Automatic Machine Component Replacement With Robotic Gripping

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Solution Overview

Problem

Existing automatic machines require manual intervention by specialized operators for component replacement, leading to long downtimes, physical fatigue, and increased error probability during format changes, especially in manufacturing and packaging machines like those for cigarettes.

Innovation Solution

A method and apparatus utilizing a control unit to initiate a configuration change procedure in the automatic machine, combined with a gripping device controlled by an electronic processor, allowing remote operation by a single operator to replace components without direct manual intervention.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Device complexity

If manual replacement by specialized operators is used, then component replacement can be performed with simple equipment, but machine downtime increases and operator physical fatigue increases

Engineering Contradiction:

Improvereplacement equipmentVSAvoidmachine downtime

Core Design Contradiction:

Device complexityVSLoss of time

Solution Approach 1:

The automatic machine performs component replacement autonomously through integrated robotic manipulators and control systems, eliminating the need for external operators and manual procedures. The system self-manages the entire replacement process including component identification, gripper positioning, and mechanical manipulation.

Inventive Principle:

Principle #25Self-service

Solution Approach 2:

Manual mechanical operations by operators are replaced with automated robotic manipulators equipped with intelligent grippers. The system uses electronic control and automated positioning systems to substitute human physical intervention, thereby reducing downtime and operator fatigue while maintaining replacement capability.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

2Device complexity

If manual replacement by specialized operators is used, then equipment requirements remain simple, but error probability increases due to human intervention

Engineering Contradiction:

Improvereplacement systemVSAvoidreplacement accuracy

Core Design Contradiction:

Device complexityVSReliability

Solution Approach 1:

Inventive Principle:

Principle #25Self-service

Solution Approach 2:

The system incorporates sensors and control systems that provide real-time feedback during the replacement process, enabling precise positioning and manipulation of components. This feedback mechanism ensures accurate component handling and reduces errors compared to manual operations.

Inventive Principle:

Principle #23Feedback

3Ease of operation

If automated gripping device is introduced, then operator fatigue is reduced and error probability decreases, but device complexity increases

Engineering Contradiction:

Improveoperator workloadVSAvoidautomation system

Core Design Contradiction:

Ease of operationVSDevice complexity

Solution Approach 1:

The robotic manipulator system is designed to perform multiple functions including component identification, gripping, positioning, and manipulation. The intelligent gripper can adapt to different component types and sizes, making the system universally applicable to various replacement scenarios without requiring separate specialized equipment for each task.

Inventive Principle:

Principle #6Universality (Multi-functionality)

Solution Approach 2:

The intelligent gripper acts as an intermediary between the control system and the physical component, translating electronic control signals into precise mechanical actions. This intermediary device bridges the gap between automated control and physical manipulation, enabling complex operations through a standardized interface.

Inventive Principle:

Principle #24Intermediary (Mediator)

4Adaptability or versatility

If multiple specialized operators are required, then manual flexibility is maintained, but productivity decreases due to long replacement times

Engineering Contradiction:

Improvemanual flexibilityVSAvoidreplacement speed

Core Design Contradiction:

Adaptability or versatilityVSProductivity

Solution Approach 1:

Inventive Principle:

Principle #25Self-service

Solution Approach 2:

The automated system enables continuous operation by eliminating the interruptions caused by manual replacement procedures. The robotic manipulator can perform replacements without the breaks, shifts, and coordination delays inherent in manual operations, maintaining continuous productive action.

Inventive Principle:

Principle #20Continuity of useful action

Data Source

PatentUS12350831B2Method for replacing a component in an automatic machine

Publication Date: 2025.07.08 GD SPA

AI summary

A method for replacing a working component in an automatic machine has a mapping phase and a working phase. The mapping phase involves defining a first reference point fixed relative to the automatic machine and a position in machine of the working component. The working phase involves: stopping the automatic machine (2); starting a procedure of configuration change preparing the automatic machine for a withdrawal of the working component; detecting the first reference point; determining the position in machine of the working component; picking up the working component from the position in machine by means of a gripping device; releasing the working component in a storing position; picking up a replacement working component from a stocking position by means of the gripping device; positioning the gripping device at the position in machine; and inserting and fixing the replacement working component in the position in machine.