Automated Case Unpacking System with Adjustable Cutter
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Solution Overview
Problem
The process of unpacking products from packaging cases is time-consuming and difficult due to the need to open and empty cases without damaging the products, and existing automated systems require multiple steps, leading to longer cycle times.
Innovation Solution
An automated product unpacking system that includes a work surface, a cutter for cutting the case sides, a case movement device, and conveyors for moving empty and filled containers, with adjustable cutter settings and a robot with a suction tool for precise case handling, allowing products to be unloaded through a bottom surface into secondary containers.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If manual unpacking is used to ensure product safety, then product damage is minimized, but unpacking time increases significantly
Solution Approach 1:
The case is cut into multiple segments (sides are cut individually) to allow controlled opening that prevents product damage while maintaining safety. The cutter divides the case into manageable sections that can be opened without harming contents.
Solution Approach 2:
The case is pre-cut on all sides before opening, preparing it in advance for safe opening. This preliminary cutting action ensures that when the case is opened, no additional force or manipulation is needed that could harm the products inside.
2Productivity
If automated unpacking systems are used to reduce time, then unpacking speed increases, but system complexity increases
Solution Approach 1:
The case movement device integrates multiple functions: it positions the case on the work surface, moves the case to the cutter, and transports the opened case to the unload position. This consolidation of transport functions reduces the number of separate components needed.
Solution Approach 2:
The cutter is designed to cut all four sides of the case, making it a universal cutting tool for different case orientations. The case movement device also serves multiple positions (work surface, cutter, unload position), reducing the need for dedicated mechanisms at each location.
3Reliability
If multiple cutting positions are used to open all case sides, then complete case opening is achieved, but the number of steps increases
Solution Approach 1:
The case movement device dynamically repositions the case between cutting operations. Instead of having fixed cutters at multiple positions, the system moves the case to different locations relative to a single cutter, reducing the number of static cutting positions needed.
Solution Approach 2:
The case movement device acts as an intermediary between the single cutter and the case, enabling the cutter to access all four sides of the case through coordinated movement. This mediator approach allows one cutter to perform the work of multiple fixed cutters.
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
The system significantly reduces cycle times and improves efficiency by automating the unpacking process, allowing for quick and safe removal of products from cases into secondary containers, enhancing portability and storage capabilities.
Implementation Method 1
The suction tool may be configured to provide variable location and size of suction based on parameters of a case to be moved
Data Source
AI summary
A product unpacking system includes a work surface at a first height and a product unloading position at a second height. An adjustable cutter is positioned adjacent to the work surface and configured to cut a plurality of sides of each case. A case movement device, such as a robot or manual mover, is configured to retrieve a case from a group of cases and move the case to the cutter to cut a plurality of sides of the case. The case movement device may then move the cut case to an unload position over a product container to allow products within the case to drop into the product container. A system of conveyors may be used to convey empty product containers toward the work surface and to convey filled product containers away from the work surface. The system may be automated to receive recipe information for each case to be unloaded and modify parameters of the system based on the case.