device and process that utilize an optical sensor to detect the profile of spools in motion, orient them correctly, and divert irregular spools for separate handling, ensuring only properly shaped spools are fed to the spooling stations, using a controlling unit to manage the sorting and orientation process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If automatic spooling systems process spools with irregular shapes and orientations, then productivity increases, but system complexity increases
Solution Approach 1:
The system performs preliminary detection and classification of spools before they enter the main processing line. Optical sensors detect spool shape and orientation characteristics in advance, and the controlling unit pre-determines the appropriate handling path, thereby avoiding complex real-time processing adjustments and maintaining system simplicity while increasing productivity
Solution Approach 2:
The patent introduces an intermediary control system consisting of optical sensors and a controlling unit that mediates between the bulk spool input and the automated spooling stations. This intermediary layer classifies and orients spools beforehand, allowing the main processing system to operate with simpler, more standardized mechanisms while handling irregular spools through the intermediary's sorting and orientation functions
2Reliability
If spools are handled individually to maintain upright position, then spool integrity is preserved, but handling time increases
Solution Approach 1:
The system preliminarily orients spools in the correct upright position before they reach the automated spooling stations through the controlling unit's coordination of transport mechanisms. This pre-positioning action ensures spool integrity is maintained without requiring complex individual handling at each station, thereby reducing overall handling time while preserving reliability
Solution Approach 2:
The patent implements continuous transport and orientation of spools through an integrated system where the controlling unit coordinates multiple transport elements. Instead of intermittent individual handling, spools undergo continuous movement through oriented transport paths, maintaining upright position throughout the process while minimizing idle time and maximizing handling efficiency
3Productivity
If all spools are processed through the same path, then device simplicity is maintained, but processing efficiency decreases
Solution Approach 1:
The patent segments the spool processing path into distinct routes based on spool characteristics. The controlling unit divides the workflow into separate paths for different spool types (regular vs. irregular shapes, different orientations), allowing each segment to be optimized for its specific requirements. This segmentation increases productivity by matching the right processing method to each spool while keeping individual route complexity manageable
Solution Approach 2:
The system dynamically adjusts the processing path based on real-time detection of spool characteristics. The controlling unit receives input from optical sensors and dynamically routes spools to appropriate processing stations, creating a flexible system that adapts to varying spool geometries. This dynamic routing increases efficiency by optimizing the path for each spool while managing overall system complexity through automated decision-making
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
This solution significantly increases the efficiency of the spooling process by accurately identifying and orienting spools in real-time, doubling the capacity of spool handling and reducing downtime by discarding unsuitable spools, thus enhancing the overall productivity of the production line.
Implementation Method 1
un known detecting device, in particular an optical sensor, arranged on the path of the conveyor belt (1) for detecting the profile of the spool (2)
Data Source
Figure 1A~1C
Figure 2
Figure 3
AI summary
Device and process for controlling spools coming in bulk from spinning and for subsequently feeding them for automatic spooling, wherein spools (2) travel on a main conveyor belt (1) whereon an optical sensor (3) is arranged, wherein the spool (2) in motion with the belt (1), thus acquiring the profile and the posture of the spool (2). On the basis of the detected profile, a deviating element (5) deviates the normal spools on a secondary sorting line (6) that receives and works the deviated spools towards the spooler and to be oriented with the base downwards, or does not deviate the anomalous spools from the main conveyor belt (1), letting them continue towards a collecting box for their subsequent separate treatment.