Visual Flange Labeling with Auto Positioning and Zero Return
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Solution Overview
Problem
Current flange labeling processes in industries such as shipbuilding and wind power are inefficient and prone to errors due to manual loading, identification, and labeling, leading to low production efficiency and poor quality, with no full-automatic solutions available.
Innovation Solution
A visual identification-based full-automatic flange labeling machine incorporating a pneumatic chuck, rotation mechanism, linear push mechanism, visual identification system, labeling actuators, return-to-zero limiting mechanism, and a controller, which automates the loading, rotation, and labeling of flanges, ensuring accurate and efficient labeling.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If manual loading and unloading of flanges are conducted, then device complexity is reduced, but productivity is low and manufacturing precision deteriorates due to manual positioning errors
Solution Approach 1:
The system uses visual identification to automatically detect and locate the initial label position on the flange, eliminating the need for manual position identification. The pneumatic chuck automatically clamps and releases the flange based on detection signals,实现 self-service loading and unloading operations that improve productivity without requiring complex manual intervention systems
Solution Approach 2:
Manual mechanical operations are replaced with automated systems: the visual identification system replaces manual visual inspection, the pneumatic chuck replaces manual clamping, and the rotation mechanism replaces manual positioning. This substitution dramatically improves labeling speed and precision while the modular design keeps overall system complexity manageable
2Manufacturing precision
If manual identification of label position is conducted, then device complexity is reduced, but manufacturing precision deteriorates due to overlapping labels and identification failures
Solution Approach 1:
Manual visual identification is replaced with an automated visual identification system that uses cameras and image processing to detect the initial label position. This system automatically determines the correct labeling position, eliminating human error and ensuring consistent high precision across all labeling operations without requiring complex manual measurement tools
Solution Approach 2:
The visual identification system provides real-time feedback on the flange's label position, allowing the control system to automatically adjust the labeling position to avoid overlap with the initial label. This closed-loop feedback mechanism ensures high manufacturing precision while keeping the system relatively simple through software-based control
3Reliability
If no check process for labeling content is implemented, then device complexity is reduced, but reliability deteriorates due to labeling errors
Solution Approach 1:
A verification mechanism is integrated into the labeling system that checks the labeling content after application. The visual identification system captures images of the applied labels and compares them against the required labeling information, providing automatic verification feedback. This ensures high reliability by detecting and preventing labeling errors while maintaining relatively simple system architecture through software-based verification
4Manufacturing precision
If the pneumatic chuck does not return to zero position, then device complexity is reduced, but manufacturing precision deteriorates due to inconsistent starting positions
Solution Approach 1:
A return-to-zero limiting mechanism is implemented that uses position detection feedback to ensure the pneumatic chuck returns to its predetermined zero position after each labeling cycle. The system monitors the chuck's position and automatically adjusts it back to the starting position, ensuring consistent positioning for the next flange while using relatively simple feedback control rather than complex mechanical positioning systems
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 achieves full-automatic flange labeling with improved accuracy and efficiency, allowing for different flange sizes to be clamped and labeled accurately, reducing noise, and implementing a return-to-zero mechanism for precise mechanical positioning.
Implementation Method 1
The pneumatic chuck is connected to the rotation mechanism, and is used for fixing a flange
Implementation Method 2
the visual identification system detects the flange and identifies an initial label position on the flange
Data Source
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AI summary
A visual identification-based full-automatic flange labeling machine, comprising a pneumatic chuck (1) provided with a first detection unit, a rotation mechanism (45) connected to the pneumatic chuck, a linear push mechanism (2) connected to the rotation mechanism, a visual identification system (5), a labeling actuator (6), a return-to-zero limiting mechanism, a workbench (7) and a controller (8). The visual identification system, the labeling actuator and the linear push mechanism are all fixed to the workbench. The rotation mechanism rotates a flange on the pneumatic chuck. The linear push mechanism pushes the flange to a labeling position and pushes the flange out of the labeling position. The labeling actuators are used for printing a new label on the flange. The linear push mechanism is provided with the return-to-zero limiting mechanism for limiting the pneumatic chuck. A second detection unit is arranged between the linear push mechanism and the pneumatic chuck and is used for detecting whether the pneumatic chuck returns to zero to be reset. The present labeling machine may improve the automation level of flange labeling.