WO2010146555A2

WO2010146555A2 - Automatic setting system

Info

Publication number: WO2010146555A2
Application number: PCT/IB2010/052733
Authority: WO
Inventors: Feride Aytul Ercil; Emrah Deniz Kunt; Ahmet Teoman Naskali; Kazim Cakir; Cenker Oden; Hakan Isik; Erhan Durusut
Original assignee: Vistek Isra Vision Anonim Sirketi
Priority date: 2009-06-18
Filing date: 2010-06-17
Publication date: 2010-12-23
Also published as: WO2010146555A3; TR200904764A2; EP2443529A2

Abstract

The present invention relates to an automatic setting system (1) which performs all of the processes of setting, fixing and obtaining final product with processed natural stones and/or ceramic pieces with full automation, and thus provides low cost, product diversity and saving of time.

Description

AUTOMATIC SETTING SYSTEM

Field of the Invention

The present invention relates to an automatic setting system which sets all three dimensional processed natural stones and/or ceramics automatically.

Background of the Invention

Tiling systems realized by processed natural stones and ceramics are works that require enormously intensive labor. Positioning the said stones randomly or according to a determined pattern is carried out manually by operators and this operation can be performed very slowly. This decreases production efficiency and increases the cost.

Since creating a pattern by arrangement of processed natural stones is a process that requires a lot of labor, costs of such products are very high.

The French patent document numbered FR2676300, an application known in the art, discloses a system which manufactures mosaics from processed natural stones according to the image or figure provided by the help of a computer.

The European patent document numbered EP0759366, an application known in the art, discloses a model that sets mosaic with automatically processed natural stones by the help of a device equipped with a computer and a reader.

Summary of the Invention

The objective of the invention is to realize an automatic setting system which performs all of the processes of setting, fixing and obtaining final product with processed natural stones and/or ceramic pieces. Another objective of the invention is to realize an automatic setting system which, through the input unit, enables input of processed natural stones and/or ceramic pieces, and, through the output unit, output of processed natural stones and ceramic settings fully completed and set in desired figures.

A further objective of the invention is to realize an automatic setting system which enables to obtain settings of processed natural stones and/or ceramics by full automation in the desired manner.

Yet another objective of the invention is to realize an automatic setting system which provides low cost, product diversity and saving of time.

Detailed Description of the Invention

The "Automatic Setting System" realized to fulfill the objective of the present invention is illustrated in the accompanying figures wherein,

Figure 1 is the schematic view of the Automatic Setting System. Figure 2 is the flowchart of the setting method used in the Automatic Setting

System.

Figure 3 is the continuation of the flowchart of Figure 2.

Figure 4 is the continuation of the flowchart of Figure 3.

Figure 5 is the schematic view of another embodiment of the Automatic Setting System.

Figure 6 is the flowchart of the setting method used in another embodiment of the

Automatic Setting System.

Figure 7 is the continuation of the flowchart of Figure 6.

Figure 8 is the continuation of the flowchart of Figure 7. The components given in the figures are numbered one by one and the numbers refer to the following:

I . Automatic setting system 2. Design unit

3. Feeding unit

4. Identification unit

5. Control unit

6. Sorting unit 7. Manipulator

8. Setting control unit

9. Fixing unit

10. Faulty piece storage unit

I 1. Unused piece storage unit 12. Drying unit

The automatic setting system (1) comprises a design unit (2) which enables designs such as patterns and pictures to be formed by natural stones and/or ceramics to be loaded to the system via a control device,

at least one feeding unit (3) through which the pieces of the product to be set are fed to the system,

at least one identification unit (4) which enables to identify the characteristic features such as color, shape, brightness of the pieces that are fed,

at least one control unit (5) which matches the design information with the images of the pieces in order to determine whether the identified pieces are usable or not due to the deformation thereon, and where the usable pieces will be positioned during the setting process and whether they are positioned correctly or not, a sorting unit (6) to which the pieces that are referred to as faulty (can not be used in the arrangement) by the control unit (5) due to the deformations thereon are sent,

