Beverage Container Orientation Manipulator for Label Alignment
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Solution Overview
Problem
Existing packaging systems face issues with accurately aligning beverage containers within outer packaging, leading to potential damage and wear of sensors and pneumatic connections, as well as visual impairments due to container contact during rotation.
Innovation Solution
A system utilizing a manipulator with a portal or multi-axis robot, combined with optical and touch sensors, to pneumatically or clampingly grip items, adjust their rotational orientation, and transfer them into packaging units while maintaining a desired visual appearance, using a horizontal conveyor and placement tables with turntables to manage multiple items simultaneously.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If manipulators with integrated sensors are used to detect and align beverage containers, then label alignment precision is improved, but sensor reliability deteriorates due to obstruction by gripping tools and vulnerability to collision damage
Solution Approach 1:
The system is divided into separate functional modules: a feeding device for container supply, a manipulator for gripping and rotation, and a separate detection device for label orientation detection. This segmentation allows the detection device to operate independently without being obstructed by the manipulator's gripping tools, while still achieving precise label alignment through coordinated control of the manipulator's rotation based on detection feedback.
2Manufacturing precision
If manipulators rotate beverage containers to align labels, then visual appearance is improved, but harmful factors increase due to contact between adjacent containers causing label damage and surface friction
Solution Approach 1:
The system transitions from rotating containers in a horizontal plane where adjacent containers may contact, to rotating them in a vertical plane using an inverted manipulator configuration. This dimensional change allows containers to be rotated along a vertical axis where they are supported by the gripping tool, preventing lateral contact and friction between adjacent containers while achieving the same label alignment objective.
3Extent of automation
If pneumatic gripping tools are rotated with beverage containers, then handling automation is improved, but device durability deteriorates due to wear and damage of pneumatic connections
Solution Approach 1:
The pneumatic gripping tool is extracted from the rotating assembly and left stationary in the inverted manipulator. The rotation function is transferred to the manipulator's mechanical structure rather than being coupled with the pneumatic tool. This extraction allows the pneumatic connections to remain fixed and undisturbed during rotation, eliminating wear and damage to pneumatic components while maintaining automated handling capability through the stationary gripper's engagement and disengagement.
4Productivity
If multiple beverage containers are received and rotated simultaneously, then productivity is improved, but manufacturing precision deteriorates due to mutual friction and optical impairments on container surfaces
Solution Approach 1:
The detection device detects the label orientation of multiple containers before they are rotated by the manipulator. This preliminary detection allows the control system to calculate and prepare the exact rotation angles needed for each container. By determining all detection and rotation parameters in advance, the system can execute simultaneous rotation of multiple containers with high precision, avoiding the need for sequential processing while maintaining label alignment accuracy despite the increased handling speed.
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
Ensures accurate alignment and reduced wear, preventing damage to sensors and pneumatic connections, while maintaining a uniform visual appearance of the containers within the packaging units.
Implementation Method 1
optical and touch sensors
Implementation Method 2
pneumatically or clampingly grip items
Data Source
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AI summary
The invention relates to a packaging system (1) for producing a packaging unit. The packaging unit comprises at least one article (2) and at least one outer packaging receiving the article (2). The packaging system (1) comprises an infeed (3) for providing a plurality of articles (2) and at least one manipulator (12, 14). The at least one manipulator (12, 14) can receive articles (2) from the infeed (3) and can transfer them into outer packagings. At least one set-down table (5) is also provided, on which articles (2) received via the at least one manipulator (12, 14) can be set down temporarily in order to identify and/or determine the rotational orientation and/or, as necessary, in order to adapt the rotational orientation to match a target rotational orientation that is to be provided in the corresponding packaging unit (8).