Case Manipulator Paddle Assembly for Flimsy Case Handling
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Solution Overview
Problem
Existing robotic systems struggle to efficiently handle and automate the placement and removal of reusable and collapsible cases or boxes, such as cardboard or plastic boxes, due to their flimsy nature, inconsistent presentation, and varying fill states, which leads to damage and deformation, making them difficult to manage in automated storage and retrieval systems.
Innovation Solution
A case manipulator system with a movable support and paddle assembly that can engage with case flaps to open, fold, and clamp them, allowing precise movement and insertion into or removal from containers, using guiding means and control systems for accurate positioning and handling.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Extent of automation
If reusable and collapsible cases are handled by robotic manipulators, then automation of inbound activities is enabled, but the cases are easily damaged or deformed due to their flimsy nature
Solution Approach 1:
The end effector applies different forces to different parts of the case - concentrated force at the center of flaps for opening, and distributed force along the edges for clamping. This localized quality of force application prevents deformation while achieving the required manipulation actions.
Solution Approach 2:
The system dynamically adjusts the opening width of the case flaps during manipulation. The flaps are opened just wide enough to insert the manipulator, then clamped at that position. This dynamic control prevents excessive force that would damage the case while still enabling automated handling.
2Productivity
If robotic load handling devices are used to lift and move cases, then productivity increases, but cases may be damaged by the manipulators
Solution Approach 1:
The end effector opens the flaps only partially - just enough to insert the manipulator arm - rather than fully opening them. This partial action reduces the risk of damage while still enabling the necessary manipulation operations, maintaining high productivity.
Solution Approach 2:
The system uses sensors to detect the position and state of case flaps during manipulation, providing feedback to control the end effector's movements. This feedback mechanism prevents excessive force application that could damage cases while maintaining efficient automated handling.
3Ease of operation
If cases are handled with force to enable automated manipulation, then ease of operation improves, but structural integrity deteriorates
Solution Approach 1:
The end effector concentrates force locally at specific points on the case flaps rather than applying force across the entire case surface. This localized force application makes manipulation easier while preserving overall case structural integrity.
Solution Approach 2:
The system pre-positions the end effector and controls the opening motion to minimize sudden force spikes. The flaps are opened gradually and clamped at a controlled position, cushioning against excessive forces that could damage the case structure.
Data Source
AI summary
A case manipulator system and a method for using the same. A case manipulator system, comprising: a first location of a case; a second location, the second location comprising a guiding means for guiding the case into or out of a container; and a case manipulator comprising a moveable support movable from a first position above the first location to a second position above the second location, and a paddle assembly having at least a first pair of paddles, the paddle assembly arranged to move the at least first pair of paddles relative to the moveable support, the case manipulator system arranged such that: a case in the first location is accessible by the case manipulator, the case manipulator system controllable to engage with the case and move the case from the first location to the second location, and insert the case into a container at the second location.