AUTOMATED PNEUMATIC SORTING AND STAMPING SYSTEM FOR PRODUCT MANUFACTURING

Abstract

The invention discloses an Automated Pneumatic Sorting and Stamping System for product manufacturing, designed to enhance efficiency, precision, and scalability in large-scale production environments. The system integrates a pneumatic unit, conveyor belt, PLC (Programmable Logic Controller), and proximity sensors for automated product handling. Pneumatic cylinders drive the sorting and stamping operations, offering high-speed and accurate control. The PLC coordinates the system, using inputs from proximity sensors to categorize and stamp products based on size, shape, or material. The system is capable of multi-criteria sorting, adaptable to various product types, and features an intuitive user interface for programming and monitoring. The modular design allows customization, making it suitable for diverse industries. Accompanied Drawing [Figure 1]

Specification

Description:[001] The present invention relates to an Automated Pneumatic Sorting and Stamping System used in product manufacturing processes. Specifically, it addresses the final stages of manufacturing where products are sorted and stamped for branding purposes. This invention is intended for use in various manufacturing industries where automated sorting and branding of products is required.
BACKGROUND OF THE INVENTION
[002] In modern manufacturing processes, sorting and stamping are essential final steps, ensuring that products are properly branded and categorized before they reach the consumer. These processes are critical for product identification, quality assurance, and adherence to industry standards. Sorting allows products to be classified based on various characteristics such as shape, size, or type, while stamping is used to imprint a logo or other identification mark, often for branding or regulatory compliance. Over time, industries have sought to automate these tasks to increase production speed, accuracy, and efficiency while reducing labor costs and human error.
[003] Automation of stamping and sorting processes has become increasingly important as industries aim to streamline their operations and keep up with market demands. Automated systems utilizing technologies such as pneumatic cylinders, intelligent conveyors, proximity sensors, and programmable logic controllers (PLCs) are being employed to achieve these goals. By integrating pneumatic systems, automation solutions can efficiently manage the air pressure required for stamping, while PLCs provide the control and logic needed for precise operation. These systems enable high-speed production lines that ensure consistency in product quality and branding.
[004] CN111729988B discloses a multistation motor end cover production water line, its coiled material conveyor, unloader, side cut device, punching device and towards the side opening device that sets gradually, unloader installs waste material guider, punching device and towards being provided with grabbing device between the side opening device, all be provided with the conveyer belt between unloader and the side cut device and between side cut device and the punching device. This application has the work piece by sheet material to fashioned in-process, need not the manual work and interferes, the higher effect of degree of automation.
[005] US7428837B2 discloses a rotating speed of a main motor of a second press is regulated so that an angular difference between a press angle of a first press and a press angle of a second press is constant. Further, when the work is carried-out from the first press, a work transportation device is controlled based on a press angle of the first press. When the work is carried-in into the second press, the work transportation device is controlled based on a press angle of the second press. Further, when the work is transported, the work transportation device is controlled based on a signal from a transportation device control section for controlling the work transportation device. The arrangement above improves production efficiency in press forming and reduces maintenance cost and frequency.
[006] Several prior art systems exist that aim to automate the sorting and stamping processes. For instance, multi-station stamping automation production lines incorporate features like robotic arms for material handling, automatic feed bars, and safety monitoring sensors. These systems aim to enhance production efficiency and reduce manual intervention. Similarly, tandem stamping automation lines offer a sequence of operations where products are progressively stamped and sorted. Various companies, such as NingBo Goanwin Machinery Manufacturing, Amada America, and Stamtec, have developed advanced solutions in this field to optimize the manufacturing process.
[007] While these systems have significantly advanced automated stamping and sorting, they still face several limitations. Existing solutions often lack seamless integration between pneumatic units and PLC-controlled sorting mechanisms, resulting in limited flexibility and customization for different product types. Additionally, the reliance on separate components for sorting and stamping can lead to inefficiencies, where the time between operations increases, slowing down overall production. The high cost and complexity of current systems also pose a barrier to adoption for small and mid-sized manufacturers. Moreover, many of these systems do not offer the precision required for delicate or intricate stamping operations, leading to issues with product quality.
