Automated Wrinkle Smoothing With Segmented Vacuum Table
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Solution Overview
Problem
Manual smoothing of wrinkled materials in manufacturing is labor-intensive, time-consuming, and requires skilled operators, leading to increased costs and production delays, especially when dealing with varying thicknesses and types of materials.
Innovation Solution
An automated system comprising a vacuum table with segmented sections and a smoothing device that moves across the material to form a smooth section, with a vacuum progressively applied to each segment to secure the smooth material, eliminating the need for human operators and adapting to different material thicknesses and types.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If human operators manually smooth each sheet of material, then the material can be smoothed without tearing, but the process takes countless labor hours and increases manufacturing costs
Solution Approach 1:
The patent replaces manual mechanical smoothing operations with an automated system that uses a vacuum table and controlled atmospheric pressure to smooth material sheets. The system uses sensors to detect wrinkles and automatically adjusts vacuum pressure in specific zones to eliminate wrinkles without requiring human operators to physically handle and smooth each sheet manually.
Solution Approach 2:
The system enables the material smoothing process to be self-regulating through automated sensor detection and responsive vacuum control. The sensors continuously monitor the material surface for wrinkles, and the system automatically applies vacuum pressure where needed, eliminating the need for human judgment and manual intervention while maintaining consistent smoothing quality.
2Manufacturing precision
If human operators manually smooth material, then wrinkles can be removed, but highly skilled operators are required and finding them is difficult and time-consuming
Solution Approach 1:
The patent replaces the need for skilled human operators with an automated sensing and actuation system. Sensors detect wrinkles objectively without requiring human expertise, and the vacuum system automatically applies appropriate pressure based on sensor feedback, eliminating the dependency on finding and training highly skilled operators.
Solution Approach 2:
The system incorporates sensors that provide real-time feedback about the material surface condition. This feedback loop allows the system to automatically detect wrinkles and adjust vacuum pressure accordingly, replacing the need for human operators to visually inspect and judge material quality with an objective, automated sensing system.
3Reliability
If a vacuum is applied to the entire vacuum table at once, then all material can be secured, but wrinkles may form in the material due to simultaneous pulling
Solution Approach 1:
The patent divides the vacuum table into multiple independently controllable vacuum zones. Each zone can be activated separately based on the detected location of wrinkles and the position of the smoothing device. This segmentation allows selective application of vacuum pressure only where needed, preventing simultaneous pulling that would cause wrinkles while still securing the material effectively.
Solution Approach 2:
The system applies vacuum pressure locally rather than uniformly across the entire table. The vacuum is activated in specific zones corresponding to where wrinkles are detected or where the smoothing device is working. This localized approach secures the material only where necessary, preventing distortion while maintaining smoothness in the active work area.
4Manufacturing precision
If the smoothing device moves slowly across the material, then wrinkles can be smoothed thoroughly, but production time increases
Solution Approach 1:
The patent maintains continuous smoothing action by coordinating the smoothing device movement with progressive vacuum zone activation. As the smoothing device moves across the material, vacuum zones are continuously activated in sequence behind it, ensuring that smoothed areas are immediately secured. This continuous coordination allows faster device movement without compromising smoothing completeness.
Solution Approach 2:
The system prepares vacuum zones in advance before the smoothing device reaches them. Sensors detect upcoming areas that may require smoothing, and the corresponding vacuum zones are pre-activated or ready to activate immediately as the smoothing device passes. This preliminary preparation allows the device to move faster while ensuring thorough smoothing and immediate securing of the material.
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 automated system significantly reduces labor hours, costs, and production time by efficiently smoothing materials quickly and consistently, minimizing inconsistencies and material tearing, and enabling faster manufacturing processes.
Implementation Method 1
A vacuum is progressively applied to a portion of the group of segments in the vacuum table corresponding to the substantially smooth section of the material to pull the substantially smooth section of the material against the vacuum table
Data Source
AI summary
A method and apparatus for smoothing a material having wrinkles. The material is positioned on a vacuum table having a group of segments. A smoothing device is moved across a surface of the material to form a substantially smooth section of the material. A vacuum is progressively applied to a portion of the group of segments in the vacuum table corresponding to the substantially smooth section of the material to pull the substantially smooth section of the material against the vacuum table.