FORM 2
The Patents Act 1970
(39 of 1970) &
The Patent Rules 2003 PROVISIONAL SPECIFICATION
(See Section 10 and rule 13)



PREAMBLE OF THE DESCRIPTION:
THE FOLLOWING SPECIFICATION PARTICULARLY DESCRIBES THE INVENTION AND THE MANNER IN WHICH IT IS TO BE PERFORMED




AUTOMATED SYSTEM AND METHOD FOR BALANCING DIFFERENTIAL OUTPUT OF TWO MACHINES
A) TECHNICAL FIELD
[0001] The present invention generally relates to machines in production or manufacturing line and particularly for balancing the differential output of two machines in a production line.
B) BACKGROUND OF THE INVENTION
[0002] Load balancing is a technique that is commonly followed in industries to distribute the load across different machines. Due to the critical role in maintaining high performance, the load balancing issues has been studied extensively in recent years and a number of load balancing techniques are available. Most of this load balancing focuses on the traditional load distribution systems. Load balancing attempts to distribute the computation load across multiple processor or machines as evenly with an objective to improve the performance.
[0003] It becomes increasingly difficult to transmit large volume of the loading objects and handle several loads simultaneously. The challenge, however is to balance the output machine load, since it changes continuously. The load imbalance generally arises when the load has to be transmitted between the different machines. This load


imbalance is mainly due to variation in the speed in which the objects are loaded from first machine to the second machine. The reason may be that the speeds of the machines are different. In that case the speed has to be adjusted or altered by human to get the balanced load to the second machine.
[0004] Earlier either the first machine was being operated with intentionally low speed to match the second one or the additional output was taken out to process later on manually. Using this method the productivity was reduced. Hence there is need to develop an automated system and method for balancing the differential outputs of machines in order to improve the productivity.
[0005] Several techniques are widely followed in industries in order to avoid the unbalance in loading between the machines. The Prior art Patent No. US5923558 discloses an automated integrated input-output control system apparatus for programmable control of tools, machinery and manufacturing processes, where the control system comprises input capability, output capability, and programmable capability. It can be integrated into industrial machinery or tools for programmable control of industrial tools, controls and operation process, using sensors and control system. It cannot be used to balance the differential outputs of the machines.
[0006] Hence there is a need to develop an automated system and method to balance the output of two machines thereby improving the productivity and the operating efficiency of two machines in a production line.
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C) OBJECTS OF THE INVENTION
[0007] The primary object of the present invention is to develop an automated system and method to balance the output of two machines to improve the productivity.
[0008] Another object of the present invention is to develop an automated system and method to balance the output of two machines to operate a machine to its full potential to increase the operating efficiency and the operating factor a machine.
[0009] Yet another object of the present invention is to develop an automated system and method to balance the output of two machines to operate an output machine even during the absence of the operator to improve the productivity and to save manpower.
[0010] Yet another object of the present invention is to develop an automated system and method to balance the output of two machines to operate an output machine even during the off shifts to increase the operating efficiency and the operating factor a machine.
[0011] Yet another object of the present invention is to develop an automated system and method to balance the output of two machines to operate an output machine even without an operator thereby eliminating the need for manual operation.
[0012] Yet another object of the present invention is to develop an automated system and method to take care the differential speed of two machines to prevent the reduction in productivity.
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[0013] These and other objects and advantages of the present invention will become readily apparent from the following detailed description taken in conjunction with the accompanying drawings.
D) SUMMARY OF THE INVENTION
[0014] The abovementioned shortcomings, disadvantages and problems are addressed herein and which will be understood by reading and studying the following specification.
[0015] The various embodiments of the present invention provide an automated method and system for balancing the operation of two machines with differential outputs. The system has a mechanical structure coupled with an instrumentation mechanism and a programmable controller to take care of the differential speed of two machines intelligently to improve the productivity of a system. The system is provided with a loading and unloading mechanism to balance the difference in the output of two machines automatically by controlling the ouput to the final processing machine.
[0016] According to one embodiment a storage system or a buffer system is coupled between the initial loading machine and the final finishing machine so that the excess components corresponding to the difference in outputs of both the initial loading and the final output machine are stored temporarily. The output machine is continuously operated until all the components stored in the buffer system are processed by the