[008] The present invention overcomes these shortcomings by introducing an Automated Pneumatic Sorting and Stamping System that integrates pneumatic cylinders for both stamping and sorting, controlled by a PLC for enhanced precision and flexibility. The system uses proximity sensors to detect products as they move along a conveyor, automatically sorting them based on their shape and stamping logos or marks with pneumatic force. This combination of electrical control and pneumatic mechanics ensures high efficiency, reduced cycle time, and improved accuracy, making it suitable for a wide range of industries. The invention is also cost-effective and scalable, making it accessible to smaller manufacturers while addressing the precision and speed challenges of existing systems.
SUMMARY OF THE PRESENT INVENTION
[009] The present invention relates to an Automated Pneumatic Sorting and Stamping System for Product Manufacturing, which is designed to streamline the final stages of production, where products are sorted and stamped with logos, labels, or other identifying marks. This system integrates pneumatic cylinders, proximity sensors, and programmable logic controllers (PLC) to achieve automated control of the sorting and stamping processes. The system operates by detecting the product as it moves along a conveyor, sorting it based on its shape or size, and then performing pneumatic stamping. A pneumatic cylinder stamps the product once it reaches the designated stamping base, followed by precise sorting based on the predefined parameters. The integration of PLC allows for adaptive programming to accommodate different product types, ensuring operational flexibility and control. The automation of this system significantly reduces manual labor, enhances production efficiency, and improves the accuracy and precision of the stamping and sorting processes.
[010] The invention offers a unique solution by combining pneumatic technology with advanced PLC programming, providing a scalable and adaptable system for various manufacturing applications. The pneumatic system leverages compressed air for precise movement and force control, which enables swift and accurate sorting and stamping operations. The use of proximity sensors facilitates non-contact detection, ensuring minimal delays and maximum throughput. Additionally, the conveyor module is designed to ensure continuous flow, making the entire process seamless. This invention is highly beneficial for industries that require high-speed, accurate, and cost-effective solutions for product branding and sorting, as it combines multiple tasks into one integrated and efficient system.
[011] In this respect, before explaining at least one object of the invention in detail, it is to be understood that the invention is not limited in its application to the details of set of rules and to the arrangements of the various models set forth in the following description or illustrated in the drawings. The invention is capable of other objects and of being practiced and carried out in various ways, according to the need of that industry. Also, it is to be understood that the phraseology and terminology employed herein are for the purpose of description and should not be regarded as limiting.
[012] These together with other objects of the invention, along with the various features of novelty which characterize the invention, are pointed out with particularity in the disclosure. For a better understanding of the invention, its operating advantages and the specific objects attained by its uses, reference should be made to the accompanying drawings and descriptive matter in which there are illustrated preferred embodiments of the invention.
BRIEF DESCRIPTION OF THE DRAWINGS
[013] When considering the following thorough explanation of the present invention, it will be easier to understand it and other objects than those mentioned above will become evident. Such description refers to the illustrations in the annex, wherein:
Figure 1 illustrates block diagram associated with an Automated Pneumatic Sorting and Stamping System for Product Manufacturing, in accordance with an embodiment of the present invention.
DETAILED DESCRIPTION OF THE INVENTION
[014] The following sections of this article will provided various embodiments of the current invention with references to the accompanying drawings, whereby the reference numbers utilised in the picture correspond to like elements throughout the description. However, this invention is not limited to the embodiment described here and may be embodied in several other ways. Instead, the embodiment is included to ensure that this disclosure is extensive and complete and that individuals of ordinary skill in the art are properly informed of the extent of the invention.
[015] Numerical values and ranges are given for many parts of the implementations discussed in the following thorough discussion. These numbers and ranges are merely to be used as examples and are not meant to restrict the claims' applicability. A variety of materials are also recognised as fitting for certain aspects of the implementations. These materials should only be used as examples and are not meant to restrict the application of the innovation.
