Weigh Station Counting Flexible Workpieces on Robotic Carrier
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Solution Overview
Problem
The garment and textile industry faces challenges in automation due to the unique, soft, flexible, and amorphous nature of textiles, leading to labor-intensive manufacturing processes and limited automation capabilities, especially in determining the discrete number of non-rigid workpieces accurately.
Innovation Solution
A system utilizing a robotic carrier with a weigh station equipped with weight sensors and circuitry to determine the number of workpieces by comparing the total weight with an expected weight range, allowing for accurate counting and transmission of data to a central control unit for controlling manufacturing operations, and incorporating a camera for navigation and error correction.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If manual counting methods are used to determine the number of workpieces, then the system is simple to implement, but the productivity is low and labor intensity is high
Solution Approach 1:
The patent replaces manual mechanical counting with an automated weighing system that uses electronic sensors and digital processing to determine the number of workpieces. The scale integrates with the conveyor system to automatically weigh batches of workpieces and calculate quantities, eliminating manual labor while maintaining system simplicity through automated computation.
Solution Approach 2:
The weighing system automatically performs the counting function without external intervention. The scale continuously monitors the conveyor belt, automatically identifies when a batch of workpieces is present, weighs them, and calculates the number of items based on the total weight and average item weight, making the system self-sufficient for the counting task.
2Measurement precision
If automated weighing systems are used to determine workpiece quantity, then the productivity increases, but the measurement precision may be insufficient for non-rigid workpieces with variable weights
Solution Approach 1:
The system dynamically adjusts the average workpiece weight parameter based on real-time measurements. When workpieces are first placed on the conveyor, the system measures their individual weights and updates the average weight parameter, allowing accurate counting even when workpiece weights vary due to natural material properties. This adaptive parameter adjustment maintains both precision and productivity.
3Productivity
If the scale continuously monitors the conveyor belt to detect workpieces, then the productivity is improved through automated detection, but the device complexity increases due to additional sensors and control mechanisms
Solution Approach 1:
The patent combines the weighing function and the detection function into a single integrated scale system. The same load cells that measure weight also detect the presence of workpieces on the conveyor belt. When the scale detects a change in weight indicating a new batch of workpieces, it automatically triggers the counting process, merging multiple functions into one device and reducing overall system complexity.
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 efficient and reliable automation in manufacturing non-rigid items by accurately determining the number of workpieces and correcting robotic carrier movement, reducing labor intensity and improving manufacturing precision.
Implementation Method 1
a scale configured to weigh the robotic carrier and one or more workpiece items loaded onto the robotic carrier, the scale having a scale base and a plurality of weight sensors connected with the scale base
Data Source
AI summary
A system for determining a discrete number of flexible, non-rigid workpiece items loaded onto a robotic carrier. The system includes a robotic carrier capable of traveling to multiple workstations, at least one of which is a weigh station. A loading mechanism is functional to load one or more workpieces onto the robotic carrier which weighed by the weigh station. By comparing the weight of the loaded items with a predetermined weight range of a single workpiece, the number of discrete workpieces loaded onto the robotic carrier can be determined. In addition, a method can be provided for determine position error of a mobile robot based on a detected center of gravity of the mobile robot.