Rack-and-Pinion End Effector for Flexible Pitch Packaging
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Solution Overview
Problem
Existing end effector designs for robotic arms in the packaging industry face challenges in efficiently picking up items from a first conveyor belt and placing them into packaging at a different pitch, with limited accessibility for maintenance and complex actuation mechanisms that complicate installation and repair.
Innovation Solution
The end effector incorporates a rack and pinion assembly with a robot interface, actuation rods connected to carrier assemblies, and cooperating members that allow indirect connection of carrier assemblies, enabling synchronized movement and easy access for maintenance, along with vacuum ports for pick-up and placement operations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If carrier assemblies are directly connected to actuation mechanism, then synchronized movement is achieved, but maintenance accessibility deteriorates
Solution Approach 1:
The end effector is divided into modular components: a stationary frame with rack assembly, movable carrier assemblies, and indirect connection mechanisms. This segmentation allows the actuation mechanism to remain stationary and accessible for maintenance while carrier assemblies move independently to achieve synchronized positioning.
Solution Approach 2:
Cooperating members act as intermediaries between carrier assemblies, enabling indirect connection and synchronized movement without direct attachment to the actuation mechanism. This intermediary system maintains synchronization while improving maintenance accessibility.
2Ease of manufacture
If pitch parameters are fixed, then manufacturing simplicity is maintained, but adaptability deteriorates
Solution Approach 1:
The end effector employs movable carrier assemblies that can be positioned at different pitches along the frame, transforming the system from static to dynamic. This allows pitch parameters to be adjusted for different packaging requirements while maintaining a simple standardized frame structure.
Solution Approach 2:
The standardized frame with rack assembly serves multiple functions: providing structural support, enabling pitch adjustment, and facilitating carrier assembly movement. This universal design allows the same basic structure to accommodate various pitch requirements.
3Manufacturing precision
If complex actuation mechanisms are used, then precise pitch control is achieved, but device complexity increases
Solution Approach 1:
The complex actuation mechanism is extracted and separated from the carrier assemblies, placed in a stationary rack assembly on the frame. This extraction simplifies the moving components while maintaining precise pitch control through the rack and pinion mechanism.
Solution Approach 2:
The patent replaces direct mechanical connection with a rack and pinion gear system, substituting a complex multi-linkage mechanism with a simpler gear-based actuation system that achieves precise positional control.
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 design enhances the efficiency of item picking and placement by allowing flexible pitch adjustments and simplifies maintenance through improved accessibility, reducing complexity and increasing operational reliability.
Implementation Method 1
Each pick-up member is operatively connected to a vacuum source
Data Source
AI summary
An end effector for the packaging industry comprises has a frame, a bridge on top of the frame, a rack and pinion assembly, actuation rods, carrier assemblies, and vacuum ports. The rack and pinion assembly is configured to be operatively connected to a robot's rotatable shaft, and to the actuation rods. The actuation rods are fixedly connected to one or more of the carrier assemblies. As the robot's shaft rotates, the rack and pinion assembly is actuated, which actuates the actuation rods, which causes the carrier assemblies fixedly connected to the actuation rods to move longitudinally along the frame. Each carrier assembly includes a carrier block and at least one pick-up member. Each carrier block has at least one arm with a grabber to cooperate with an adjacent arm with grabbers of an adjacent carrier block(s) of the same subgroup.