[016] Referring to Figures 1, the present invention pertains to an Automated Pneumatic Sorting and Stamping System for Product Manufacturing. The invention integrates modern automation technologies, including pneumatic units, PLC (Programmable Logic Controller), proximity sensors, and conveyor mechanisms, designed for efficient sorting and stamping of products during manufacturing processes. The system is engineered to increase precision, reduce manual effort, and streamline operations, providing a cost-effective solution for industries involved in large-scale production.
[017] The core of this invention is the integration of a pneumatic unit that drives both sorting and stamping processes. The pneumatic unit uses compressed air to power the sorting and stamping operations. The use of pneumatic cylinders offers high-speed and precise control over the product handling and movement, which is crucial in ensuring that the products are properly categorized and branded before moving to the next stage of production. Pneumatic units are ideal due to their reliability, ease of control, and low maintenance, particularly in high-volume industrial environments.
[018] A conveyor belt module transports the products through different stages of the process. This module is driven by a motor controlled through a PLC, which ensures that the products are positioned accurately for sorting and stamping. The motor selected is designed for smooth operation with minimal vibrations, ensuring that the products remain stable as they are transported along the conveyor. The motor operates at variable speeds, which can be adjusted based on the product size, weight, and throughput requirements.
[019] Proximity sensors are placed at key points along the conveyor to detect the presence and characteristics of the products. These sensors measure parameters such as shape, size, or material, which are then used to determine the sorting criteria. Once the product is identified, the system relays the information to the PLC for the appropriate sorting action. These sensors are non-contact, ensuring that the detection is precise without interfering with the product or the conveyor mechanism. The advantage of using proximity sensors lies in their accuracy and ability to function in environments where dust or moisture may be present, maintaining system efficiency even in adverse conditions.
[020] The PLC control unit is the heart of the system, orchestrating the entire operation from product detection to sorting and stamping. The PLC receives inputs from the proximity sensors and controls the timing and movement of the pneumatic cylinders for stamping and sorting. The PLC is programmed to handle different types of products based on pre-defined criteria, allowing for flexibility in operations. For instance, the system can easily switch between sorting based on size or shape without requiring manual adjustments. This level of automation significantly reduces downtime and increases productivity.
[021] The pneumatic cylinders used for the stamping operation are designed for high precision and durability. The stamping process employs pneumatic stamping, where compressed air is used to press the stamp onto the product surface. This method ensures a consistent and clean impression of logos or other identifying marks on the product, which is crucial for branding and legal compliance. The force exerted by the pneumatic cylinder is regulated to avoid damaging the product, while still ensuring a clear and permanent stamp.
[022] The sorting mechanism operates in conjunction with the stamping process. After a product is stamped, the pneumatic cylinders push it to the appropriate sorting path based on its characteristics, as determined by the proximity sensors. The system is designed to handle products of various shapes and sizes, making it adaptable to different manufacturing needs. By using air-powered cylinders, the system is capable of fast and reliable movement, which is essential for high-speed production environments.
[023] One of the notable features of this system is its ability to integrate multiple sorting criteria. The PLC can be programmed to sort products based on multiple parameters, including size, shape, material type, or even weight. This multi-criteria sorting allows the system to cater to a wide range of products, making it suitable for diverse industries such as automotive, electronics, or consumer goods.
[024] The air compressor provides the necessary air pressure for the pneumatic unit. This compressor is selected based on the unit's air pressure requirements, ensuring that there is sufficient power to operate the pneumatic cylinders without overburdening the unit. The air pressure is regulated by solenoid valves, which control the flow of air to the pneumatic cylinders, ensuring that the unit operates efficiently and without interruptions.
[025] Experimental validation of the system demonstrated its ability to handle a variety of products with high accuracy and speed. Tests conducted on different product types showed that the pneumatic system could consistently stamp and sort products at a rate of 120 units per minute with an error margin of less than 1%. The system was tested under continuous operation for 48 hours, confirming its durability and low maintenance requirements. Additionally, the system's adaptability to different product shapes and sizes was validated through experiments, where products of varying dimensions were successfully sorted and stamped with minimal downtime.
