Dual-Pallet Workpiece Transfer Layout With Reduced Robot Reach
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Solution Overview
Problem
The configuration of two pallets side by side increases the reach range and weight of the robot, leading to higher costs due to the need for a larger and more rigid robot arm.
Innovation Solution
A workpiece loading and unloading device with two pallets positioned side by side, where the robot arm moves within a combined range to reach all workpieces on one pallet and only some on the adjacent pallet, and a pallet movement mechanism shifts the second pallet to align with the first when all workpieces are transferred, allowing the arm to separate.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If two pallets are placed side by side to enable continuous operation without pallet replacement, then productivity is improved, but the robot arm length and weight increase leading to higher cost
Solution Approach 1:
The system dynamically switches between two operational modes: when the first pallet is being used, the second pallet is positioned out of reach; when the first pallet is depleted, the second pallet moves into position. This dynamic reconfiguration allows continuous operation without requiring the robot to simultaneously reach both pallets, avoiding the need for an excessively long arm.
Solution Approach 2:
The solution introduces temporal dimension to the pallet arrangement problem. Instead of having both pallets statically accessible at the same time, the system uses time-based sequencing where pallets are accessed in alternating cycles. The pallet movement portion transitions the second pallet from an inaccessible position to an accessible position only when needed, effectively using time to resolve the spatial conflict.
2Productivity
If two pallets are placed side by side to enable continuous operation without pallet replacement, then productivity is improved, but the robot arm length increases leading to higher cost
Solution Approach 1:
The system dynamically switches between two operational modes: when the first pallet is being used, the second pallet is positioned out of reach; when the first pallet is depleted, the second pallet moves into position. This dynamic reconfiguration allows continuous operation without requiring the robot to simultaneously reach both pallets, avoiding the need for an excessively long arm.
Solution Approach 2:
The solution introduces temporal dimension to the pallet arrangement problem. Instead of having both pallets statically accessible at the same time, the system uses time-based sequencing where pallets are accessed in alternating cycles. The pallet movement portion transitions the second pallet from an inaccessible position to an accessible position only when needed, effectively using time to resolve the spatial conflict.
3Adaptability or versatility
If the robot arm is lengthened to reach all workpieces on two side-by-side pallets, then the reach range is improved, but the rigidity requirement increases the robot weight and cost
Solution Approach 1:
The robot does not need to reach the entire second pallet simultaneously. Instead, it progressively accesses workpieces on the second pallet as they become available, moving from one pallet to the other in a stepwise manner. This partial action approach reduces the required reach distance compared to needing to access the farthest points of both pallets at once.
Data Source
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AI summary
To narrow an operating area of the robot on a pallet side of the robot in a workpiece loading and unloading device, wherein the workpiece loading and unloading device (100) includes a placement portion (301) that includes two pallets (310) placed thereon, each of the two pallets configured to store a plurality of workpieces (10) arranged and thereon, a pallet movement portion (302) that is configured to move the pallet (310) placed in the placement portion, an arm (120) that is configured to move relative to an automatic lathe (200) that machines the workpiece (10), a hand (120) that is configured to transfer the workpiece (10) between the pallet (310) and the automatic lathe (200), and a controller (130), wherein the controller (130) controls the arm (110) to move within a combined range of a first range S1 and a second range S2, in the first range, the hand (120) reaches all of an area of the first pallet (310) and in the second range S2, the hand (120) reaches only some of an area of the second pallet (310), and controls the pallet movement portion (302), such that the first pallet (310) is unladed, and the second pallet (310) moves to the first position P1 while the arm (120) separates from the second pallet (310).