a manipulator (7) which allows the identified pieces to be arranged on a table according to their characteristic features and in accordance with the position and orientation information coming from the control unit (5),

a setting control unit (8) which enables to determine the deficiencies and faults in the arrangement performed by the manipulator (7),

a fixing unit (9) which enables to feed the fixing element required for the pieces to remain fixed on the table during and after the setting process,

a faulty piece storage unit (10) where the pieces that can not proceed to the sorting unit (6) because of their faults are collected, and

an unused piece storage unit (1 1) in which pieces that are sent from the identification unit (4) to the manipulator (7) because they are not faulty but are redundant for the design, and can not be arranged by the manipulator are collected (7).

The design unit (2) comprises at least one control device. Design information such as picture, pattern of the figure desired to be formed by the ceramic or natural stones is input to the design unit (2) by means of the said control device.

The feeding unit (3) basically comprises at least one reservoir in which the pieces that the product will include are located and a motion mechanism which enables the pieces to be picked up from the reservoir and fed to the system. The said motion mechanism may be comprised of systems such as conveyors, rotary platforms. In the identification unit (4), the image and surface feature information of the pieces fed by the feeding unit (3) for performing the setting that will realize the design are obtained by means of cameras and/or sensors. Then the said information is sent to the control unit (5).

The identification unit (4) classifies the stones it perceives by referring to the database of usable stone classes which are identified to the system in advance also by the identification unit (4). This classification is performed by taking as basis the similarities of texture and color features of surfaces of the stones. If the classified stone is decided to be used in the setting, the stone proceeds towards the control unit (5); otherwise, information is sent to the sorting unit (6) to inform that the stone is redundant. The control unit (5) carries out shape and surface control. It specifies the information (position and orientation information) related to where the pieces selected as usable will be positioned on the table and transmits this information to the manipulator (7), whereby enabling the manipulator (7) to place the correct piece to the correct place. Additionally, it compares the setting information sent by the setting control unit (8) with the design information and thereby controls whether the design is realized in the desired manner. The arrangement control unit (8) controls whether the setting is realized appropriate to the design. For this, after each positioning movement of the manipulator (7), the setting is checked for suitability to the design pattern.

The manipulator (7) enables the piece to be picked up from the feeding unit (3) and placed to its target position included in the setting information coming from the control unit (5) according to the position and orientation information received from the control unit (5). In the said manipulator (7), motion mechanisms such as industrial robots, Cartesian motion systems and rotary axes are utilized.

The sorting unit (6) enables the pieces, which are referred as faulty by the control unit (5) or which could not be used by the manipulator (7) and are redundant in the setting, to be sent either to the unused piece storage unit (1 1) or the faulty piece storage unit (10).

The setting control unit (8) is preferably comprised of sensor and/or camera system disposed on the table on which the manipulator (7) sets the pieces. The setting information obtained by the setting control unit (8) is sent to the control unit (5).

The fixing unit (9) feeds the fixer, which enables the pieces positioned on the table by the manipulator (7) to remain fixed on the table during and after the setting process, onto the table. The said fixer may be, according to the requirement of the system, elements that may provide fixing by means of adhesives such as glue filet, adhesive paper or glue and may eliminate the requirement of use of molds.

In the inventive automatic setting system (1), the operator inputs the design unit (2), via the control device, the shape and color information related to the design of the product to be obtained by the pieces. According to the said information that is input, the system automatically sets the pieces and makes the same design that is initially input available to the user at the output of the system. The design information can be provided to the control unit (5) by the control device, or via internet or network, or by a mobile device that can connect to the control device via various connection protocols (USB, Firewire, RS232, Infrared, Bluetooth, etc.) that allow data exchange.

