A method for automatically nesting oversized cartons

Abstract

The present invention discloses a method for automatically nesting oversized cartons, comprising the following steps: loading, wherein a first manipulator picks up a carton from a material rack; correcting, wherein the carton is placed on a correction rack for correction, wherein the first manipulator sucks the long side and the short side of the carton; pre-unpacking, wherein the carton is moved to the position directly above the product to be nested, wherein the second manipulator sucks the long side of the carton close to the side thereof, and the first manipulator releases the sucked short side of the carton; unpacking, wherein the second manipulator moves in an arc shape to completely open the carton; nesting, wherein the product position is detected and deviations are automatically compensated, wherein the two ends of the carton in the length direction are adjusted to an inclined shape, and the carton is nested on the product in a simulated manual nesting method; upon completion, the first manipulator and the second manipulator reset, thereby completing the automatic nesting operation. The beneficial effects of the present invention are as follows: the automatic handling, correction, unpacking, and nesting operations of oversized cartons are realized, and the unpacking and nesting operations of oversized cartons are ensured to be smooth by simulating manual unpacking and nesting; and the nesting speed is fast and the efficiency is high.

Description

Technical Field

[0001] The present invention relates to the technical field of packaging, in particular to an automatic box nesting method for oversized cartons. Background Art

[0002] Photovoltaic modules, also known as solar cell modules or solar panels, are the core and most important component of solar power generation systems. During the production process, finished modules need to be boxed. Because stacked modules are very large, the cartons used for boxing must be very large, even oversized. Large and oversized cartons are prone to deformation, making boxing difficult. Therefore, how to achieve boxing of large and oversized cartons remains a major challenge in the packaging industry. Manual boxing is often labor-intensive and inefficient. Automated boxing, however, typically involves a robot, but using a glove box, cannot address the deformation issues of large and oversized cartons. Furthermore, the boxes are large, heavy, and prone to falling during handling and boxing due to their large linear dimensions and weight. This is particularly challenging for very small size differences, where a single side of the carton is only a few millimeters larger than the product's. For example, the patent publication number is CN113716117A, and the patent name is a new type of large-size photovoltaic module packaging line and process thereof. Its packaging process is S9. Manual completion of side enclosures, that is, using manual methods to cooperate with a robot to put the carton on the product, is a semi-manual operation. The manual workload is still very large, and the efficiency is low, and it is impossible to achieve fast and automated boxing. The patent publication number is CN217836248U, and the patent name is a robotic automatic unpacking and boxing equipment. It discloses the use of an auxiliary unpacking and boxing unit to cooperate with an unpacking and handling robot to unpack and box, but the auxiliary unpacking and boxing unit can only move horizontally and vertically, and its boxing is upright. However, this boxing method is difficult to implement for cartons whose single-side dimensions are only a few millimeters larger than the single-side dimensions of the product. Therefore, there is an urgent need for a method that can realize the boxing of products with ultra-small size differences with oversized cartons to meet higher product boxing requirements. Summary of the Invention

[0003] The object of the present invention is to provide a method for automatically nesting oversized cartons to solve the problems raised in the above-mentioned background technology.

[0004] To achieve the above objectives, the present invention provides the following technical solution: a method for automatically nesting oversized cartons, comprising using a first manipulator with vacuum suction cups and a second manipulator, wherein a correction frame is provided on the side of the first manipulator, and the nesting steps are as follows:

[0005] Step 1: Loading: The first robot picks up the carton from the rack;

[0006] Step 2: Correction: The first manipulator places the sucked carton on the correction rack for correction, and then adjusts the suction position of the first manipulator. The first manipulator simultaneously sucks the long side and short side of the carton on the correction rack at this time;

[0007] Step 3: Pre-unpacking: The first robot moves the carton to the top of the product to be boxed, and then the second robot grabs the long side of the carton close to its side, and the first robot releases the short side of the carton;

[0008] Step 4: Open the carton. The first manipulator remains stationary, and the second manipulator moves in an arc from the long side to the short side of the carton opposite to it and away from the first manipulator until the carton is completely opened.