final output machine, even though the component loading operation by the initial component loading operation is over.
[0017] According to one embodiment of the present invention, the buffer system consists of a drum, which has 24 chutes on it. The drum is operated with a pawl and ratchet mechanism. The drum is operated with an electro- pneumatically driven device. The electro-pneumatic drive system has three main pneumatic cylinders. The three cylinders are used for rotating the drum, locking the drum at a given position and to position the drum at a given position to receive and to discharge the excess components. Seven inductive proximity sensors are provided to detect the level of components in the main chute which is used for feeding the components. The entire logic control of the system is managed and controlled with a programmable logic controller.
[0018] Thus the various embodiments of the present invention provide an automated method and system for balancing the operation of two machines with differential outputs. The system has a storage drum provided with plurality of chutes to receive and store the input components from the first machine. The components are stored and downloaded to the second machine until all the input components from the first machine are processed by the second machine. An electro-pneumatic system is provided to drive the storage drum to receive and discharge the input components. A sensor system is provided to detect the loading and the unloading of components from each chute.
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[0019] These and other objects and advantages of the present invention will become readily apparent from the following detailed description taken in conjunction with the accompanying drawings.
E) BRIEF DESCRIPTION OF THE DRAWINGS
[0020] The other objects, features and advantages will occur to those skilled in the art from the following description of the preferred embodiment and the accompanying drawings in which:
[0021] FIGURE. 1 shows a block diagram of an automated system for balancing the operation of two machines with differential outputs, according to one embodiment of the present invention.
[0022] FIGURE. 2 shows a side sectional view of an automated system for balancing the operation of two machines with differential outputs, according to one embodiment of the present invention.
[0023] FIGURE. 3 shows a side sectional view of a latching mechanism in an automated system for balancing the operation of two machines with differential outputs, according to one embodiment of the present invention.
[0024] FIGURE. 4 shows a side view of a rotating mechanism for the drum in an automated system for balancing the operation of two machines with differential outputs, according to one embodiment of the present invention.


[0025] FIGURE. 5 shows a schematic diagram of a sensor bracket in an automated system for balancing the operation of two machines with differential outputs, according to one embodiment of the present invention.
[0026] Although specific features of the present invention are shown in some drawings and not in others. This is done for convenience only as each feature may be combined with any or all of the other features in accordance with the present invention.
F) DETAILED DESCRIPTION OF THE INVENTION
[0027] In the following detailed description, reference is made to the accompanying drawings that form a part hereof, and in which the specific embodiments that may be practiced is shown by way of illustration. These embodiments are described in sufficient detail to enable those skilled in the art to practice the embodiments and it is to be understood that the logical, mechanical and other changes may be made without departing from the scope of the embodiments. The following detailed description is therefore not to be taken in a limiting sense.
[0028] The various embodiments of the present invention provide an automated method and system for balancing the operation of two machines with differential outputs. The system has a mechanical structure coupled with an instrumentation mechanism and a programmable controller to take care of the differential speed of two machines intelligently to improve the productivity of a system. The system is provided with a loading and unloading mechanism to balance the difference in the
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output of two machines automatically by controlling the output to the final processing machine.
[0029] According to one embodiment of the present invention, the system has a storage drum provided with plurality of chutes to receive and store the input components from the first machine. The components are stored and downloaded to the second machine until all the input components from the first machine are processed by the second machine. An electro-pneumatic system is provided to drive the storage drum to receive and discharge the input components. A sensor system is provided to detect the loading and the unloading of components from each chute.
[0030] According to one embodiment a storage system or a buffer system is coupled between the initial loading machine and the final finishing machine so that the excess components corresponding to the difference in outputs of both the initial loading and the final output machine are stored temporarily. The output machine is continuously operated until all the components stored in the buffer system are processed by the final output machine, even though the component loading operation by the initial component loading operation is over.
[0031] According to one embodiment of the present invention, the buffer system consists of a drum, which has 24 chutes on it. The drum is operated with a pawl and ratchet mechanism. The drum is operated with an electro- pneumatically driven device. The electro-pneumatic drive system has three main pneumatic cylinders. The three cylinders are used for rotating the drum, locking the drum at a given position and to position the drum at a given position to receive and to discharge the excess
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components. Seven inductive proximity sensors are provided to detect the level of components in the main chute which is used for feeding the components. The entire logic control of the system is managed and controlled with a programmable logic controller. The components output from the loading machine are stored successively in each chute in the storage drum having 24 chutes. The components are successively loaded in the chutes so that the components are loaded in a chute after ensuring the loading of components in the preceding chute. The loading of components in each chute is detected by a proximity sensor. Similarly the components in each chute are downloaded successively from each chute to the final output processing machine until the components in all the chutes are downloaded. The downloading of the components in each chute is monitored by a proximity sensor. The final output machine is operated even in the absence of operator and even during the off shift hours until all the loaded and stored components are processed.
[0032] FIGURE. 1 shows a block diagram of an automated system for balancing the operation of two machines with differential outputs, according to one embodiment of the present invention. With respect to FIG.l, the input component loading machine has a processing speed which is higher than that of the final processing machine. At the first machine, the loading and processing of components is done with higher speed and it is operated by an operator. The second machine is automatic press machine has a lower processing speed. The loading and processing of components is done on the first machine. The second machine is a press machine. A buffer system or a storage system is coupled between the first and the second machines to balance the differential speed of the machines by storing the additional components while both the machines are on. Even when the operator leaves the first machine, the storage system


