Robotic Blank Stack Unloading with Interlayer Channel Gripping

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Solution Overview

Problem

Manual unloading of stacks of blanks from support elements requires physical effort, leading to discomfort and potential injuries, and lacks reliability and alignment maintenance during the unloading process.

Innovation Solution

A method utilizing a robotic arm with a handling member featuring prongs that engage channels defined by protrusions on an interlayer, allowing for automated and reliable unloading and movement of stacks of blanks while maintaining alignment, using a gripping element to clamp and lift the stacks.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of operation

If manual unloading of stacks of blanks is performed, then the process is simple and requires basic equipment, but it requires significant physical effort causing discomfort and potential injuries

Engineering Contradiction:

Improvephysical effort requiredVSAvoidunloading efficiency

Core Design Contradiction:

Ease of operationVSProductivity

Solution Approach 1:

The patent replaces the manual mechanical system with an automated robotic system. A robotic arm equipped with a specialized handling member (featuring prongs that engage with channels in the interlayer) automatically grasps, lifts, and transports stacks of blanks from support elements to packaging machines, eliminating the need for manual physical effort while significantly improving unloading efficiency

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The handling member is designed to automatically engage with the interlayer structure through its prongs fitting into channels. The system serves itself by using the existing interlayer structure as part of the gripping mechanism, allowing the robotic system to autonomously perform the unloading operation without human intervention

Inventive Principle:

Principle #25Self-service

2Productivity

If automated robotic unloading is implemented, then physical effort is reduced and productivity increases, but the device complexity increases

Engineering Contradiction:

Improveunloading efficiencyVSAvoidsystem complexity

Core Design Contradiction:

ProductivityVSDevice complexity

Solution Approach 1:

The handling member is designed as a multi-functional component that combines several functions: the prongs engage with channels for gripping, the structure provides lifting capability, and it enables precise positioning. This universal design reduces the need for multiple separate components, thereby managing device complexity while achieving high productivity

Inventive Principle:

Principle #6Universality (Multi-functionality)

Solution Approach 2:

The interlayer with its integrated channels serves as an intermediary element that facilitates the connection between the robotic handling member and the stacks of blanks. This intermediary structure simplifies the gripping mechanism by providing built-in engagement points, reducing the complexity of the robotic end-effector design

Inventive Principle:

Principle #24Intermediary (Mediator)

3Adaptability or versatility

If stacks of blanks are moved freely in space during unloading, then flexibility in positioning is improved, but maintaining alignment of blanks within the stack becomes difficult

Engineering Contradiction:

Improvespatial movement flexibilityVSAvoidalignment maintenance

Core Design Contradiction:

Adaptability or versatilityVSManufacturing precision

Solution Approach 1:

The handling member is designed to engage the entire stack uniformly through multiple prongs contacting the interlayer at different points. This creates an equipotential gripping force distribution across the stack, allowing free spatial movement while maintaining uniform pressure that prevents blank misalignment during transport

Inventive Principle:

Principle #12Equipotentiality

Solution Approach 2:

The handling member uses multiple segmented prongs that independently engage with channels in the interlayer. This segmentation allows the gripping force to be distributed across multiple contact points, enabling flexible spatial positioning while maintaining precise alignment of individual blanks within the stack through uniform support

Inventive Principle:

Principle #1Segmentation

Data Source

PatentEP4660110A1Method for unloading from a support element a stack of blanks

Publication Date: 2025.12.10 RA JONES & CO INC

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AI summary

Method for unloading from a supporting element (2) a stack of blanks (3) resting on an interlayer (4) comprising one or more protrusions that delimit one or more channels. The method comprises: positioning a robotic arm (50) on which a handling member (52) is mounted, comprising one or more prongs and a gripping element movable between a gripping position and a disengagement position; inserting each prong between the stack of blanks (3) and the interlayer (4), so that each prong engages a respective channel; moving the gripping element until reaching the gripping position to clamp the stack of blanks (3) between the gripping element and each prong; lifting the stack of blanks (3) to unload the stack of blanks (3); and moving the stack of blanks (3) in space.