[0009] Step 5: Put the carton on. First, the second manipulator detects the position of the product and automatically compensates for the deviation. Then, the first manipulator and the second manipulator move synchronously to adjust the two ends of the carton in the length direction to an inclined shape with one high and one low. Then, the first manipulator and the second manipulator descend at the same time, and put the lower end of the carton on one end of the product first. Then, the first manipulator and the second manipulator rotate the carton synchronously, and rotate the high end of the carton downward and put it on the other end of the product. Finally, the first manipulator and the second manipulator drive the carton to move downward synchronously to completely put the carton on the product.

[0010] Step 6: Finished. The first and second manipulators release the sucked cartons and reset to complete the automatic box nesting operation.

[0011] It is further preferred that the inclination angle of the carton before the box is put into the box in step five is 20-40 degrees, so as to simulate the manual box-putting action, facilitate the box-putting on the product, ensure the smooth box-putting without jamming.

[0012] Further preferably, when unpacking the carton in step 4, the first manipulator and the second manipulator are placed in diagonally opposite directions to facilitate opening of the carton in a folded state.

[0013] It is further preferred that a roller conveyor line is provided between the first manipulator and the second manipulator to facilitate automatic conveying of the product to the box position and realize automatic loading.

[0014] Further preferably, a ground rail line is provided below the first manipulator and is transported along the conveying direction of the roller conveyor line, and the correction frame is provided at the end of the ground rail line away from the second manipulator.

[0015] It is further preferred that a plurality of material racks are provided on the side of the first manipulator away from the second manipulator, which is convenient for placing cartons and refilling materials, thereby realizing continuous box-wrapping operations; the length direction of the material racks intersects with and is not perpendicular to the conveying direction of the ground rail line, that is, the length direction of the material racks is inclined relative to the conveying direction of the ground rail line, which is convenient for the first manipulator to suck and carry cartons.

[0016] It is further preferred that a first fixed frame with a rectangular structure is provided at the end of the finger of the first manipulator, a second fixed frame with a rectangular structure is provided at one end along the length direction of the first fixed frame, a plurality of first vacuum suction cups are provided along the edge of the first fixed frame, and a plurality of second vacuum suction cups are provided along the edge of the second fixed frame. The plurality of first vacuum suction cups can be used to suck the long side of an oversized carton, and the suction can be firm; the plurality of second vacuum suction cups can be used to suck the short side of an oversized carton, and the suction can be firm.

[0017] Further preferably, a travel limit switch is provided on the first fixing frame for detecting the moving position of the first manipulator to ensure that the first manipulator accurately grasps the carton.

[0018] It is further preferred that a third fixed frame with a rectangular structure is provided at the end of the finger of the second manipulator, and a plurality of third vacuum suction cups are provided along the edge of the third fixed frame. The second manipulator can suck the long side of the oversized carton firmly through the plurality of third vacuum suction cups.

[0019] Further preferably, a corner of the third fixed frame is provided with a mounting plate perpendicular thereto, the mounting plate is arranged on the side of the third fixed frame away from the second manipulator finger, a first ranging sensor is installed on the mounting plate, and a second ranging sensor is provided on the third fixed frame near the mounting plate. The position of the product can be detected by the first ranging sensor and the second ranging sensor, so that the position deviation of the carton can be compensated before the carton is put into the box, thereby ensuring smooth box putting.

[0020] Beneficial effects: The automatic box-nesting method for oversized cartons of the present invention realizes automatic handling, correction, unpacking and box-nesting operations of oversized cartons through the first manipulator and the second manipulator; multiple vacuum suction cups can ensure the adsorption force of the first manipulator and the second manipulator on the carton without damaging the carton; the first manipulator and the second manipulator can adopt the method of unpacking to simulate manual opening, and simulate the manual box-nesting method, and tilt the carton before box-nesting to ensure smooth box-nesting; the automatic box-nesting method effectively realizes the box-nesting operation of oversized cartons, with fast box-nesting speed, high efficiency and high box-nesting quality, which solves the problems of manual box-nesting and the problem that the existing machine box-nesting cannot nest oversized cartons. BRIEF DESCRIPTION OF THE DRAWINGS

[0021] Figure 1 This is a schematic flow chart of the method for automatically nesting oversized cartons disclosed in an embodiment of the present invention;

[0022] Figure 2 This is a schematic diagram of the axonometric structure of the first manipulator and the second manipulator when they are nested in the box according to an embodiment of the present invention;

