Drum Coupler Robot with Vision and Force Feedback

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Solution Overview

Problem

Automated coupler systems for drums storing liquid chemicals are costly and difficult to operate manually, posing risks to workers due to chemical exposure.

Innovation Solution

A drum coupling automation robot equipped with a robot arm, coupler gripper, force and torque sensor, vision sensor, and control circuit, which automates the coupling process using a general-shaped coupler, ensuring precise and safe attachment of couplers to drums.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Extent of automation

If a dedicated coupler system is used for automated drum coupling, then automation capability is improved, but device complexity and cost increase

Engineering Contradiction:

Improveautomation capabilityVSAvoiddevice complexity

Core Design Contradiction:

Extent of automationVSDevice complexity

Solution Approach 1:

The robot arm and gripper are designed to perform multiple functions: gripping the coupler body, positioning the coupler key code, and fastening the coupler nut. This multi-functional design eliminates the need for dedicated coupling equipment, achieving automation while reducing device complexity and cost.

Inventive Principle:

Principle #6Universality (Multi-functionality)

Solution Approach 2:

The coupler's key code structure engages automatically with the drum's key code through mechanical interaction. The first roller rotates with the coupler key code, and the second roller fastens the coupler nut automatically during the coupling process, reducing the need for complex control mechanisms.

Inventive Principle:

Principle #25Self-service

2Device complexity

If manual operation of automated coupler system is used, then device complexity is reduced, but ease of operation deteriorates and worker safety is compromised

Engineering Contradiction:

Improvedevice complexityVSAvoidease of operation

Core Design Contradiction:

Device complexityVSEase of operation

Solution Approach 1:

This principle does not apply to this patent.

Inventive Principle:

Principle #38Strong oxidants (Accelerated oxidation)

Solution Approach 2:

The patent replaces manual mechanical operations with an automated robot arm that performs gripping, positioning, and fastening operations. This substitution maintains simplicity while dramatically improving ease of operation and worker safety by eliminating direct human contact with chemical drums.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

3Device complexity

If workers manually operate the coupler system, then device complexity is reduced, but harmful factors increase due to chemical exposure risk

Engineering Contradiction:

Improvedevice complexityVSAvoidchemical exposure risk

Core Design Contradiction:

Device complexityVSObject-affected harmful factors

Solution Approach 1:

The robot arm acts as an intermediary between the operator and the chemical drum. It performs all coupling operations remotely, eliminating direct worker contact with chemicals while maintaining a simple overall system design. The force and torque sensor serve as intermediaries to detect coupling status without visual contact.

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

Manual mechanical operations are replaced with automated robotic operations, eliminating worker exposure to chemical hazards while keeping the system relatively simple through the use of standard robot components and sensors.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

4Manufacturing precision

If precise coupler attachment is ensured through manual operation, then manufacturing precision is maintained, but productivity decreases

Engineering Contradiction:

Improvecoupler attachment precisionVSAvoidoperational efficiency

Core Design Contradiction:

Manufacturing precisionVSProductivity

Solution Approach 1:

Force and torque sensors provide real-time feedback on the coupling process, detecting when the coupler key code engages with the drum key code and when the coupler nut is properly fastened. This feedback ensures precise attachment while enabling automated control, thereby increasing productivity without sacrificing precision.

Inventive Principle:

Principle #23Feedback

Solution Approach 2:

Manual precision operations are replaced with automated robotic operations guided by sensor feedback. The robot arm can repeatedly perform the coupling operation with consistent precision, significantly improving productivity over manual operations while maintaining high attachment accuracy through force and torque monitoring.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Data Source

PatentUS12576522B2Drum coupling automation robot and drum coupling automation method

Publication Date: 2026.03.17 SAMSUNG ELECTRONICS CO LTD

AI summary

A drum coupling automation robot includes a robot, a robot arm attached to the robot, a coupler gripper connected to the robot arm, a force and torque sensor connecting one end of the robot arm to the coupler gripper and measuring force and torque applied to the coupler gripper, a vision sensor attached to the force and torque sensor, and a control circuit electrically connected to the robot, the robot arm, the coupler gripper, the force and torque sensor, and the vision sensor.