Dual-Function Manipulator for Box and Package Pallet Loading
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Solution Overview
Problem
Existing systems for handling packaging units, particularly those containing fragile products like eggs, are inefficient and lack durability in handling large numbers, especially when loading onto pallets, often requiring complex movements in a single vertical plane.
Innovation Solution
A system comprising a pallet supporter, separate package and box feeding tracks, and a manipulator unit that moves packaging units and boxes onto a pallet, allowing efficient and durable handling with minimal force, using a manipulator unit with a gripper capable of handling both empty and filled packaging units.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a single manipulator unit handles both empty boxes and filled packaging units, then system complexity is reduced and productivity increases, but the manipulator unit must be designed with higher versatility and greater manipulating force capability
Solution Approach 1:
The manipulator unit is designed with a universal gripper mechanism that can handle both empty packaging boxes and filled packaging units. The gripper includes adjustable gripping elements and a positioning system that adapts to different object sizes and weights, allowing a single manipulator unit to perform multiple functions without requiring separate specialized manipulators for each task.
Solution Approach 2:
The manipulator unit incorporates dynamic adjustment capabilities including variable gripping force control and adjustable gripper positioning. The system can dynamically adapt its manipulating force and position based on whether it is handling lightweight empty boxes or heavier filled units, optimizing performance for each task while maintaining a single unified manipulator design.
2Reliability
If packaging units are handled with high manipulating force to ensure stability, then handling reliability improves, but damage to fragile products increases
Solution Approach 1:
The manipulator unit employs variable manipulating force control that adjusts the gripping force parameter based on the specific task requirements. When handling empty boxes, higher force ensures stable positioning, while when handling filled packaging units containing fragile products, the force is reduced to minimize damage risk. This dynamic parameter adjustment maintains reliability while protecting products.
Solution Approach 2:
The system incorporates cushioning mechanisms in the gripper design and control system that prevent excessive force transmission to fragile packaging units. The manipulator controller is programmed to apply only the minimum necessary force required for secure handling, effectively cushioning against potential damage before it can occur during the handling process.
3Strength
If a manipulator unit is designed for heavy loads to handle filled boxes, then it can handle all packaging units, but it cannot efficiently handle lightweight empty boxes with minimal force
Solution Approach 1:
The manipulator unit incorporates dynamic force adjustment capabilities that allow it to optimize its manipulating force for each specific task. The control system continuously monitors the handling requirements and adjusts the applied force accordingly, enabling efficient handling of both lightweight empty boxes and heavier filled units with a single appropriately-sized manipulator.
Solution Approach 2:
The system changes the manipulating force parameter dynamically based on the weight and handling requirements of the object being processed. For empty boxes, the manipulator operates at lower force levels for efficient handling, while for filled boxes it increases the force parameter to provide sufficient gripping strength, maintaining optimal productivity across different load conditions.
Data Source
AI summary
System for handling packaging units, comprising: —a pallet supporter (2) configured for supporting at least one pallet (1); —a package feeding track (8) for feeding the packaging units (4) towards a first area near the pallet supporter (2); —a box feeding track (7) for feeding empty packaging boxes (6) towards a second area near the pallet supporter (2); —a manipulator unit (3) configured to move an empty box (6) from the box feeding track (7) onto a pallet (1) supported by the pallet supporter (2), wherein the manipulator unit (3) is also configured to move packaging units (4) into a box (6) supported on a pallet (1) supported by the pallet supporter (2). The invention also provides an innovative method for handling packaging units.