Panel Sorting Device with Alignment and Robotic Arm
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Solution Overview
Problem
In the production of small-sized panels, especially in Low Temperature Poly-silicon factories, the back-end of the production line lacks automation, resulting in high manpower requirements, increased costs, and safety concerns due to manual handling.
Innovation Solution
A panel sorting device comprising a placement rack, alignment device, classification robotic arm, and transfer robotic arm, which automatically corrects panel positions and transfers them according to specifications, utilizing a photography module, analysis module, and data transfer module to enhance efficiency and safety.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Extent of automation
If manual handling is used for panel sorting and transfer, then flexibility in handling various panel types is maintained, but labor costs increase and safety risks arise
Solution Approach 1:
The sorting device is divided into independent functional modules: a robotic arm for panel acquisition, an alignment device for position correction, and a placement rack for storage. Each module operates independently but coordinates through a control system, allowing the system to achieve high automation while maintaining manageable complexity through modular design.
Solution Approach 2:
The placement rack is designed with multiple layers and adjustable positions to accommodate different panel specifications. The robotic arm and alignment device work together as a universal system that can handle various panel types (different sizes and specifications) through programmable control, eliminating the need for separate handling systems for each panel type.
2Productivity
If traditional manual sorting methods are used, then device complexity is low, but productivity and handling efficiency are reduced
Solution Approach 1:
The alignment device continuously monitors panel positions and provides real-time feedback to the control system. Based on this feedback, the robotic arm dynamically adjusts its movements to correct positional deviations and place panels accurately in the placement rack, enabling high-speed automated operation with precision comparable to manual handling.
Solution Approach 2:
The system performs preliminary alignment and position correction before final panel placement. The alignment device pre-adjusts panel positions based on detected deviations, and the robotic arm pre-calculates placement trajectories, ensuring that panels are correctly positioned before being transferred to the placement rack, thereby improving overall sorting efficiency.
3Reliability
If automated robotic systems are implemented, then safety is improved and labor costs are reduced, but device complexity and initial investment increase
Solution Approach 1:
The alignment device serves as an intermediary between the robotic arm and the placement rack. It bridges the gap by detecting panel positions and coordinating the robotic arm's movements, ensuring safe and accurate panel transfer without requiring direct complex interaction between the robotic arm and placement rack control systems.
Solution Approach 2:
The system replaces manual mechanical handling with an automated robotic system controlled by electronic signals and vision technology. The robotic arm, guided by the alignment device's optical detection and control system's computational algorithms, performs panel acquisition and placement tasks that were previously done manually, eliminating safety risks associated with human workers while managing complexity through electronic control.
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 device improves automated handling efficiency, reduces costs, and saves space by enabling quick and accurate sorting and transfer of panels, while minimizing human intervention and enhancing safety.
Implementation Method 1
The photography module is configured to photograph the panels on the production line in position
Implementation Method 2
The analysis module is configured to analyze the data based on the data taken by the photography module, and obtains the positional deviation of the panel
Data Source
AI summary
Disclosed is a panel sorting device which includes a placement rack, an alignment device, and a classification robotic arm. The placement rack has multiple layers. In each layer of the placement rack, at least one panel is placed according to a predetermined sequence and corresponding position. The alignment device is configured to obtain the positional deviation of the panel moved on a production line. The classification robotic arm is configured to correct the panel position in the placement rack based on the positional deviation acquired by the alignment device, and place the panel in the corresponding layer of the placement rack according to the predetermined sequence and position. The panel sorting device can quickly grab the panel and automatically sort the panels according to the product's specifications. As a result, it can increase demand for automated handling and production yield, and reduce costs and save installation space.