[0023] Figure 3 This is a schematic diagram of a top view of the structure of the first manipulator and the second manipulator when they are in the box according to an embodiment of the present invention;

[0024] Figure 4 A schematic structural diagram of a first manipulator disclosed in an embodiment of the present invention;

[0025] Figure 5 This is a schematic structural diagram of the finger tips of the first manipulator disclosed in an embodiment of the present invention;

[0026] Figure 6 A schematic structural diagram of a second manipulator disclosed in an embodiment of the present invention;

[0027] Figure 7 This is a schematic structural diagram of the finger tips of the second manipulator disclosed in an embodiment of the present invention.

[0028] Figure markings: 1-first manipulator, 11-first fixed frame, 12-second fixed frame, 13-first vacuum suction cup, 14-second vacuum suction cup, 15-travel limit switch, 2-second manipulator, 21-third fixed frame, 22-third vacuum suction cup, 23-mounting plate, 24-first distance measuring sensor, 25-second distance measuring sensor, 3-correction frame, 4-material rack, 5-roller conveyor line, 6-ground rail line. DETAILED DESCRIPTION

[0029] The following are specific embodiments of the present invention and the accompanying drawings to further describe the technical solutions of the present invention, but the present invention is not limited to these embodiments.

[0030] like Figure 1-7As shown, a method for automatically nesting oversized cartons includes a first robot 1 and a second robot 2 equipped with vacuum suction cups. A calibration rack 3 is provided on the side of the first robot 1. The first and second robots 1 and 2 automatically handle, unpack, and nest oversized cartons. The calibration rack 3 calibrates the cartons to ensure the correct suction position of the first robot 1. Among them, the finger end of the first manipulator 1 is provided with a first fixed frame 11 with a rectangular structure, and one end along the length direction of the first fixed frame 11 is provided with a second fixed frame 12 with a rectangular structure. A plurality of first vacuum suction cups 13 are provided along the edge of the first fixed frame 11, and a plurality of second vacuum suction cups 14 are provided along the edge of the second fixed frame 12; the first fixed frame 11 is used for the installation of the first vacuum suction cup 13, which can suck the long side of the carton, and the second fixed frame 12 is used for the installation of the second vacuum suction cup 14, which can suck the short side of the carton. The first vacuum suction cup 13 and the second vacuum suction cup 14 can simultaneously suck one long side and one short side of the carton, so that the carton can be transported in a folded state (i.e., in sheet form), which is convenient for transportation; and the first fixed frame 11 and the second fixed frame 12 enable the first manipulator 1 to suck and transport oversized cartons. The plurality of first vacuum suction cups 13 and the plurality of second vacuum suction cups 14 ensure that the oversized cartons are firmly sucked, and can prevent the cartons from deforming or falling off during the suction process.

[0031] A rectangular third mounting bracket 21 is provided at the end of the second manipulator 2's fingers, with a plurality of third vacuum cups 22 positioned along the edge of the third mounting bracket 21. The third mounting bracket 21 is used to mount the third vacuum cups 22, which are used to suction the long sides of the carton. The carton can be opened through the suction coordination of the first manipulator 1 and the second manipulator 2. A mounting plate 23 is provided perpendicular to the third mounting bracket 21 at one corner. The mounting plate is located on the side of the third mounting bracket 21 away from the second manipulator 2's fingers. A first distance sensor 24 is mounted on the mounting plate, and a second distance sensor 25 is provided on the third mounting bracket 21 near the mounting plate 23. The first and second distance sensors 24, 25 can detect deviations in the length and width of the carton and the product, enabling automatic correction of deviations when the carton is nested. This ensures that the second manipulator 2 can automatically compensate for positional deviations when nesting the carton, ensuring the accuracy of the nesting process.

[0032] In this application, the steps of the method for automatically nesting oversized cartons are as follows:

[0033] Step 1: Loading: The first robot 1 picks up the carton from the rack 4 at its rear side and absorbs the carton in a folded state;

[0034] Step 2: Calibration. The first manipulator 1 places the sucked carton on the calibration rack 3 at the right end of the ground rail line 6 for calibration. The position of the carton on the calibration rack 3 is the set position. Then, the stroke limit switch 15 on the first fixed rack is used to adjust the suction position of the first manipulator 1 to ensure that the first manipulator 1 accurately adsorbs the carton. The first manipulator 1 simultaneously adsorbs the long side and short side of the carton on the calibration rack 3. The first vacuum suction cup 13 adsorbs the long side of the carton, and the second vacuum suction cup 14 adsorbs the short side of the carton.

