Delta Robots for Automated High-Speed Container Opening
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Solution Overview
Problem
Fulfillment centers face productivity impediments due to the time-consuming task of manually opening inbound shipments, as human operators must manually cut through sealing tapes or adhesives on containers arriving at high volumes.
Innovation Solution
Implementing a system with delta robots equipped with cutting implements along a conveying system, which automatically recognize and cut the seams of sealed containers as they travel, eliminating the need for human intervention.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If manual opening of containers is used, then human operators can handle various container types, but productivity is reduced due to time-consuming manual cutting of sealing tapes
Solution Approach 1:
The system uses automated robots with cutting implements that can independently identify and cut sealing tapes on containers without human intervention. The robots navigate to containers, detect seam locations, and execute cutting operations autonomously, eliminating the need for manual labor in the container opening process.
Solution Approach 2:
The patent replaces manual mechanical cutting with automated robotic systems equipped with cutting implements. The robots use sensors to detect container seams and coordinate precise cutting motions, substituting human operators with an automated electromechanical system that operates at higher speeds and consistency.
2Productivity
If automated robot systems are implemented, then productivity increases, but device complexity increases due to integration of robots and conveying systems
Solution Approach 1:
The robotic system is designed to handle multiple container types and sealing methods through programmable operations. The same robot platform can adapt to different container geometries, seam locations, and sealing tape types by receiving updated navigation and cutting parameters, eliminating the need for dedicated equipment for each container type.
Solution Approach 2:
The system introduces a control system as an intermediary that coordinates between the conveying system and robotic cutting units. This central control architecture manages the synchronization between container transport and robot positioning, simplifying the integration complexity by providing a unified command layer.
3Speed
If high-speed conveying is used, then throughput increases, but the precision of cutting seams at high speeds becomes more difficult to achieve
Solution Approach 1:
The robotic system employs dynamic positioning and motion control that adapts to the conveying speed. The robots calculate and adjust their cutting trajectories in real-time based on the container's position and velocity, maintaining cutting precision despite high-speed operation. The system transitions from static positioning to dynamic tracking of moving targets.
Solution Approach 2:
The system incorporates sensors that continuously monitor container position, seam location, and robot trajectory. This feedback loop allows the control system to make real-time adjustments to cutting parameters, compensating for any deviations caused by high-speed conveying and ensuring accurate seam cutting throughout the process.
Data Source
AI summary
Conveying systems for transporting sealed containers, such as boxes, may be provided with one or more delta robots configured to cut one or more adhesive tapes or other layers provided on the sealed containers. The delta robots may include one or more blades or other cutting implements on end effectors, which may be repositioned by the delta robots in response to instructions. Such instructions may be generated based on images or imaging data captured from the sealed containers, which may be analyzed to recognize features, locations and orientations of the adhesive tapes or other layers applied across faces, seams or edges of the sealed containers. Using such robots, the sealed containers may be partially or completely opened prior to reaching one or more workers, who may quickly and efficiently access the internal contents of such containers with limited effort.