Cobot-Assisted Load Former for Compact Partial Automation
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Solution Overview
Problem
Existing load forming processes for paperboard blanks are inefficient and costly, requiring full automation which is expensive and has a large footprint, or are slow and tedious when fully manual, necessitating a more efficient and cost-effective partial automation solution.
Innovation Solution
A load former system that utilizes collaborative robots (cobots) to assist human operators by handling tasks such as placing auxiliary sheets and applying load tags, while minimizing the need for safety guarding and reducing the system's footprint.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If full automation is implemented, then productivity is improved, but device complexity and cost increase significantly
Solution Approach 1:
The automation system is segmented into discrete functional modules: cobot 140 for auxiliary sheet placement, cobot 150 for load tag application, and cobot 160 for pallet/bottom sheet handling. Each cobot performs a specific task independently, allowing the system to achieve partial automation without requiring a completely automated complex system. This segmentation resolves the contradiction by providing automation benefits while keeping individual components manageable in complexity.
2Productivity
If full automation is implemented, then productivity is improved, but the system footprint increases
Solution Approach 1:
Multiple cobots are mounted on or integrated with the existing load former frame 18, merging the automation functions into the existing structure rather than requiring separate standalone automation systems. This integration approach reduces the overall system footprint while maintaining productivity benefits, as the cobots share the common frame infrastructure and operational space.
3Device complexity
If full manual operation is used, then device complexity is reduced, but productivity decreases
Solution Approach 1:
The system implements partial automation where cobots 140, 150, and 160 perform specific repetitive tasks (auxiliary sheet placement, load tag application, and pallet handling) while human operators continue to perform bundle placement and supervisory functions. This partial automation approach selectively applies automation to tasks where it provides the most productivity benefit while maintaining human involvement for tasks requiring judgment and flexibility, thus improving productivity without requiring complete automation.
4Productivity
If cobots are introduced, then productivity is improved, but safety risks may increase
Solution Approach 1:
The cobots serve as intermediaries that handle dangerous or repetitive tasks such as lifting heavy auxiliary sheets, applying load tags, and maneuvering pallets, thereby reducing the physical strain and injury risk for human operators. The collaborative robot design allows them to work in close proximity to human operators with built-in safety features, effectively mediating between the need for automation and worker safety concerns.
Data Source
AI summary
A load former includes a frame, a loading zone and a horizontal cookie sheet supported by the frame and having a support portion shiftable between a first position in which the support portion is located on a first side of the vertical wall and forms a floor of the loading zone and a second position in which the first portion is located in a holding space on the second side of the vertical wall. A platform is located beneath the loading zone on a lift table. At least one cobot is supported by the frame or mounted in a fixed position relative to the frame and configured to lift a pallet and/or an auxiliary sheet of material and place it in at least one predetermined location on the load former or on at least one object supported by the load former. Also a method of operating the load former.