[0035] Step 3: Pre-unpacking: The first robot 1 moves the carton to the roller conveyor line 5 in front of the first robot 1, which is positioned just above the product to be boxed. Then, the second robot 2 in front of the roller conveyor line 5 uses the third vacuum suction cup 22 to suck the long side of the carton close to its side. The second vacuum suction cup 14 on the first robot 1 is closed, and the short side of the carton sucked by the second vacuum suction cup 14 is released.

[0036] Step 4: Open the carton. The first manipulator 1 remains stationary, and the second manipulator 2 moves in an arc from the long side to the short side of the front side of the carton and in a direction away from the first manipulator 1 (i.e., the front), simulating the manual opening method to open the carton.

[0037] Step 5, put the carton, first, the first distance measuring sensor 24 and the second distance measuring sensor 25 installed on the second manipulator 2 detect the position of the product, and then move the carton to automatically compensate for the deviation, then the first manipulator 1 and the second manipulator 2 move synchronously, and adjust the two ends of the length direction of the carton to an inclined shape of one high and one low, that is, the left is low and the right is high or the left is high and the right is low, and the inclination angle of the carton is 20-40 degrees, then the first manipulator 1 and the second manipulator 2 descend at the same time, and put the lower end of the carton on one end of the product first, then the first manipulator 1 and the second manipulator 2 rotate the carton up and down synchronously, and rotate the high end of the carton downward and put it on the other end of the product, finally, the first manipulator 1 and the second manipulator 2 drive the carton to move downward synchronously, and completely put the carton on the product;

[0038] Step 6: Finished. The first vacuum cup 13 on the first manipulator 1 and the third vacuum cup 22 on the second manipulator 2 release the sucked cartons. Then the first manipulator 1 and the second manipulator 2 move and reset to complete the automatic box nesting operation.

[0039] In this application, the optimal tilt angle of the carton before the box is put into the box in step five is 30 degrees, which ensures that the tilt angle of the carton is not too large, and the rotation angles of the first manipulator 1 and the second manipulator 2 are easy to achieve quickly, ensuring smooth box putting.

[0040] In the present application, the first manipulator 1 and the second manipulator 2 are placed in diagonally opposite directions when the carton is unpacked in step four. When the folded carton begins to open, the front and back sides of the carton move from the long side to the short side, that is, the first manipulator 1 and the second manipulator 2 move toward each other. Placing the first manipulator 1 and the second manipulator 2 in diagonally opposite directions can facilitate the relative movement of the first manipulator 1 and the second manipulator 2, and facilitate the smooth opening of oversized cartons.

[0041] In this application, there are roller conveyor lines 5 set on the left and right between the first manipulator 1 and the second manipulator 2, which are used for automatic transportation of products, realize automated boxing operations, and can achieve rapid boxing, reduce manual work, and facilitate automatic loading of products and automatic unloading after boxing.

[0042] In this application, a ground rail line 6 is provided below the first manipulator 1, which is transported along the conveying direction of the roller conveyor line 5. The ground rail line 6 facilitates the left and right movement of the first manipulator 1, and facilitates the first manipulator 1 to transport the cartons on the material rack 4 to the correction rack 3 for correction, and to transport the corrected cartons to the top of the product; the correction rack 3 is arranged at the end of the ground rail line 6 away from the second manipulator 2, which effectively utilizes the space and reduces the moving distance of the first manipulator 1 each time it transports the carton, which can effectively ensure the accuracy of the box nesting and prevent the carton from falling off.

[0043] In this application, a plurality of material racks 4 are provided on the side of the first manipulator 1 away from the second manipulator 2. In this application, two material racks 4 are provided, which effectively increases the stacking amount of cartons and facilitates the replenishment of cartons during the box-nesting process, thereby realizing continuous box-nesting operations; the length direction of the material rack 4 intersects with and is not perpendicular to the conveying direction of the ground rail line 6, which facilitates the first manipulator 1 to absorb and carry oversized cartons, and facilitates the transportation of cartons to the correction rack 3.