Operation method (100) of the automatic setting system (1 ) is as follows:

Firstly, the information pertaining to the design that is desired to be realized using natural stones and/or ceramics is input to the design unit (2) via the control device (101). Then a start command is given to the system (1) via the design unit (2)

(102). Subsequently, the pieces are started to be fed from the feeding unit (3) to the system (1 ) (103). The pieces entering the system first arrive to the identification unit (4) and there, the shape, image and surface information of the pieces are obtained by means of the camera and/or sensors (104). Fault analysis is performed by using the obtained information (105). Fault analysis is preferably performed at the control unit (5). The control unit (5) determines whether the pieces are faulty or not by using image and surface information of the pieces. The pieces that are referred to as faulty are sent to the sorting unit (6) by the identification unit (4) upon a command given by the control unit (5) (106). The sorting unit (6) sends the pieces coming from the identification unit (4) to the faulty piece storage unit (10) (107). The pieces that are not faulty are sent from the identification unit (4) to the manipulator (7) again in accordance with a command given by the control unit (5) (108). In the meantime, upon the command it receives from the control unit (5), the fixing unit (9) feeds the fixing element onto the table on which the setting will be realized (109). After the entire table is covered by the fixing element, the manipulator (7) sets the received pieces on the table according to the position and orientation information received from the control unit (5) (1 10). After the setting process is completed, the control unit (8) takes the images of the product via the camera and sensors (1 1 1) and the said taken images are compared with the design information (1 12). The said comparison is preferably performed at the control unit (5). After comparing the image information provided by the setting control unit (8) and the design information, if the two pieces of information are compatible, the control unit (5) enables outputting of the product, which has acquired its finished state, out of the system and terminates the setting process (1 13). If there are differences between the image information and the design information, the control unit (5) gives a warning signal which informs that an operator interruption is required for the piece which is set and includes a setting fault or difference with the design (1 18). The system is stopped for a short period of time by the operator who notices the signal (1 19). If there are not any differences between the image information and the design information and the setting process is terminated, the control unit (5) checks whether or not there are any pieces left at the manipulator (7). After the setting process is completed, if there are any pieces that are transmitted to the manipulator (7) operation area by the feeding unit (3), these pieces are sent to the sorting unit (6) by the feeding unit (3) motion mechanism (1 14). The sorting unit (6) sends the received pieces to the unused piece storage unit (1 1) (1 15). If at the end of step 1 13 there are no pieces that are fed, or after the pieces are sent to the unused piece storage unit (1 15), the setting system is shut down (1 16).

In one embodiment of the invention, the fixing element fed to the system by the fixing unit (9) is a glue-like adhesive. There is provided a drying unit (12) behind the fixing unit (9) for drying the said adhesive. The drying unit (12) is composed of a kiln system operating at a certain temperature. The temperature in the drying unit (12) is constant.

In cases where adhesive is used in the fixing unit (9) in the inventive automatic setting system (1), if the image information provided by the setting control unit

(8) and the design information are identical, the product, which is integrated by being fixed via an adhesive, is sent to the drying unit (12) and is dried in order for the adhesive to be effective (1 17). The product, which leaves the drying unit (12) acquiring its finished state, is output from the system and the setting process is terminated (1 13).

In one embodiment of the invention, the cameras used in the identification and setting control units (4, 8) have their own control devices. The design features input to the design unit (2) are sent from the design unit to the control devices of the identification (4) and arrangement control units (8). Thus, the identification unit (4) can perceive and separate the faulty pieces by itself without sending the image and surface information of the piece that it has obtained via its camera and sensors to a separate unit (control unit (5)), and determines the orientation and position information of the pieces to be used on the table and transmits them to the manipulator (7). The setting control unit (8) compares the image information that it has obtained at the end of the setting process with the design information, and thereby determines whether the setting is realized correctly or not. This way, both the production rate increases and the faults that may occur due to the communication problems between the units are avoided.

The inventive "Automatic Setting System (1)" is described by way of examples and illustrated by figures to facilitate a better understanding thereof. However, the scope of the invention cannot be limited to these examples and figures. It is possible for a person skilled in the art to develop other embodiments within the framework of the basic principles of the invention. The scope of the invention is essentially according to the claims.

