Robotic Tile Alignment Machine with Edge Sensors
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Solution Overview
Problem
Manual installation of tiles and other items in patterns is time-consuming and costly, requiring skilled labor and leading to potential worker fatigue and increased costs due to the need for multiple workers, while existing machines lack the precision and versatility to handle varied tile sizes and shapes efficiently.
Innovation Solution
A machine with a robotic assembly and suction cups, equipped with edge and height sensors, capable of moving along X-Y axes, which can align and install items on both horizontal and vertical surfaces, using a vacuum source to pick up and position tiles with precision, and apply bonding materials accurately.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If manual installation by skilled craftsmen is used, then alignment precision and handling of varied tile sizes/shapes is maintained, but installation time increases and labor costs increase
Solution Approach 1:
The robotic system performs self-alignment through sensors that automatically detect tile edges and surfaces, eliminating the need for continuous human measurement and adjustment. The system serves itself by autonomously navigating, detecting, and positioning tiles based on sensor feedback rather than human guidance.
Solution Approach 2:
Manual mechanical alignment operations by craftsmen are replaced with an automated robotic system that uses sensors, motors, and control algorithms to achieve precise tile placement. The robotic arm with multiple joints substitutes human hands and tools for picking, carrying, and positioning tiles.
2Manufacturing precision
If multiple skilled workers are deployed, then complex pattern alignment is achieved, but labor costs and worker fatigue increase
Solution Approach 1:
A single robotic system performs multiple functions that previously required multiple workers: picking tiles, navigating to positions, detecting alignment references, adjusting orientation, and placing tiles. The multi-functional robot consolidates the roles of several specialized craftsmen into one automated unit.
Solution Approach 2:
The robotic system merges detection, positioning, and placement functions into a single integrated system. Sensors detect tile edges and surfaces, the control system processes this information, and the robotic arm executes placement - all in one coordinated operation rather than separate manual steps performed by different workers.
3Productivity
If robotic automation is implemented, then installation speed and consistency are improved, but adaptability to varied tile geometries and surface conditions decreases
Solution Approach 1:
The robotic arm features multiple joints with variable degrees of freedom that can dynamically adjust to accommodate different tile sizes, shapes, and placement positions. The system transitions from static, fixed-position automation to dynamic, adaptable motion that can handle varied geometries through real-time coordinate transformation and joint adjustment.
Solution Approach 2:
The system adapts to varied tile geometries by changing operational parameters such as gripper position, arm joint angles, and suction cup activation patterns. The control system modifies these parameters based on sensor input about tile dimensions and desired placement configurations, enabling flexibility without sacrificing automation speed.
4Adaptability or versatility
If manual tile placement is used, then adaptability to complex surfaces is maintained, but physical strain and worker fatigue increase
Solution Approach 1:
The robotic system replaces human physical operations with automated mechanical arms and suction-based gripping. This substitution eliminates the repetitive lifting, carrying, and precise positioning that causes muscle strain, back problems, and fatigue in manual tile installation while maintaining the ability to work on various surfaces.
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 machine significantly reduces installation time and costs by automating the alignment and placement of tiles, allowing for faster and more accurate pattern creation on various surfaces, including complex geometries, while minimizing the physical strain on workers.
Implementation Method 1
The suction cup is connected to a vacuum source and is capable of picking up, positioning and releasing a tile
Data Source
AI summary
A machine for aligning items in a pattern and a method of using the machine. The machine includes a robotic assembly having four spaced apart joints. The joints including a base joint which is mounted to a stationary surface and a wrist joint onto which an effector is secured. A suction cup is mounted on the effector and is connected to a vacuum source. The suction cup is capable to picking up, positioning and releasing a new item relative to a first laid item and a second laid item. The first and second laid items each have an upper surface and each is aligned perpendicular to one another. The machine further includes three edge sensors and three height sensor. At least one of the edge and height sensors are secured to a first side of the effector and is capable of detecting an edge aligned along an X-X axis of the first laid item and the height of the upper surface of the first laid item, and at least one of the edge and height sensors are secured to a second side of the effector and is capable of detecting an edge aligned along a Y-Y axis of the second laid item and the height of the upper surface of the second laid item. The machine further includes a control mechanism for operating the robotic assembly, the vacuum source and the edge and height sensors. Lastly, the machine includes a power source for supplying power to the control mechanism.