Elastic Blanket Container Handling for Precise Robotic Layer Forming
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Solution Overview
Problem
Existing systems for preparing layers before palletizing or positioning containers suffer from instability, inaccuracy, reduced flexibility, and increased energy consumption, particularly when handling smaller packages, limiting production speed and efficiency.
Innovation Solution
A device using elastic pressure for container handling, coupled to a robot, allows for precise movements in transverse, longitudinal, and rotational axes, with automatic switching and minimal downtime, reducing the need for space and energy consumption.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional roller drive systems are used below the conveyor belt, then the system provides continuous product flow, but it generates relative instability and inaccuracy in packaging positioning
Solution Approach 1:
The patent replaces the traditional mechanical roller drive system with a robotic manipulator that uses controlled mechanical movements to pick, move, and place packages. This substitution eliminates the instability and positioning inaccuracy inherent in roller drive systems while maintaining continuous product flow through coordinated robotic operations.
Solution Approach 2:
The robotic manipulator acts as an intermediary between the feeding system and the forming table, providing precise control over package positioning and movement. This intermediary device enables accurate placement of packages without the drawbacks of direct roller drive contact with the packaging.
2Productivity
If robots or movement devices are used for forming flexible layers, then handling flexibility is improved, but the number of cycles per minute per grip is limited
Solution Approach 1:
The system performs preliminary actions by pre-positioning multiple packages on the forming table before the robotic manipulator begins its picking and placing sequence. This preparation allows the robot to operate more efficiently with fewer stops and starts, increasing the cycles per minute achievable per grip operation.
Solution Approach 2:
The robotic manipulator operates continuously to pick packages from the feeding system and place them on the forming table without interruption. This continuous operation eliminates idle time between grips, maximizing productivity and enabling higher cycle rates compared to traditional intermittent systems.
3Productivity
If alternative feeding systems and multiple grippers are added to increase production, then the number of packages handled per operation increases, but hardware complexity and energy consumption increase
Solution Approach 1:
The robotic manipulator is designed as a universal device that can handle packages of varying sizes and configurations by adjusting its grip and movement parameters. This multi-functionality eliminates the need for multiple specialized grippers, reducing hardware complexity and energy consumption while maintaining the ability to increase production capacity through software-controlled operation sequences.
4Speed
If robots operate on two axes for moving products, then the system structure is simplified, but work speed is reduced and working area increases
Solution Approach 1:
The robotic manipulator operates on three axes (X, Y, and Z) rather than two, adding vertical movement capability. This dimensional enhancement allows the robot to access packages and positioning points more efficiently, increasing work speed by eliminating the need for lateral repositioning and reducing the overall working area required for the same production capacity.
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
The device achieves up to 150 cycles per minute with reduced space and energy requirements, enabling efficient and agile handling of containers, including format changes with minimal interruptions.
Implementation Method 1
an elastic blanket (3) made of material such as elastic/polymer is installed, which must have the property of maintaining the integrity of the product handled
Data Source
AI summary
The present patent application for the invention of a device, coupled to a robot or other handling system, deals with the pressure on the container, which allows the product to be moved to be held, moving and rotating them, defining their positioning and organizing them for later palletizing or positioning for subsequent operations. The invention comprises a device (D) composed of a headstock or structure (1) made of metal or another type of material, to be coupled, by means of a coupling (2), to a robot (R1) or other handling equipment; and, in the lower part of the device (D), an elastic blanket (3) made of material such as elastic/polymer is installed, which must have the property of maintaining the integrity of the product handled, in this case the container (4), single or grouped, and allow it to be moved over the work area (A1). The device (D), according to the invention, is operated from movements for the formation of layers or mosaics (M) from a dedicated software, and this association enables the movement of the containers (4) in transverse and longitudinal axes, or swivels.