Dual Robotic Arm Tray Transfer for Aseptic Container Packaging
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Solution Overview
Problem
Existing apparatuses using a single robotic arm for packaging containers in aseptic environments suffer from reduced productivity due to down times during filling, closing, and weighing operations, as other trays must wait for the robotic arm to complete operations before starting a new cycle.
Innovation Solution
An apparatus with two robotic arms coordinated by electronic control means allows simultaneous and continuous transfer of transport members to filling units, ensuring continuous filling and closing operations without interruptions, using a first robotic arm to transfer trays while a second arm prepares the next tray for filling.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a single robotic arm is used to move trays for filling, closing and weighing operations, then the apparatus can be easily cleaned and sanitized for aseptic work environments, but other trays must wait stationary during operations reducing productivity
Solution Approach 1:
The patent divides the single robotic arm function into two separate robotic arms. The first robotic arm is dedicated to moving trays to the filling unit, while the second robotic arm handles moving trays to the closing and weighing units. This segmentation allows both arms to operate simultaneously and independently, eliminating the waiting time that occurred with a single arm, thereby maintaining aseptic conditions while significantly improving productivity to 36,000 containers per hour.
2Device complexity
If a single robotic arm completes all operations on one tray before moving to the next, then operational simplicity is maintained, but down time occurs between cycles
Solution Approach 1:
The patent implements continuous operation by having the first robotic arm continuously move trays to the filling unit while the second robotic arm continuously moves trays to the closing and weighing units. Both arms operate in parallel without interruption, ensuring that the filling, closing, and weighing operations proceed continuously without the downtime that occurs when a single arm must complete all operations sequentially. This eliminates idle time between cycles and maximizes productivity.
3Productivity
If traditional mechanical movement means are used instead of robotic arms, then productivity is higher, but polluting particles are produced and cleaning is difficult in aseptic environments
Solution Approach 1:
The patent replaces traditional mechanical movement means (conveyor belts, gears, chains, slides, and lifters) with robotic arms that use controlled mechanical motion without contact with containers. The robotic arms pick up trays and move them through the filling, closing, and weighing operations without the friction, wear, and potential contamination associated with traditional mechanical conveyance systems. This substitution eliminates polluting particles while maintaining high productivity and enabling easy cleaning and sanitization for aseptic environments.
Data Source
AI summary
An apparatus for automatically packaging containers along a work path, wherein one or more containers to be filled are supported by corresponding trays includes at least: a feed station to sequentially feed the trays in which the containers are disposed; a filling unit to sequentially perform a plurality of operations of filling the containers; a first robotic arm capable of performing at least one programmed function, in order to selectively transfer the trays one at a time toward the filling unit, and electronic control means. The apparatus also includes a second robotic arm, which is also capable of autonomously performing the same programmed function as the first robotic arm.