Claims

1. An automatic setting system (1) comprising a design unit (2) which enables designs such as patterns and pictures to be formed by natural stones and/or ceramics to be loaded to the system via a control device; and characterized by

at least one control unit (5) which matches the design information with the images of the pieces in order to determine whether the identified pieces are usable or not due to the deformation thereon, and where the usable pieces will be positioned during the setting process and whether they are positioned correctly or not,

a sorting unit (6) to which the pieces that are referred to as faulty (can not be used in the setting) by the control unit (5) due to the deformations thereon are sent,

a manipulator (7) which allows the identified pieces to be set on a table according to their characteristic features and in accordance with the position and orientation information coming from the control unit (5),

an setting control unit (8) which enables to determine the deficiencies and faults in the setting perfoπned by the manipulator (7), a fixing unit (9) which enables to feed the fixing element required for the pieces to remain fixed on the table during and after the setting process,

an unused piece storage unit (1 1 ) in which pieces that are sent from the identification unit (4) to the manipulator (7) because they are not faulty but are redundant for the design, and can not be arranged by the manipulator are collected (7).

2. An automatic setting system (1) according to Claim 1, characterized by a feeding unit (3) comprising at least one reservoir in which the pieces that the product will include are located and a motion mechanism which enables the pieces to be picked up from the reservoir and are fed to the system.

3. An automatic setting system (1) according to any of the preceding claims, characterized by an identification unit (4) comprising cameras and/or sensors that enable obtaining the image and surface feature information of the pieces fed by the feeding unit (3) for performing the arrangement that will realize the design.

4. An automatic setting system (1) according to any of the preceding claims, characterized by a manipulator (7) comprising a motion mechanism which is used in accordance with the position and orientation information coming from the control unit (5) to enable positioning of the pieces on the table.

5. An automatic setting system (1 ) according to any of the preceding claims, characterized by an setting control unit (8) which is comprised of a sensor and camera system disposed on the table on which the manipulator (7) sets the pieces.

6. An automatic setting system ( 1 ) according to any of the preceding claims, operating in accordance with the setting method (100) comprising the steps of inputting the design information (101), giving the start command ( 102), feeding the pieces to the system (103), obtaining the image and surface information of the piece (104), performing fault analysis using the information obtained in step 104 (105), sending the faulty pieces to the sorting unit ( 106), sending the faulty pieces from the sorting unit to the faulty piece storage unit (107), sending the faultless pieces determined at the end of step 105 to the manipulator (108), feeding fixing element onto the table when the pieces are being sent to the manipulator (109), setting the pieces on the table (1 10), obtaining the image information of the whole formed by assembling the pieces (1 1 1), comparing the design and image information (1 12), if the design and image information are not the same at step 1 12, the control unit giving a warning signal (1 18), the operator, who notices the signal, stopping the system for a short period of time (1 19), if the design and image information are the same at step 1 12, terminating the setting process (1 13), sending the pieces remaining in the manipulator to the sorting unit (1 14), sending the remaining pieces from the sorting unit to the unused piece storage unit (1 15), shutting down the setting system (1 16).

7. An automatic setting system (1) according to any of the preceding claims, operating in accordance with the arrangement method (100) wherein the step of performing fault analysis (105) is carried out by the control unit

(5).

8. An automatic setting system (1) according to any of the preceding claims, operating in accordance with the setting method (100) wherein the step of comparing the design and image information (112) is carried out by the control unit (5).

9. An identification unit (4) according to Claim 3, characterized by a camera having its own control devices.

10. An automatic setting system (1 ) according to Claim 6, operating in accordance with the arrangement method (100) wherein the step of performing fault analysis (105) is carried out by the identification unit (4).

11. An setting control unit (8) according to Claim 5, characterized by a camera having its own control devices.

12. An automatic setting system (1) according to Claim 6, operating in accordance with the setting method (100) wherein the step of comparing the design and image information (1 12) is carried out by the setting control unit (8).

