Dual Robotic Case Packing System for Standup Products
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Current case packing systems face challenges in achieving high speed and flexibility while efficiently loading articles into containers, particularly in meeting 'shelf-ready packaging' requirements, due to limitations in robot movement range and complexity in implementing multiple robot heads.
Innovation Solution
A dual robotic case packing system with multi-axis robots, where one robotic mechanism picks and places articles into intermediate bins and another simultaneously grabs and loads them into containers, using a vacuum pick handler and multi-finger grippers, respectively, to achieve efficient and upright loading.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If multiple robot heads are used along the conveyor to increase packing speed, then productivity increases, but device complexity and ease of operation worsen due to awkward means for moving robot heads
Solution Approach 1:
The system divides the packing function into two separate robotic mechanisms: one dedicated to picking articles from the conveyor and placing them in bins, and another dedicated to grabbing articles from bins and loading them into containers. This segmentation allows each robot to be optimized for its specific task with simpler, more reliable motion mechanisms.
Solution Approach 2:
Intermediate bins are introduced as a buffer between the article conveyor and the container loading position. The first robotic mechanism deposits articles into these bins, and the second robotic mechanism retrieves them for container loading. This intermediary system decouples the two operations, allowing independent optimization and simplifying the motion requirements of each robot.
2Adaptability or versatility
If multi-axis robots are used to provide greater flexibility in motion, then adaptability improves, but productivity decreases due to slower operation speed
Solution Approach 1:
The system segments the motion requirements into two distinct robotic mechanisms with different capability profiles. The first robot uses a three-axis mechanism optimized for high-speed picking and bin deposition, while the second robot uses a multi-axis mechanism optimized for flexible container loading. This segmentation allows each robot to be specialized for its specific task rather than requiring both to have full multi-axis capability.
Solution Approach 2:
Different robotic mechanisms are assigned to different locations in the system based on local requirements. The picking station (first robot) prioritizes speed with a simpler three-axis mechanism, while the container loading station (second robot) prioritizes flexibility with a multi-axis mechanism. Each location has the appropriate level of complexity for its specific function.
3Device complexity
If three-axis robots are used for picking articles, then device complexity is reduced, but adaptability worsens due to limited range of movement in certain directions
Solution Approach 1:
The system segments the motion tasks so that the three-axis robot handles only the picking and bin-deposition functions, which have limited motion requirements. The container loading function, which requires greater adaptability for various container types and orientations, is assigned to a multi-axis robot. This segmentation allows the three-axis robot to maintain simplicity while the multi-axis robot provides the necessary flexibility where required.
Solution Approach 2:
The intermediate bins serve as a transition zone that decouples the motion requirements of the two robotic mechanisms. The first robot only needs to deposit articles into the bins, a simple vertical placement task suitable for a three-axis robot. The second robot retrieves articles from the bins and handles the complex container loading, utilizing its multi-axis capability for adaptability.
4Device complexity
If articles are loaded directly from conveyor to container, then device complexity is reduced, but adaptability worsens for meeting shelf-ready packaging requirements
Solution Approach 1:
The system segments the loading process into two distinct operations performed by separate robotic mechanisms. The first robot handles article picking and bin deposition, while the second robot handles article retrieval and container loading with orientation control. This segmentation enables the second robot to specifically optimize for shelf-ready packaging by controlling article orientation during container loading, a function that would be difficult to integrate into a single direct-loading system.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This system enhances packing speed and flexibility, enabling efficient filling of bins and simultaneous loading into containers, meeting 'shelf-ready packaging' requirements by optimizing the movement and placement of articles, thereby improving operational efficiency and meeting market demands.
Implementation Method 1
A first robotic mechanism moves articles on the article conveyor to the first, second, and third bins
Implementation Method 2
A second robotic mechanism moves articles from the first, second, and third bins to containers on the case conveyor
Data Source
AI summary
A case packing system for loading articles into containers includes an article conveyor for conveying articles, a case conveyor for conveying containers, and first, second, and third bins. A first robotic mechanism moves articles on the article conveyor to the first, second, and third bins. A second robotic mechanism moves articles from the first, second, and third bins to containers on the case conveyor. A controller operatively coupled to the first robotic mechanism and the second robotic mechanism is configured to pick and place with the first robotic mechanism one or more conveyed articles into the first, second, and third bins, and grab and load with the second robotic mechanism one or more articles from the first, second, and third bins into containers on the case conveyor.