Robotic Work Cell With Carousel End-Tool for Bulk Item Processing
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Solution Overview
Problem
Current robotic systems are unable to match the speed and accuracy of human operators in processing bulk items, such as customizing promotional products like hand sanitizer bottles, due to difficulties in sorting and manipulating randomly oriented objects, and they often require a larger footprint, making automation impractical in space-constrained environments.
Innovation Solution
A robotic work cell that separates bulk objects into two-dimensional arrangements using a dynamic object separating mechanism, employs a vision system for identification, and utilizes a pick-and-place robot to reorient and transfer objects to a carousel-type robotic end-tool for precise processing, allowing for efficient and accurate customization of objects like hand sanitizer bottles.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Extent of automation
If state-of-the-art robotic systems are used to process bulk items, then automation is achieved, but the speed and accuracy of processing deteriorates compared to human operators
Solution Approach 1:
The system segments the bulk items into individual positions on a conveyor belt, separating them spatially and temporally. This allows the vision system to capture clear images of each item without occlusion, and enables the robotic arm to process items sequentially with precise positioning, thereby maintaining high processing speed and accuracy while achieving full automation.
Solution Approach 2:
The system performs preliminary actions by pre-positioning items on the conveyor belt in a structured manner before processing begins. The vision system also performs preliminary identification and localization of each item's features (logo position, orientation, etc.), allowing the robotic arm to execute precise manipulation operations without real-time computation delays, thus maintaining high processing speed.
2Extent of automation
If state-of-the-art robotic systems are used to process bulk items, then automation is achieved, but the footprint of the system deteriorates (occupies more space) compared to human-operated systems
Solution Approach 1:
The system merges multiple functions into a compact integrated structure: the conveyor belt serves both as a transport mechanism and a positioning structure; the vision system is integrated above the conveyor to share space; the robotic arm is positioned to operate directly over the conveyor path. This functional integration significantly reduces the overall footprint compared to traditional distributed robotic systems while maintaining full automation capability.
Solution Approach 2:
The system transitions from a horizontal spread-out layout to a vertical stacked arrangement. The vision system operates in the vertical dimension above the conveyor belt, and the robotic arm operates in the vertical space above the items. This dimensional reorganization allows all components to occupy overlapping footprints, minimizing the total floor space required for the automated system.
3Productivity
If human operators are used to process bulk items, then processing speed and accuracy are maintained, but the extent of automation deteriorates
Solution Approach 1:
The system implements self-service through the vision system that automatically identifies and localizes item features without human intervention. The vision system independently captures images, processes them to determine logo positions and orientations, and provides this information to the robotic arm control system, enabling fully automated decision-making and execution that matches or exceeds human processing speed and accuracy.
Solution Approach 2:
The vision system provides real-time feedback about item position, orientation, and features to the robotic arm control system. This feedback loop allows the robotic arm to adjust its movements dynamically based on actual item characteristics, achieving the same adaptability and precision that human operators possess, while maintaining full automation. The feedback mechanism ensures processing accuracy matches human levels despite the automated nature of the system.
Data Source
AI summary
A robotic work cell uses an object separating mechanism to disperse bulk objects into a 2D arrangement on a horizontal surface and uses a vision system to generate pick-up (positional) data and rotational orientation data for each sequentially selected target object of the 2D arrangement. A pick-and-place robot mechanism uses the positional data to pick-up each target object and uses the rotational orientation data to reorientate the target object during transfer to a designated hand-off location. A carousel-type robotic end-tool disposed on a 4-axis object-processing robot mechanism rotates a gripper mechanism around a vertical axis to move the target object from the hand-off location to a designated processing location, where an associated processing device performs a desired process (e.g., label application) on the target object. In one embodiment the gripper mechanism is selectively rotatable around a horizontal axis to facilitate processing on opposing surfaces of the target object.