Dynamic Pillow Bag Placement on Compound-Angled Universal Surface
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Solution Overview
Problem
Existing systems fail to accurately and efficiently form patterns with pillow bags of varying positions, orientations, and dimensions due to imprecision in measuring and placing them, leading to damage and inefficiencies in manufacturing, handling, and transportation processes.
Innovation Solution
A system that measures the thickness and position of moving pillow bags using sensors and feed forward units to dynamically adjust the pick and place process, allowing for precise placement on a compound-angled universal surface, and includes a quality control mechanism to reject bags that do not meet criteria.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If traditional fixed-position pick and place systems are used, then device complexity is reduced, but manufacturing precision deteriorates due to inability to accommodate varying bag positions and orientations
Solution Approach 1:
The system employs dynamic vision guidance and real-time measurement feedback to adjust robot pick and place operations, enabling adaptation to varying bag positions, orientations, and dimensions while maintaining high placement precision
Solution Approach 2:
Measurement devices capture real-time data on bag thickness and position, feeding this information back to the control system which adjusts placement parameters accordingly, ensuring precise positioning despite variations in product geometry
2Manufacturing precision
If measurement and adjustment mechanisms are added to the system, then manufacturing precision improves, but device complexity increases
Solution Approach 1:
The system replaces complex mechanical adjustment mechanisms with vision-based measurement and software-controlled robot positioning, achieving high precision through computational methods rather than mechanical complexity
Solution Approach 2:
The vision system creates a digital representation of the bag's position and dimensions, allowing the control system to plan and execute precise placement operations based on this virtual model without requiring physical measurement apparatus
3Productivity
If traditional assumption-based picking is used, then measurement precision is reduced, but productivity is improved due to simpler processes
Solution Approach 1:
The measurement device captures bag thickness and position data before the pick operation, allowing the system to pre-calculate optimal placement parameters and execute the transfer operation without delays
Solution Approach 2:
The system implements continuous measurement and placement operations with minimal interruption, using real-time data to maintain continuous production flow while achieving precise placement of each bag
4Loss of substance
If imprecise placement methods are used, then device complexity is reduced, but loss of substance increases due to damage to pillow bags
Solution Approach 1:
The system adjusts placement parameters such as robot end-effector position, speed, and orientation based on real-time measurement data, optimizing the transfer process to minimize mechanical stress and damage to the pillow bags
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 reduces damage and inefficiency by ensuring accurate placement of pillow bags, conserves resources, and increases production quality and efficiency, enabling the creation of complex patterns while minimizing waste.
Implementation Method 1
a first input device conveys a non-rigid object into contact with the feed forward unit, which contact causes a displacement of the feed forward unit, wherein the displacement is used to measure directly or indirectly a measured dimension of the non-rigid object
Implementation Method 2
a robot with an end effector transfers product from the universal surface to the ultimate package and the end effector comprises a vacuum nozzle
Implementation Method 3
the top surface of the universal surface, upon which a pattern is placed, is at a compound angle so that one corner is lower than all the other corners. One result of the compound angle is that gravity tends to pull bags towards the lowest corner
Data Source
AI summary
An apparatus and method for transferring a pattern from a universal surface to an ultimate package. The apparatus comprises an end effector for a pattern transfer robot. The end effector comprises a crowder plate with crowder plate slats spaced apart a distance to form openings between the crowder plate slats. The universal surface comprises a finger wall with finger wall slats spaced apart a distance to form openings between the finger wall slats. A portion of the crowder plate slats are sized to pass between a portion of mating finger wall slats.