Double Robot Line for Tandem Press Material Transfer
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Solution Overview
Problem
Conventional automatic press-molded article manufacturing systems using a single robot line often result in idle presses due to slower robot transfer and supply processes, leading to reduced productivity and yield.
Innovation Solution
A double robot line system with pairs of robots positioned apart to alternately move and supply raw materials and press-molded articles, ensuring seamless operation and higher productivity by synchronizing with press processing stages, and a method for automatic exchange of press molds and grippers to maintain continuous production.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a single robot line is used to transfer and supply raw materials to presses, then the system structure is simple, but the presses remain idle waiting for robot supply, reducing productivity
Solution Approach 1:
The single robot line is segmented into multiple independent robot units (first robot, second robot, third robot, fourth robot) that operate in parallel. Each robot is assigned to specific presses, allowing simultaneous material supply to multiple presses without idle waiting time, thereby resolving the contradiction between productivity and system complexity.
Solution Approach 2:
The system transitions from a sequential single-robot operation to a parallel multi-robot configuration across spatial dimensions. Multiple robots operate simultaneously on different presses, converting a one-dimensional sequential process into a multi-dimensional parallel process, which eliminates idle press time and increases overall productivity.
2Productivity
If press molding speed is increased to match robot transfer speed, then productivity improves, but the system becomes less adaptable to varying production requirements
Solution Approach 1:
The system employs dynamic speed adjustment capabilities where each robot can independently adjust its operating speed to match different production requirements. This allows the system to maintain high productivity when needed while also adapting to slower production rates or different product specifications, resolving the contradiction between speed and adaptability.
Solution Approach 2:
The multi-robot system is designed with universal functionality where robots can be reassigned to different presses based on production needs. The system can handle various product types and production volumes by dynamically allocating robot resources, maintaining both high speed capability and system flexibility.
3Ease of operation
If manual mold changing is used to switch between different press molds, then the system is easier to operate, but production continuity is interrupted and yield is reduced
Solution Approach 1:
The system implements automatic mold changing capability where the robot system can independently replace molds on presses without manual intervention. This self-service function eliminates production interruptions during mold changes, maintaining continuous operation and high productivity while the centralized control system manages the complexity of coordination.
Solution Approach 2:
A control system acts as an intermediary between the robot units and presses, coordinating automatic mold changing operations. This mediator manages the complexity of synchronizing robot movements with press operations, enabling automated mold changes that maintain production continuity while keeping the system manageable.
4Reliability
If redundant robots are added to ensure continuous operation during failures, then system reliability improves, but device complexity increases
Solution Approach 1:
The system is configured with pre-planned redundant robot positions and failover capabilities. When a robot failure is detected, the control system automatically reassigns tasks to available robots using pre-established backup configurations, ensuring continuous operation without requiring complex real-time decision-making or additional physical redundancy beyond the multi-robot setup.
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 double robot line system significantly increases the yield of press-molded articles per minute, reduces manufacturing time, and allows for seamless operation even if one robot fails, while the automated mold and gripper exchange ensures continuous production without manual intervention.
Implementation Method 1
a pair of raw material transfer robots transferring the raw materials loaded on the destackers while holding the raw materials by suction
Data Source
AI summary
The present invention relates to an automatic press-molded article manufacturing system using a double robot line for a tandem press line and, more specifically, to an automatic press-molded article manufacturing system using a double robot line for a tandem press line, wherein a plurality of destackers and positioners are disposed, each group having two robots is separately disposed and moves alternately, so as to continuously and rapidly transfer and supply the raw material in proportion to a press working time, in a raw material transfer process, a material supply process, an article supply process, and a product withdrawal process.