X-Ray Component Counter for Automated Reel Storage
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Solution Overview
Problem
Current methods for counting components on reels, especially when multiple types are present, are manually intensive, prone to errors, and inefficient, particularly for high-speed applications, as they rely on optical techniques obstructed by protective coverings and lack automation.
Innovation Solution
An x-ray imaging system integrated with image processing algorithms and a docking interface for automatic counting and storage, allowing for modular operation and automated transport using conveyors or robots, with optional label application and treatment capabilities.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If optical techniques are used for component counting, then the system is simple and easy to operate, but the counting accuracy deteriorates when protective coverings obscure viewing
Solution Approach 1:
The patent introduces an x-ray imaging system as an intermediary between the component reel and the counting system. The x-ray images penetrate protective coverings that block optical techniques, allowing accurate component identification and counting without manual intervention. The image processing algorithm acts as a mediator that automatically analyzes x-ray images to distinguish different component types and count them accurately.
2Device complexity
If manual component identification and counting is performed, then the system complexity is low, but the productivity and throughput are reduced
Solution Approach 1:
The system implements self-service automation where the x-ray imaging system automatically captures images of components on reels, the image processing algorithm autonomously analyzes these images to identify and count different component types, and the system automatically tracks inventory levels. This eliminates the need for manual recognition and counting operations while significantly increasing throughput and productivity.
3Productivity
If automated reel-storage/retrieval system is implemented, then the productivity increases, but the device complexity increases
Solution Approach 1:
The patent merges the x-ray imaging system, image processing algorithm, reel storage system, and conveyor/robotic transfer mechanisms into an integrated automated counting system. The docking interface combines the parts counter with storage units, allowing automated reel transfer and inventory management. This consolidation increases productivity while managing complexity through unified system architecture.
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 rapid, accurate, and automated component identification and counting, increasing throughput by reducing manual intervention and improving accuracy through x-ray imaging and automated data exchange with manufacturing systems.
Implementation Method 1
an x-ray imaging system to image parts disposed in at least one of a component reel, component trays, cut tape
Data Source
AI summary
An automatic parts counter with an x-ray imaging system to image parts disposed in at least one of a component reel, component trays, cut tape; an image processing algorithm to count the image parts; and a docking interface for docking to a storage unit.