[0044] Finally, it should be noted that the above descriptions are merely preferred embodiments of the present invention and are not intended to limit the present invention. Although the present invention has been described in detail with reference to the aforementioned embodiments, those skilled in the art will be able to modify the technical solutions described in the aforementioned embodiments or substitute equivalents for some of the technical features. Any modifications, equivalent substitutions, and improvements made within the spirit and principles of the present invention shall be included within the scope of protection of the present invention.

Claims

1. A method for automatically nesting oversized cartons, comprising using a first manipulator with vacuum suction cups and a second manipulator, wherein the first manipulator is provided with a correction frame on the side thereof, characterized in that: The steps of the box are as follows: Step 1: Loading: The first robot picks up the carton from the rack; Step 2: Correction: The first manipulator places the sucked carton on the correction rack for correction, and then adjusts the suction position of the first manipulator. The first manipulator simultaneously sucks the long side and short side of the carton on the correction rack at this time; Step 3: Pre-unpacking: The first robot moves the carton to the top of the product to be boxed, and then the second robot grabs the long side of the carton close to its side, and the first robot releases the short side of the carton; Step 4: Open the carton. The first manipulator remains stationary, and the second manipulator moves in an arc from the long side to the short side of the carton opposite to it and away from the first manipulator until the carton is completely opened. Step 5: Put the carton on. First, the second manipulator detects the position of the product and automatically compensates for the deviation. Then, the first manipulator and the second manipulator move synchronously to adjust the two ends of the carton in the length direction to an inclined shape with one high and one low. Then, the first manipulator and the second manipulator descend at the same time, and put the lower end of the carton on one end of the product first. Then, the first manipulator and the second manipulator rotate the carton synchronously, and rotate the high end of the carton downward and put it on the other end of the product. Finally, the first manipulator and the second manipulator drive the carton to move downward synchronously to completely put the carton on the product. Step 6: Finished. The first and second manipulators release the sucked cartons and reset to complete the automatic box nesting operation.

2. The method for automatically nesting an oversized carton according to claim 1, characterized in that: In the step 5, the inclination angle of the carton before being put into the box is 20-40 degrees.

3. The method for automatically nesting an oversized carton according to claim 1, characterized in that: When unpacking the carton in step 4, the first manipulator and the second manipulator are placed in diagonally opposite directions.

4. The method for automatically nesting an oversized carton according to claim 1, characterized in that: A roller conveyor line is provided between the first manipulator and the second manipulator.

5. The method for automatically nesting an oversized carton according to claim 4, characterized in that: A ground rail line is provided below the first manipulator and is transported along the conveying direction of the roller conveyor line. The correction frame is provided at the end of the ground rail line away from the second manipulator.

6. The method for automatically nesting an oversized carton according to claim 5, characterized in that: A plurality of material racks are provided on the side of the first manipulator away from the second manipulator, and the length direction of the material racks intersects with and is not perpendicular to the conveying direction of the ground rail line.

7. The method for automatically nesting an oversized carton according to claim 1, characterized in that: A first rectangular fixing frame is provided at the end of the finger of the first manipulator, a second rectangular fixing frame is provided at one end along the length direction of the first fixing frame, a plurality of first vacuum suction cups are provided along the edge of the first fixing frame, and a plurality of second vacuum suction cups are provided along the edge of the second fixing frame.

8. The method for automatically nesting an oversized carton according to claim 7, characterized in that: The first fixing frame is provided with a travel limit switch.

9. The method for automatically nesting an oversized carton according to claim 1, characterized in that: A third fixing frame with a rectangular structure is provided at the end of the finger of the second manipulator, and a plurality of third vacuum suction cups are provided along the edge of the third fixing frame.

10. The method for automatically nesting an oversized carton according to claim 9, characterized in that: A mounting plate perpendicular to the third fixing frame is provided at one corner thereof, the mounting plate being arranged on the side of the third fixing frame away from the second manipulator finger, a first ranging sensor being mounted on the mounting plate, and a second ranging sensor being provided on the third fixing frame near the mounting plate.

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