13. An automatic setting system (1) comprising a design unit (2) which enables designs such as patterns and pictures to be formed by natural stones and/or ceramics to be loaded to the system via a control device; and characterized by at least one feeding unit (3) through which the pieces of the product to be set are fed to the system,

a sorting unit (6) to which are sent the pieces that are referred to as faulty

(can not be used in the setting) by the control unit (5) due to the deformations thereon,

a setting control unit (8) which enables to determine the deficiencies and faults in the setting performed by the manipulator (7),

a fixing unit (9) which enables to feed the glue-like adhesive required for the pieces to remain fixed on the table during and after the setting process,

a faulty piece storage unit (10) where the pieces that can not proceed to the sorting unit (6) because of their faults are collected, an unused piece storage unit (1 1) in which pieces that are sent from the identification unit (4) to the manipulator (7) because they are not faulty but are redundant for the design, and can not be arranged by the manipulator (7) are collected, and

a drying unit (12) which dries the adhesive fed by the fixing unit (9).

14. An automatic setting system (1) according to Claim 13, characterized by a feeding unit (3) comprising at least one reservoir in which the pieces that the product will include are located and a motion mechanism which enables the pieces to be picked up from the reservoir and fed to the system.

15. An automatic setting system (1) according to Claims 13 to 14, characterized by an identification unit (4) comprising cameras and/or sensors that enable obtaining the image and surface feature information of the pieces fed by the feeding unit (3) for performing the setting that will realize the design.

16. An automatic setting system (1) according to Claims 13 to 15, characterized by an identification unit (4) comprising cameras and/or sensors that enable obtaining the image and surface feature information of the pieces fed by the feeding unit (3) for performing the setting that will realize the design.

17. An automatic setting system (1) according to Claim 13 to 16, characterized by a manipulator (7) comprising a motion mechanism which is used in accordance with the position and orientation information coming from the control unit (5) to enable positioning of the pieces on the table.

18. An automatic setting system (1) according to Claims 13 to 17, characterized by a setting control unit (8) which is comprised of a sensor and camera system disposed on the table on which the manipulator (7) arranges the pieces.

19. An automatic setting system (1) according to Claims 13 to 18, operating in accordance with the setting method (100) comprising the steps of inputting the design information (101), giving the start command (102), feeding the pieces to the system (103), obtaining the image and surface information of the piece (104), performing fault analysis using the information obtained in step 104 (105), sending the faulty pieces to the sorting unit (106), sending the faulty pieces from the sorting unit to the faulty piece storage unit (107), sending the faultless pieces determined at the end of step 105 to the manipulator (108), feeding fixing element onto the table when the pieces are being sent to the manipulator (109), setting the pieces on the table (1 10), obtaining the image information of the whole formed by assembling the pieces (1 1 1), comparing the design and image information (1 12), if the design and image information are not the same at step 1 12, the control unit giving a warning signal (1 18), the operator, who notices the signal, stopping the system for a short period of time (1 19), if the design and image information are the same at step 1 12, terminating the setting process (1 13), the whole formed by the pieces entering into the drying unit and being dried therein in order for the adhesive to be effective (1 17), sending the pieces remaining in the manipulator to the sorting unit (1 14), sending the remaining pieces from the sorting unit to the unused piece storage unit (1 15), shutting down the setting system (1 16).

20. An automatic setting system (1) according to Claims 13 to 19, operating in accordance with the setting method ( 100) wherein the step of performing fault analysis (105) is carried out by the control device unit (5).

21. An automatic setting system (1) according to Claims 13 to 20, operating in accordance with the setting method (100) wherein the step of comparing the design and image information (1 12) is carried out by the control unit

(5).

22. An identification unit (4) according to Claim 16, characterized by a camera having its own control devices.

23. An automatic setting system (1) according to Claim 19, operating in accordance with the setting method ( 100) wherein the step of performing fault analysis (105) is carried out by the identification unit (4).

24. An setting control unit (8) according to Claim 18, characterized by a camera having its own control devices.

25. An automatic setting system (1) according to Claim 19, operating in accordance with the setting method (100) wherein the step of comparing the design and image information (1 12) is carried out by the setting control unit (8).