Vertical Reel Storage With Camera-Guided Tray Retrieval
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Solution Overview
Problem
Storing and managing large inventories of electronic component reels is costly and time-consuming, particularly due to challenges in efficiently utilizing rack space and quickly retrieving specific reels using automated equipment.
Innovation Solution
A vertical component storage system with a storage stack, operator access station, and automated elevator, utilizing cameras and image processing to identify and locate components on trays, and an automated elevator to move trays between storage locations, along with illumination to guide retrieval.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If automated equipment is used to store and retrieve reels, then retrieval speed is improved, but system complexity increases
Solution Approach 1:
The system uses camera-based automatic identification and tracking of reels, allowing the automated equipment to independently locate and retrieve reels without complex control systems. The camera captures images of reel identifiers, and the system automatically processes this visual information to guide retrieval operations.
Solution Approach 2:
The patent replaces complex mechanical tracking and positioning systems with a camera-based visual identification system. Instead of using sophisticated mechanical sensors and actuators to locate reels, the system uses optical capture and image processing to identify reel positions and guide the automated retrieval mechanism.
2Quantity of substance
If rack space is densely utilized, then storage capacity is improved, but accessibility of specific reels deteriorates
Solution Approach 1:
The camera system continuously monitors and identifies the locations of reels within the densely packed storage rack. This visual feedback allows the control system to precisely locate and access specific reels even when they are stored in compact, high-density configurations. The system receives real-time location data from the camera and uses it to guide automated retrieval.
Solution Approach 2:
The camera-based identification system acts as an intermediary between the densely stored reels and the automated retrieval mechanism. It captures visual information about reel positions and translates this into actionable data that enables the retrieval system to access specific reels without requiring physical inspection or manual searching.
3Device complexity
If manual searching is used to locate specific reels, then system simplicity is maintained, but time consumption increases
Solution Approach 1:
The patent replaces manual visual searching with an automated camera-based identification system. The camera captures images of reel identifiers and positions, and the system automatically processes this information to locate specific reels. This substitution eliminates the time-consuming nature of manual searching while keeping the overall system structure relatively simple.
Solution Approach 2:
The camera system performs automatic identification and location tracking of reels without requiring human intervention. The system independently captures visual data, processes it to determine reel positions, and uses this information to guide retrieval operations, thereby eliminating the time loss associated with manual searching.
Data Source
AI summary
Implementations of the present disclosure include a component storage and retrieval system that includes a storage stack, an operator access station, and an automated elevator. The storage stack defines discrete tray storage locations. The operator access station includes a surface adapted to support a tray. The automated elevator moves a tray from the access station surface to a designated one of the discrete tray storage locations, and retrieves a selected tray from the storage stack and brings the selected tray to the access station. The access station includes a camera positioned such that a tray supported on the surface is within a field of view of the camera. The camera generates data representing an image of the tray, from which the system identifies a component on the tray, and determines where on the tray the component is located. The system communicates the identified location to an operator.