Card Insertion System Using Dynamic Plate Posture Adjustment
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Solution Overview
Problem
In logistics processes using returnable boxes with card holders, cards are still manually inserted into the card holders, lacking automation and efficiency.
Innovation Solution
A card insertion system comprising a storage box with a side wall portion, a card holder, and a card supporting member with a moving mechanism and controller, allowing the card to be automatically inserted into the card holder by guiding the card supporting member to a specific part and changing its posture to direct the card into the entrance space of the card holder.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If manual card insertion is used in card holders on returnable boxes, then the process is simple to operate, but productivity is low and manpower cannot be reduced
Solution Approach 1:
The card insertion system uses a card supporting member with a plate that automatically guides and inserts the card into the card holder through controlled movement and posture changes, enabling the system to perform the insertion task autonomously without manual intervention, thereby improving productivity while keeping the device structure relatively simple
2Extent of automation
If automatic card insertion is implemented, then productivity increases and manpower is reduced, but the device structure becomes more complex
Solution Approach 1:
The card supporting member is designed with movable capabilities, allowing it to change position and posture dynamically during the card insertion process. The moving mechanism enables the plate to approach the card holder, orient itself correctly, and insert the card automatically, achieving high automation through controlled dynamic movement rather than complex static structures
Solution Approach 2:
The card supporting member with plate serves multiple functions: holding the card, moving toward the card holder, orienting itself to the correct posture, and inserting the card. This multi-functional design reduces the need for separate components, thereby achieving automation without proportionally increasing device complexity
3Speed
If the card supporting member approaches the card holder directly, then the insertion process is fast, but the card may be bent or crushed by convexities on the storage box surface
Solution Approach 1:
The system performs preliminary actions by first moving the card supporting member to a specific part position before the actual card insertion. The controller manages the sequence of movements, allowing the plate to approach the card holder gradually and orient itself properly before inserting the card, preventing deformation from convexities while maintaining efficient insertion speed through optimized movement paths
4Manufacturing precision
If the plate is oriented to face the specific part, then the approach is obstructed by convexities on the storage box, but direct orientation toward the entrance space causes deviation
Solution Approach 1:
The card supporting member dynamically adjusts its posture and movement path based on its position relative to the card holder. The controller manages the sequence: first moving to a specific part position, then orienting the plate to face the entrance space, and finally inserting the card. This dynamic adaptation ensures precise positioning while avoiding obstructions from convexities without requiring overly complex movement instructions
Data Source
Figure 1
Figure 2A~2B
Figure 3
AI summary
A conveying system (10) introduced into a factory conveying process has a robot (11) and a hand 30. The hand (30) has a card chucking device (41) that can hold a card (CA1) in an interspace (44) between plates (42, 43). The card (CA1) is inserted into an interspace formed between a side plate (86) of a returnable box (80) and the card holder on the side plate (86). In this insertion, with the tip portion (43a) of the lower plate (43) facing the specific part, which is located on the upper side of the entrance space of the card holder on the side plate 86, the hand (30) is from the front position of the side plate (86) toward the specific part. When the lower plate (43) contacts the side plate (86), the posture of the robot body is controlled such that the tip portion (43a) of the lower plate (43) is displaced downward along the side plate (86) and faces downward.