Dual Stacking Robots for Pressed Part Throughput
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Solution Overview
Problem
Existing stacking devices in press lines face challenges in efficiently stacking pressed parts due to limited capacity, leading to potential part jamming, as they are not adequately adapted to the press output, necessitating an increase in stacking capacity.
Innovation Solution
A device featuring a pair of independent stacking robots that work alternately or simultaneously, controlled by a control device, allowing for simultaneous or alternating picking up and stacking of parts into a common container, significantly increasing the stacking capacity by eliminating downtime and optimizing part transfer.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a single stacking robot is used, then the device complexity is low, but the stacking capacity is insufficient to handle high press output
Solution Approach 1:
The stacking device is segmented into multiple independent stacking robots (at least two) that can operate simultaneously or alternately. Each robot is assigned to handle specific portions of the stacking task, allowing the system to process parts at a rate matching high press output without overwhelming a single robot.
Solution Approach 2:
The invention introduces a temporal dimension to the stacking operation by enabling robots to work alternately or simultaneously. This allows the system to maintain continuous operation at high throughput by overlapping the picking and stacking operations in time, effectively increasing capacity without proportionally increasing physical complexity.
2Productivity
If stacking robots work sequentially, then the control is simple, but downtime occurs between operations
Solution Approach 1:
The control device coordinates multiple stacking robots to perform picking and stacking operations continuously without interruption. By overlapping operations in time and ensuring that at least one robot is always productive, the system eliminates downtime and maintains continuous useful action, matching high press output rates.
Solution Approach 2:
The control device monitors and coordinates the operations of multiple stacking robots, using feedback mechanisms to synchronize their actions. This ensures smooth transitions between robots, optimizes their coordinated movement, and maintains continuous operation by adjusting robot sequences based on real-time operational status.
3Reliability
If stacking capacity is increased to match press output, then part jamming is prevented, but the device becomes more complex
Solution Approach 1:
The stacking function is segmented across multiple independent robots, each handling specific portions of the stacking task. This segmentation allows the system to achieve high stacking capacity matching press output while distributing the complexity across multiple simpler, coordinated units rather than one complex system.
Solution Approach 2:
The control device dynamically adjusts the operation sequences and timing of multiple stacking robots based on real-time conditions. This dynamic coordination enables the system to adapt to varying part flows and maintain reliable continuous operation without requiring a fixed, overly complex static configuration.
Data Source
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AI summary
In a device for stacking stackable parts, in particular pressed parts, comprising a conveying station with at least one conveyor track on which the parts can be transported individually, and at least one stacking container into which the parts can be stacked, wherein a stacking device is provided for transferring the parts between the conveying station and the stacking container, which picks up parts from the conveyor track of the conveying station and stacks them into the stacking container, the stacking device comprises at least one or two stacking robot pairs (23a, 23b) operating independently of each other, wherein the stacking robots (23a, 23b) alternately or simultaneously pick up parts (13) from the conveyor track (16) and are controlled by a control device (52) such that a first and/or second stacking robot (23a, 23b) picks up at least one part (13) from the conveyor track (16), while simultaneously the second and/or first stacking robot (23a,23b) transfers or stacks a previously picked-up part (13) to the stacking container (21) used by both stacking robots (23a, 23b), whereby, if the parts (13) are picked up simultaneously by the first and second stacking robots (23a, 23b), simultaneous stacking into the common stacking container (21) takes place at two different stacking locations.