automatically feeds the loaded components to the second machine to process the stored components.
[0033] FIGURE. 2 shows a side sectional view of an automated system for balancing the operation of two machines with differential outputs, according to one embodiment of the present invention. With respect to the FIG.2, the buffer system consists of a drum, which has 24 chutes on it. The drum is operated with a pawl and ratchet mechanism. The drum is operated with an electro- pneumatically driven device. The electro-pneumatic drive system has three main pneumatic cylinders. The three cylinders are used for rotating the drum, locking the drum at a given position and to position the drum at a given position to receive and to discharge the excess components. Seven inductive proximity sensors are provided to detect the level of components in the main chute which is used for feeding the components. The entire logic control of the system is managed and controlled with a programmable logic controller.
[0034] The system has a main shaft 30 at the centre. The drum with the 24 chutes is supported on a base plate 20 mounted on a base frame 10. The components move from the fixed chute 50 towards the drum and it goes to the press unit through the component guide plate. The components starts filling in the lowermost rung of the drum so that l/3rd of the storage capacity is filled. Then the next rung gets filled up so that 2/3rd of the storage capacity is filled. The last rung is filled at the end. Thus the dynamic balancing of the system is ensured. The components are stopped by the component stopper cylinder 110. The pick and place unit of press machine picks up the stored components from the storage drum.


[0035] The vertical pick and place cylinders 60 transfer the components on the fixed chute 50 and move the component forward so that the components are moved towards the chutes 80. The drum will be rotated only when the components are transferred by the cylinders from the crimping machine onto the fixed chute 50 so that the component will not get stuck up between the horizontal chute and the rotating drum. The components start filling in the chutes 80. When the components start filling at a certain height/level in the main chute 80, the proximity sensors arranged on a sensor plate 70 positioned proximate to the chutes 80 detect the components and give the output. The components are loaded and unloaded based on the output of the sensors.
[0036] The loading of the components in the drum is explained as follows. When the proximity sensor PX1 is switched on and the proximity sensor PX2 is switched off, then the rotation of one chute is started. The remaining 23 chutes are rotated continuously until the proximity sensor PX2 is switched on. When both the proximity sensors PX1 and PX2 are switched on and there is no signal from other sensors, then the system will wait for the chute to get filled. When the proximity sensor PX3 is switched on and the proximity sensor PX4 is switched off, then the rotation of another chute is started. This rotation will continue for the next 23 chutes until the proximity sensor PX4 is switched on. When the proximity sensors PX1, PX2, PX3 and PX4 are switched on and there is no signal from other sensors, then the system will wait for the chute to get filled. When the proximity sensor PX5 is switched on and the proximity sensor PX6 is switched off, then the rotation of one chute is started. This rotation will continue for the next 23 chutes until the proximity sensor PX6 is switched on. When all the sensors give an output, then a control signal is output to a lamp for glowing. Thus the components are loaded into the storage drum.


