Automated Bag Handling for Precise Plastic Handle Attachment
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Solution Overview
Problem
Existing automated and semi-automated systems for securing plastic handles to bags are imprecise, slow, and labor-intensive, often requiring manual loading and leading to production stoppages if a malfunction occurs, especially when handling specialty bags with precise requirements like heavy-duty bags with perforated tear spouts.
Innovation Solution
A computer-controlled automated bag handling method that precisely attaches a plastic handle to a plastic bag by using robots with orientable engaging hands and ultrasonic welding, capable of detecting and reorienting bags in motion to secure the handle at a precise location along the bag's edge, including those with perforated tear spouts, and forming bundles for shipping while inspecting and rejecting inferior bags.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If automated or semi-automated systems are used for handle attachment, then productivity is improved, but manufacturing precision deteriorates due to inability to achieve precise handle placement
Solution Approach 1:
The patent replaces traditional mechanical positioning systems with a vision-guided robotic system. Cameras capture bag positions and orientations, computer vision algorithms process this data to determine precise handle attachment locations, and robotic arms execute the attachment with high precision. This substitution of mechanical positioning with optical sensing and computational processing enables both high productivity and manufacturing precision.
2Productivity
If on-line automated systems are used for repetitive handle attachment, then productivity is improved, but reliability deteriorates due to production stoppages when malfunctions occur
Solution Approach 1:
The patent segments the handle attachment process into independent modular stations, each capable of handling bags independently. The system includes multiple bag transfer stations and handle attachment stations that can operate in parallel. If one station experiences a malfunction, other stations can continue operating, preventing complete production stoppage and maintaining reliability while preserving productivity.
3Adaptability or versatility
If manual loading and handling is used, then adaptability is improved for handling various bag types, but productivity deteriorates due to labor intensity and slowness
Solution Approach 1:
The patent employs dynamically adjustable robotic systems with programmable controllers that can adapt to different bag types, sizes, and handle configurations. The vision system dynamically determines optimal attachment points based on real-time bag characteristics, and robotic parameters are automatically adjusted. This dynamic adaptability replaces static manual handling, maintaining versatility while dramatically increasing productivity through automated high-speed operation.
4Manufacturing precision
If precise handle attachment is required for specialty bags with tear spouts, then manufacturing precision is improved, but device complexity increases due to need for advanced positioning and detection
Solution Approach 1:
The patent implements a universal vision-guided robotic platform that handles multiple bag types and attachment requirements through software configuration rather than hardware redesign. The same camera system, computer vision algorithms, and robotic arms that attach handles to heavy-duty bags with tear spouts can also handle standard bags and different handle types. This multi-functionality reduces overall system complexity compared to having specialized equipment for each bag type while maintaining high manufacturing precision.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This method enables high-precision, continuous, and efficient attachment of plastic handles to bags, reducing labor and minimizing production disruptions, ensuring accurate placement and quality control, and allowing for handling of bags out of alignment, thus improving overall packaging efficiency.
Implementation Method 1
transferring the engaged top one of the bags to a handle securing station with the leading straight edge thereof disposed at a precise location relative to the plastic handle retained at the handle securing station
Data Source
AI summary
An automatic handle attaching method for precisely securing a plastic handle on an edge of a preformed plastic bag is described. A delivery conveyor for conveying spaced-apart groups of flat plastic bags with each group having two or more bags disposed one on top of the other and offset along a leading straight edge thereof which is oriented approximately transverse to a conveying direction of a conveyor. A bag handling mechanism has an orientable bag engaging hand secured to an articulated arm to orient the bag engaging hand in alignment with a top one of the groups of bags to transfer the bag to a handle securing station where the bag handle is welded thereto. After the handle is welded its relationship with respect to other parts of the bag is verified.