Dual-Stocker Workpiece Loading for High-Speed Press Lines
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Solution Overview
Problem
Existing workpiece loading apparatuses using articulated robots face limitations in adapting to increased speed of the press working line due to increased inertia, vibration, and cost, requiring line stops for stocker switching, which reduces productivity.
Innovation Solution
A workpiece loading apparatus with independent horizontal and raising/lowering mechanisms, utilizing A-side and B-side palletizing stages and lifting devices, and a workpiece transfer device to transfer workpieces to either stocker, allowing continuous operation without stopping the line and enabling high-speed loading.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Speed
If an articulated robot is used to load workpieces to the stocker in order, then the workpiece can be transported with accurate position control, but the inertia force and vibration increase along with acceleration and deceleration, limiting the increase in loading speed
Solution Approach 1:
The workpiece transfer device is divided into separate horizontal moving mechanism and raising/lowering mechanism, allowing independent control of each motion component. This segmentation enables precise control of workpiece movement, reducing unwanted vibrations while maintaining high loading speeds by optimizing each mechanical subsystem independently.
2Object-generated harmful factors
If the device rigidity is increased to suppress vibration, then the workpiece can be loaded with minimal vibration, but the weight increases, causing increase in apparatus size, cost, and sophistication
Solution Approach 1:
The system employs dynamic control of the separate horizontal and vertical mechanisms, using coordinated motion control algorithms that adapt to real-time conditions. This dynamic approach suppresses vibration without requiring increased mechanical rigidity or weight, as the control system actively compensates for inertial effects during acceleration and deceleration phases.
3Productivity
If a single stocker is used, then the apparatus structure is simple, but the switching time period becomes longer than the production cycle time, requiring the line to stop and reducing productivity
Solution Approach 1:
The system transitions from a single-stocker configuration to a dual-stocker arrangement, adding a spatial dimension to the loading process. By introducing a second stocker that can be loaded while the first is being emptied, the system eliminates idle time and continuous line stops, significantly improving productivity without excessive structural complexity.
4Productivity
If multiple articulated robots are used to load workpieces to both sides of the press working line, then the switching time period is reduced and productivity is improved, but the apparatus complexity and cost increase
Solution Approach 1:
A single workpiece transfer device with dual functionality is designed to service both the A-side and B-side palletizing stages. The transfer device can selectively load workpieces to either stocker location, eliminating the need for separate articulated robots for each side while maintaining high productivity through efficient task allocation and coordination.
Data Source
AI summary
A workpiece loading apparatus includes a pick-up stage, an A-side palletizing stage and a B-side palletizing stage, an A-side lifting device, a B-side lifting device, and a workpiece transfer device. The workpiece transfer device is configured to transfer a workpiece picked up from the pick-up stage to one of an A-side stocker or a B-side stocker until the stocker becomes full, and a corresponding one of the A-side lifting device or the B-side lifting device is configured to operate so that a height of the corresponding one of the A-side stocker or the B-side stocker is aligned with a workpiece horizontal movement height of the workpiece transfer device. When one of the A-side stocker or the B-side stocker becomes full, the workpiece transfer device switches an operation to transfer of the workpiece to another one of the stockers.