[0037] The stored components are downloaded from the storage drum and passed on to the final output processing machine until all the stored components in the drum are processed. The unloading of the components from the storage drum is as follows. A process similar to the loading process is performed in a reverse order to unload the components from the storage drum. When the proximity sensors PX5, PX3 are switched off and the proximity sensor PX6 or PX4 is switched on, one rotation of chute occurs. This rotation will continue for the next 23 chutes until the proximity sensors PX6 and PX4 are switched off. Then the components are unloaded from the chutes. When the proximity sensors PX6, PX5, PX4, PX3 and PXl are switched off and the proximity sensor PX2 is switched on, then one rotation of chute occurs until PX2 is off. Now all the components in each chute are unloaded and this will be sensed by PX7 sensor. When the sensor PX7 is switched off, one rotation of chute occurs. When the sensor PX7 goes off on a particular chute and it does not sense any components on the remaining 23 chutes, then the system will stop.
[0038] The storage drum is rotated successively to load and unload the input components in each chute. The rotation of the storage drum is explained as follows. When the system gets a rotation command, the solenoid coil of positioning cylinder 100 is energized and is moved out of the bushing. Then the backward Reed switch 200 is turned on. As a result, the solenoid coil of latching cylinder 230 is energized to delatch the latching lever 260 and ratchet 4 systems. The backward Reed switch 250 is turned on to energise the rotating cylinder 130. The rotating cylinder 130 is energized and started to rotate. There are three reed switches provided in the rotating cylinder 130. The reed switch 140 is provided at the top, while the reed switch 150 is


positioned at the middle of the cylinder 130 and the last reed switch 160 is arranged at the bottom of the cylinder 130. As soon as the cylinder is started to rotate, the reed switch 160 is turned on. When the cylinder reaches the middle the reed switch 150 is turned on and the latching cylinder 230 is de-energized immediately. Then the reed switch 240 is turned on and the positioning cylinder 100 is de-energized. Afterwards the reed switch 190 is turned on and then reed switch 140 of rotating cylinder 130 is
turned on.
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[0039] FIGURE. 3 shows a side sectional view of a latching mechanism in an automated system for balancing the operation of two machines with differential outputs, according to one embodiment of the present invention. With respect to FIG.3, the storage drum has 24 chutes to store the loaded components. The drum has a base plate 220 to support a chute in which the components 270 are loaded. The drum is rotated and latched to a position using a pawl and ratchet 40 system so that a chute is made to receive the loaded component 270 into it. A latching lever is used to lock the ratchet 40 to hold the chute at the loading point and at the unloading point to load and unload the components easily. A latching cylinder 230 is provided to actuate the latching lever 260 to release and hold the ratchet system 40. Two reed switches 240,250 are provided to energise and de-energise the solenoid coils in the latching cylinder. A reed switch 240 is switched on to de-energise the solenoid coil of the latching cylinder 230 to actuate the latching lever 260 to hold the ratchet system 40. A reed switch at the back position 250 is switched on to energise the solenoid coil of the latching cylinder to delatch the latching lever 260 and to release the ratchet 4 system.

•■>

[0040] FIGURE. 4 shows a side view of a rotating mechanism for the drum in an automated system for balancing the operation of two machines with differential outputs, according to one embodiment of the present invention. The storage drum is rotated successively to load and unload the input components in each chute. The rotation of the storage drum is explained as follows. When the system gets a rotation command, the solenoid coil of positioning cylinder is energized and is moved out of the bushing. Then the backward Reed switch is turned on. As a result, the solenoid coil of latching cylinder is energized to delatch the pawl and ratchet 40 systems. The backward Reed switch is turned on to energise the rotating cylinder 130. The rotating cylinder 130 is energized and started to rotate. There are three reed switches provided in the rotating cylinder 130. The three reed switches are provided respectively at the top, middle and at the bottom of the cylinder 130. As soon as the cylinder 130 is started to rotate, the reed switch at the bottom is turned on. When the cylinder 130 reaches the middle position, the reed switch at the middle is turned on and the latching cylinder is de-energized immediately. Then the reed switch at the front position is turned on to de-energise the positioning cylinder. Afterwards the reed switch 140 at the top position is turned on to stop the rotating cylinder 130.
[0041] FIGURE. 5 shows a schematic diagram of a sensor bracket in an automated system for balancing the operation of two machines with differential outputs, according to one embodiment of the present invention. A sensor plate provided with a plurality of sensors is positioned proximate to the chute in a drum to monitor the loading and the unloading of the components in a chute in the storage drum.


