Bin Picking with an Intermediate Station for Precise Workpiece Removal
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Solution Overview
Problem
Existing automated bin picking systems face challenges in process reliability, speed, and accuracy when removing workpieces from containers, particularly when workpieces are randomly arranged, as they require precise positioning and gripping, which is difficult with conventional grippers.
Innovation Solution
The introduction of an intermediate station where workpieces are deposited and then precisely positioned and separated using a second gripper, allowing for more flexible gripping options, such as magnetic or pneumatic grippers, which do not require exact alignment for initial removal from the container, and a controller for path planning and gripper control to optimize the process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a conventional gripper is used to directly remove workpieces from a container with randomly arranged workpieces, then the system structure is simple, but the positioning accuracy and gripping reliability are insufficient
Solution Approach 1:
The system is divided into two functional segments: a first gripper for rough handling and removal of workpieces from the container, and a second gripper for precise positioning and gripping at the intermediate station. This segmentation allows each gripper to be optimized for its specific task, with the first gripper focusing on removal efficiency and the second gripper on positioning precision, thereby resolving the contradiction between positioning accuracy and system complexity.
Solution Approach 2:
An intermediate station is introduced as a mediator between the container and the final destination. The first gripper places workpieces at this intermediate station with relaxed positioning requirements, and the second gripper then picks them up for precise positioning. This intermediary structure decouples the positioning requirement from the removal operation, enabling high positioning accuracy without requiring the first gripper to achieve precise positioning during removal.
2Manufacturing precision
If precise positioning is required during workpiece removal from the container, then the positioning accuracy is improved, but the process speed decreases due to the difficulty of gripping randomly arranged workpieces
Solution Approach 1:
The gripping process is segmented into two stages: rapid removal by the first gripper without precise positioning requirements, and precise positioning by the second gripper at the intermediate station. This segmentation allows the system to achieve high process speed during the removal phase while maintaining high positioning accuracy during the positioning phase, eliminating the trade-off between speed and precision.
Solution Approach 2:
The first gripper performs preliminary action by removing workpieces from the container and placing them at the intermediate station without requiring precise positioning. This preliminary removal action prepares the workpieces for the subsequent precise positioning operation by the second gripper, allowing the system to prioritize speed in the first stage and precision in the second stage.
3Reliability
If the first gripper directly places workpieces at the final position, then the process steps are reduced, but the gripping reliability is insufficient due to the difficulty of achieving both removal and precise positioning in one step
Solution Approach 1:
The gripping and positioning operation is segmented into two reliable steps: the first gripper reliably removes workpieces from the container with magnetic or pneumatic gripping, and the second gripper reliably positions them at the final location. Each gripper is optimized for its specific task, ensuring high gripping reliability for both removal and positioning operations, while the intermediate station provides a buffer that manages the increased process complexity.
Solution Approach 2:
The intermediate station acts as a mediator that decouples the removal and positioning operations. The first gripper reliably places workpieces at the intermediate station without needing to achieve final positioning accuracy, and the second gripper then reliably transports them to the final position. This intermediary structure enhances gripping reliability by allowing each gripper to focus on its specific task without the complexity of combining both functions in one step.
4Ease of operation
If magnetic or pneumatic grippers are used for initial removal, then the ease of operation is improved by allowing non-optimal gripping positions, but the positioning precision decreases
Solution Approach 1:
The system segments the gripping function: the first gripper (magnetic or pneumatic) provides ease of operation by allowing flexible gripping at non-optimal positions during removal, while the second gripper provides precise positioning at the intermediate station and final destination. This segmentation allows each gripper type to be used for its strengths, resolving the contradiction between gripping flexibility and positioning precision.
Solution Approach 2:
The intermediate station serves as a mediator that captures workpieces removed by the flexible but imprecise first gripper and transfers them to the precise second gripper. This intermediary structure allows the system to benefit from the ease of operation provided by magnetic or pneumatic grippers during removal while recovering positioning precision through the second gripper's accurate handling at the intermediate station and final destination.
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 approach simplifies the emptying of containers, increases process efficiency, and ensures complete removal of workpieces, even when they are disordered, by allowing for non-optimal gripping positions and precise repositioning at the intermediate station, thereby enhancing reliability, speed, and accuracy.
Implementation Method 1
A magnetic and/or pneumatic gripper is particularly preferred as the first gripper for grasping the workpiece in the container
Implementation Method 2
A magnetic and/or pneumatic gripper is particularly preferred as the first gripper for grasping the workpiece in the container
Data Source
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AI summary
The device has detection unit (30) that is provided for detecting workpieces arranged in container. A gripper (34) is provided for gripping and removing the workpieces from container. A controller is provided for analyzing data of detection unit, and for path planning and controlling of gripper. An intermediate station (35) is provided for storing the pieces after removing from container. A positioning device (41) is provided for positioning and/or isolating the workpieces on/from intermediate station. An independent claim is included for a method for automated removal of work pieces arranged in container.