Dual Manipulator Product Loading Apparatus for High-Speed Packaging
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Solution Overview
Problem
Existing packaging systems with a single manipulator struggle with complex operations and high transfer rates due to increased weight and reduced efficiency when product orientation changes, and systems with two manipulators face interference issues and increased footprint.
Innovation Solution
An apparatus with a first manipulator that picks up products from a conveyor and deposits them in an intermediate station, and a second manipulator that rotates and positions them into containers on a separate conveyor, housed within the first manipulator's working area to avoid collisions and maintain a compact frame size.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If a single manipulator is used to perform both pick-up and deposition operations, then the apparatus structure remains compact, but the transfer rate is limited to 20-25 cycles per minute and cannot handle complex product orientation changes
Solution Approach 1:
The patent divides the loading operations into two separate manipulators: a first manipulator for picking up products from the first conveyor and a second manipulator for depositing them into containers on the second conveyor. This segmentation allows each manipulator to specialize in specific tasks, enabling the system to achieve higher transfer rates (exceeding 25 cycles per minute) while maintaining operational simplicity through dedicated functions for each manipulator.
2Adaptability or versatility
If a single manipulator performs complex operations including product rotation, then additional mechanisms weighing down the pick-up head are required, but the manipulator speed decreases due to greater weight
Solution Approach 1:
The patent separates rotation operations from deposition operations by assigning the first manipulator to perform rotation and positioning of products, while the second manipulator handles the deposition into containers. This segmentation eliminates the need for additional heavy mechanisms on the pick-up head, as rotation is performed by the first manipulator's positioning capabilities rather than by weighing down the second manipulator's head.
3Length of stationary object
If the distance between the first and second conveyor exceeds 500-600 mm, then the manipulator must make longer runs, but the number of cycles per minute that the manipulator can perform is reduced
Solution Approach 1:
The patent divides the transfer operation into two separate manipulators that can operate independently and simultaneously. The first manipulator picks up products from the first conveyor while the second manipulator deposits them into containers on the second conveyor. This segmentation allows each manipulator to work on shorter, more efficient strokes, thereby maintaining high cycle rates even when the distance between conveyors exceeds 500-600 mm.
4Productivity
If two independent manipulators are used to increase transfer rate, then the frame size must be larger, but this increases production area and cost
Solution Approach 1:
The patent positions the second manipulator within the working area of the first manipulator, creating a nested configuration where the smaller second manipulator operates inside the envelope of the larger first manipulator. This nesting arrangement allows both manipulators to function independently without requiring a proportionally larger frame, thereby increasing transfer rate while minimizing the increase in production footprint and apparatus cost.
5Productivity
If two manipulators are used to perform loading operations, then the transfer rate increases, but the working areas of the two manipulators overlap and create potential interferences
Solution Approach 1:
The patent places the second manipulator within the working area of the first manipulator in a nested configuration, where the second manipulator's smaller workspace is contained within the first manipulator's larger workspace. This spatial arrangement, combined with coordinated control, allows both manipulators to operate simultaneously at high speeds without collisions, as their paths are carefully planned to avoid interference zones.
Solution Approach 2:
The patent employs a control system that coordinates the operations of both manipulators, using feedback from sensors and position monitoring to detect and avoid potential collision zones. The control system adjusts the timing and paths of both manipulators in real-time, allowing them to operate at high transfer rates while maintaining reliability by preventing collisions through continuous monitoring and adaptive control.
Data Source
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AI summary
An apparatus for loading products into containers, comprising: - a stationary frame (12), - a first conveyor (20) for advancing a flow of products along a longitudinal direction (X), - an intermediate station (22), - a second conveyor (24) for advancing a continuous flow of containers (C), - a first manipulator (26) configured to pick-up products from the first conveyor (20) and to deposit them in the intermediate station (22), and - a second manipulator (28) configured to pick-up products from the intermediate station (22) and to deposit them in the said containers (C), wherein the first manipulator (26) comprises two arms (56) spaced apart in said longitudinal direction (X) and carrying a first pick-up head (30), wherein the two arms (56) of the first manipulator (26) move together in respective plane portions (P) transverse with respect to said longitudinal direction (X), and wherein the second manipulator (28) is arranged between said plane portions (P).