Sphere Orientation Using Internal Feature Imaging
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Solution Overview
Problem
Existing methods struggle to efficiently orient and align spheres, such as game balls, during manufacturing, especially at high production rates, as external features are not easily discernible and require manual alignment, leading to misplacement of designs or images.
Innovation Solution
A method that identifies and utilizes internal features, either inherent or intentionally inserted, using imaging devices to calculate and rotate the sphere into a desired orientation, eliminating the need for visible surface features and enabling faster throughput.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If external features on the sphere surface are used for orientation, then the sphere can be aligned to a specific position, but the alignment process becomes slow and difficult to support high production rates
Solution Approach 1:
The patent extracts the orientation reference from the external surface features and relocates it to internal features within the sphere. This allows the external surface to remain undisturbed while internal structures (such as molded-in features, embedded markers, or density variations) serve as the basis for automated optical detection and alignment, thereby enabling high-speed processing without sacrificing orientation accuracy.
Solution Approach 2:
The patent replaces manual mechanical alignment methods with an automated optical detection system. The system uses cameras or sensors to detect internal features, calculates the required orientation adjustments, and automatically positions the sphere, eliminating the need for slow manual alignment while maintaining precise orientation control.
2Ease of operation
If visible external features are used for alignment, then the sphere can be oriented, but the features are not easily or quickly discernible at high production rates
Solution Approach 1:
The patent extracts the alignment reference from the external surface and places it internally within the sphere. This allows the alignment system to access clear, well-defined features without being constrained by the speed at which external features can be visually detected, thereby facilitating ease of operation while supporting high production rates.
Solution Approach 2:
The patent replaces manual visual inspection and alignment with an automated optical detection system that can quickly and accurately identify internal features. This substitution enables the system to operate at high speeds without the limitations of human visual processing, thereby improving both ease of operation and productivity.
3Manufacturing precision
If manual alignment methods are used, then the sphere can be oriented to the desired position, but the process is too slow for common manufacturing method rates
Solution Approach 1:
The patent incorporates orientation reference features into the sphere during the molding or manufacturing process itself. These pre-built internal features serve as ready-made alignment targets, eliminating the need for time-consuming post-manufacturing alignment procedures and enabling rapid, precise orientation at high production rates.
Solution Approach 2:
The patent replaces slow manual alignment operations with an automated system that uses optical detection and computational algorithms to rapidly determine the sphere's orientation and apply the necessary adjustments. This substitution dramatically reduces alignment time while maintaining or improving precision, making the process compatible with high-speed manufacturing.
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
Enables accurate and efficient alignment of spheres without relying on surface features, allowing for higher production rates and precise placement of decorations or designs, improving manufacturing efficiency.
Implementation Method 1
The internal feature may be a filament inserted into the ball after or during manufacturing and may be drilled into the sphere or placed within the sphere at a location congruent with the parting line from a sphere molding process
Data Source
AI summary
A method for aligning a sphere to a desired orientation includes imaging a non-surface alignment feature of the sphere and calculating a current orientation of the sphere based on an image of the non-surface alignment feature. Using these calculations, a relationship between the current orientation of the sphere and the desired orientation of the sphere is calculated and communicated to a motion control device, and aligning the sphere into the desired orientation using the motion control device.