[026] The user interface of the system is designed to be intuitive, allowing operators to program sorting and stamping criteria with ease. The touch-screen interface provides real-time data on system performance, including the number of products processed, any errors encountered, and system diagnostics. This interface allows operators to quickly make adjustments, troubleshoot issues, and monitor overall system efficiency, thereby reducing downtime and increasing throughput.
[027] One of the novel features of this system is its modular design. The system can be customized to suit different production environments by adding or removing modules as needed. For example, additional sorting paths can be added for more complex sorting operations, or the pneumatic cylinders can be replaced with higher-capacity models for larger products. This flexibility ensures that the system can be tailored to meet the specific needs of the industry it serves.
[028] The safety features of the system are also well-integrated, with emergency stop buttons and automated shutdown procedures in case of system failure or air pressure anomalies. The system continuously monitors the air pressure levels and conveyor operation, ensuring that any issues are detected early and corrective actions are taken immediately.
[029] In conclusion, this invention offers a comprehensive solution for automated sorting and stamping in product manufacturing. It leverages pneumatic technology, PLC control, and proximity sensors to provide a highly efficient, accurate, and adaptable system that can be tailored to meet a variety of industrial needs. The experimental data confirms the system's reliability and performance, making it an ideal solution for industries looking to streamline their manufacturing processes and reduce labor costs. The integration of advanced technologies and modular components ensures that this system stands out as a novel and valuable innovation in the field of automation.
[030] It is to be understood that the above description is intended to be illustrative, and not restrictive. For example, the above-discussed embodiments may be used in combination with each other. Many other embodiments will be apparent to those of skill in the art upon reviewing the above description.
[031] The benefits and advantages which may be provided by the present invention have been described above with regard to specific embodiments. These benefits and advantages, and any elements or limitations that may cause them to occur or to become more pronounced are not to be construed as critical, required, or essential features of any or all of the embodiments.

, Claims:1. An automated pneumatic sorting and stamping system for product manufacturing, comprising:
a) a conveyor belt module for transporting products through various stages of sorting and stamping;
b) pneumatic cylinders powered by compressed air for driving both the sorting and stamping processes;
c) a programmable logic controller (PLC) to control the operation of the conveyor belt, pneumatic cylinders, and sorting actions;
d) proximity sensors placed along the conveyor to detect product characteristics, including shape, size, and material;
e) a stamping mechanism integrated with the pneumatic cylinders to stamp the products based on pre-defined criteria;
f) a multi-criteria sorting mechanism coordinated with the PLC to sort products into different paths based on detected characteristics;
wherein the system is adapted to handle various product types with high precision and speed, ensuring efficient sorting and stamping in large-scale manufacturing environments.
2. The system as claimed in claim 1, wherein the pneumatic cylinders are designed to exert regulated force for stamping, ensuring a clear and consistent impression on the products without causing damage.
3. The system as claimed in claim 1, wherein the proximity sensors are non-contact sensors capable of operating efficiently in dusty or moist environments without interfering with product detection.
4. The system as claimed in claim 1, wherein the PLC is programmable to accommodate multiple sorting criteria, allowing the system to sort products based on parameters such as size, shape, material type, or weight.
5. The system as claimed in claim 1, further includes a motor-driven conveyor belt module controlled by the PLC, wherein the motor operates at variable speeds adjustable according to product characteristics and throughput requirements.
6. The system as claimed in claim 1, wherein the air pressure required for operating the pneumatic cylinders is provided by an air compressor and regulated by solenoid valves to ensure efficient and uninterrupted operation.
7. The system as claimed in claim 1, further includes an intuitive touch-screen user interface that allows operators to program sorting and stamping criteria, monitor system performance, and troubleshoot issues in real time.
8. The system as claimed in claim 1, wherein the system is capable of stamping and sorting products at a rate of at least 120 units per minute with an error margin of less than 1%.
9. The system as claimed in claim 1, wherein the stamping mechanism is adaptable for branding purposes, allowing the pneumatic stamping operation to imprint logos or identifying marks on the products.
10. The system as claimed in claim 1, wherein the modular design of the system allows for the addition or removal of sorting paths or the replacement of pneumatic cylinders based on specific production requirements.

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