Stud Orientation System Curvature Correction
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Solution Overview
Problem
In prefabricated house manufacturing, the variability in wood stud curvature due to moisture absorption leads to inconsistent orientation, causing handling and structural issues, and existing systems are inefficient in automating the correction of stud orientation in high-speed production lines, resulting in increased costs and suboptimal product quality.
Innovation Solution
A system comprising a sensor arrangement and a turning mechanism that measures and corrects the curvature of studs in real-time, ensuring all studs are oriented with their convex edges facing inward, using a combination of sensors and pivotable arms to align and turn studs 180 degrees if necessary, integrated with a conveyor system for high-speed processing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If multiple pallets with different dimensions are stored for flexibility in production, then adaptability is improved, but storage space requirements and transportation costs increase
Solution Approach 1:
The system changes the parameter of stud orientation (curvature direction) rather than storing multiple types of studs. By detecting and correcting the curvature orientation of each stud individually, the system achieves production flexibility without needing to store multiple pallets with different dimensions, thus reducing storage space requirements
Solution Approach 2:
The patent replaces the mechanical approach of storing physically different stud types with an automated detection and correction system using sensors and turning mechanisms. This substitution allows a single storage solution to serve multiple production needs by dynamically adjusting stud orientation
2Adaptability or versatility
If multiple pallets with different dimensions are transported to the production line, then adaptability is improved, but transportation costs and complexity increase
Solution Approach 1:
Instead of transporting multiple types of pallets, the system changes the orientation parameter of individual studs using automated turning mechanisms. This simplifies the logistic system to a single pallet type while maintaining adaptability through real-time stud orientation correction
Solution Approach 2:
The system enables self-service by automatically detecting and correcting stud orientation without human intervention. The sensor arrangement and turning arrangement work autonomously to ensure proper stud orientation, eliminating the need for complex manual logistics and handling systems
3Productivity
If high-speed production lines are used, then productivity is improved, but the complexity of automating stud orientation correction increases
Solution Approach 1:
The patent replaces complex mechanical handling systems with a sensor-based detection and automated turning mechanism. This substitution enables high-speed operation by using non-contact sensing and automated control, reducing the mechanical complexity while maintaining high productivity
Solution Approach 2:
The system implements feedback control by using sensor arrangements to detect stud curvature orientation and automatically adjusting the turning mechanism accordingly. This closed-loop feedback enables high-speed production with precise orientation control, managing system complexity through intelligent control algorithms
Data Source
Figure 1
Figure 2
Figure 3A~3B
AI summary
The invention relates to a system and a method configured to orient a plurality of studs into one and the same curvature based orientation. The system comprises a conveyor (108; 105) having a feeding direction and being arranged to receive a stud (200A, 200B) being oriented with its longitudinal extension in a direction transverse to the feeding direction. The system further comprises a sensor arrangement (160) configured to measure the curvature of the stud (200A, 200B) as seen along its longitudinal extension and as seen in a major plane of the conveyor (108; 105). Additionally, the system comprises a turning arrangement (170) configured to turn the stud (200A, 200B) 180 degrees around its longitudinal extension.