Boxing Line Gap Detection With Buffer Replenishment
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Solution Overview
Problem
Efficiency losses in boxing machines occur due to empty spaces in the array of products fed to the machine, causing the robotic units to wait for subsequent products, which reduces production speed.
Innovation Solution
A system and method that includes a detection device to identify empty spaces in the product array, utilizing a buffer and replenishment conveyors to supply additional products to maintain continuous production, ensuring the robotic units can form product groups efficiently.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a buffer is used to accumulate products during temporary stops, then product accumulation is improved, but empty spaces in the product array still cause robotic units to wait
Solution Approach 1:
The system performs preliminary action by detecting empty spaces in the product array before they reach the robotic units, and pre-positioning replacement products from the buffer to fill these gaps. This proactive approach ensures continuous product flow and eliminates waiting time for robotic units.
Solution Approach 2:
The system implements feedback through sensors that continuously monitor the product array for empty spaces and provide real-time information to the control system. This feedback loop enables dynamic adjustment of product feeding from the buffer, ensuring the robotic units always have products to process without waiting.
2Manufacturing precision
If the robotic unit waits for subsequent products to fill empty spaces, then product orientation precision is maintained, but production speed decreases
Solution Approach 1:
Products are pre-oriented and pre-positioned in the buffer before being transferred to fill empty spaces in the main array. This preliminary preparation ensures that when products are needed to fill gaps, they are already correctly oriented and ready for immediate insertion, maintaining precision without sacrificing speed.
Solution Approach 2:
The buffer acts as an intermediary zone where products are prepared and staged before entering the main product array. This intermediate buffer zone allows products to be pre-positioned and oriented without disrupting the continuous flow to robotic units, decoupling the precision requirements from the speed requirements.
Data Source
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AI summary
A system (10) for boxing products (P) and method.