Boxing Conveyor Gap Detection and Product Backfilling
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Solution Overview
Problem
Existing boxing systems experience efficiency losses due to empty spaces in the product row fed to the boxing machine, caused by product falls, quality control ejections, or picking, leading to robotic unit delays.
Innovation Solution
A system with a detection device to identify empty spaces and a manipulator to deposit products from a buffer into these spaces, maintaining row continuity, using cameras, load cells, or ultrasonic/laser sensors for precise positioning.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If products are fed continuously to the boxing machine, then productivity is improved, but empty spaces in the product row cause robotic unit delays and efficiency losses
Solution Approach 1:
The system performs preliminary detection of empty spaces in the product row using sensors before the robotic unit arrives. The control system pre-plans the robotic unit's path and picking sequence to account for detected empty spaces, allowing the robotic unit to maintain continuous operation without waiting for product alignment.
Solution Approach 2:
The robotic unit dynamically adjusts its picking sequence and motion path based on real-time detection of empty spaces. The control system continuously updates the robotic unit's operation plan to optimize picking efficiency while accommodating variable product positions and gaps in the row.
2Stability of the object's composition
If the robotic unit waits for subsequent products to fill empty spaces, then product row continuity is improved, but productivity decreases due to operational delays
Solution Approach 1:
The system uses detection devices to provide real-time feedback about empty spaces in the product row. The control system processes this feedback and dynamically adjusts the robotic unit's picking sequence to maintain continuous operation, eliminating the need to wait for product row continuity while preserving effective productivity.
3Adaptability or versatility
If advanced robotic technology with anthropomorphic robots is used, then adaptability to different product sizes and types is improved, but device complexity increases
Solution Approach 1:
The robotic unit is designed with universal end-effectors and programmable control that enable it to handle multiple product types and sizes using the same hardware platform. The system achieves versatility through software configuration rather than physical reconfiguration, reducing overall device complexity while maintaining adaptability.
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
Restores production efficiency by preventing slowdowns and maintaining continuous product flow, optimizing production plant performance and reducing the risk of jams.
Implementation Method 1
detecting on the feeding conveyor 20 the presence and position of empty spaces ES that interrupt the continuity of the row of products R by means of a detection device 22
Implementation Method 2
using cameras, load cells, or ultrasonic/laser sensors for precise positioning
Implementation Method 3
using cameras, load cells, or ultrasonic/laser sensors for precise positioning
Implementation Method 4
picking up products P from the buffer 24 by at least one manipulator 84 and depositing the products P on the feeding conveyor 20 in respective empty spaces ES
Data Source
Figure 1~2
Figure 3
Figure 4
AI summary
A system (10) for boxing products (P), comprising at least one manipulator (84) configured to pick up products (P) from a buffer (24) and to deposit the products (P) on a feeding conveyor (20) in respective empty spaces (ES) based on information about the position of empty spaces (ES) provided by a detection device (22).