[0042] The loading of the components in the drum is explained as follows. When the proximity sensor PX1 is switched on and the proximity sensor PX2 is switched off, then the rotation of one chute is started. The remaining 23 chutes are rotated continuously until the proximity sensor PX2 is switched on. When both the proximity sensors PX1 and PX2 are switched on and there is no signal from other sensors, then the system will wait for the chute to get filled. When the proximity sensor PX3 is switched on and the proximity sensor PX4 is switched off, then the rotation of another chute is started. This rotation will continue for the next 23 chutes until the proximity sensor PX4 is switched on. When the proximity sensors PX1, PX2, PX3 and PX4 are switched on and there is no signal from other sensors, then the system will wait for the chute to get filled. When the proximity sensor PX5 is switched on and the proximity sensor PX6 is switched off, then the rotation of one chute is started. This rotation will continue for the next 23 chutes until the proximity sensor PX6 is switched on. When all the sensors give an output, then a control signal is output to a lamp for glowing. Thus the components are loaded into the storage drum.
[0043] The stored components are downloaded from the storage drum and passed on to the final output processing machine until all the stored components in the drum are processed. The unloading of the components from the storage drum is as follows. A process similar to the loading process is performed in a reverse order to unload the components from the storage drum. When the proximity sensors PX5, PX3 are switched off and the proximity sensor PX6 or PX4 is switched on, one rotation of chute occurs. This rotation will continue for the next 23 chutes until the proximity sensors PX6 and PX4 are switched off. Then the components are unloaded from the r


chutes. When the proximity sensors PX6, PX5, PX4, PX3 and PXI are switched off and the proximity sensor PX2 is switched on, then one rotation of chute occurs until PX2 is off. Now all the components in each chute are unloaded and this will be sensed by PX7 sensor. When the sensor PX7 is switched off, one rotation of chute occurs. When the sensor PX7 goes off on a particular chute and it does not sense any components on the remaining 23 chutes, then the system will stop.
[0044] Thus the various embodiments of the present invention provide an automated method and system for balancing the operation of two machines with differential outputs. The system has a storage drum provided with plurality of chutes to receive and store the input components from the first machine. The components are stored and downloaded to the second machine until all the input components from the first machine are processed by the second machine. An electro-pneumatic system is provided to drive the storage drum to receive and discharge the input components. A sensor system is provided to detect the loading and the unloading of components from each chute.
G) ADVANTAGES OF THE INVENTION
[0045] The various embodiments of the present invention provide an automated method and system for balancing the operation of two machines with differential outputs intelligently to improve the productivity of a system. The system is provided with a loading and unloading mechanism to balance the difference in the output of two machines automatically by controlling the output to the final processing machine. The system balances the differential speed of the machines by storing the additional


components while both the machines are operated continuously. The system has a storage system to store the excess components corresponding to the difference in outputs of both the initial loading and the final output machines are stored temporarily. The output machine is continuously operated until all the components stored in the buffer system are processed by the final output machine, even though the component loading operation by the initial component loading operation is over.
[0046] The system balances the output of two machines automatically and intelligently to improve the productivity. The system and method to balance the output of two machines to operate a machine to its full potential to increase the operating efficiency and the operating factor a machine. The system enables to operate an output machine even during the absence of the operator to improve the productivity and to save manpower. The system enables to operate an output machine even during the off shifts to increase the operating efficiency and the operating factor a machine. The system provides a facility to operate an output machine even without an operator thereby eliminating the need for manual operation. The system takes care of the differential speed of two machines to prevent the reduction in productivity.
[0047] Although the invention is described with various specific embodiments, it will be obvious for a person skilled in the art to practice the invention with modifications. However, all such modifications are deemed to be within the scope of the claims.
[0048] It is also to be understood that the following claims are intended to cover all of the generic and specific features of the present invention described herein and all the