Robotic Handling of Flexible Packaging Using 3D Vision and Force Control
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Solution Overview
Problem
The chemical-pharmaceutical industry faces challenges in automatically manipulating flexible primary packaging, such as opening, unloading, loading, and closing, within dimensionally stable secondary packaging, due to the need for manual intervention and the risk of contamination.
Innovation Solution
A system comprising a two-armed robot with force-controlled grippers and a stereo camera system for 3D image recording, which autonomously manipulates the primary packaging by calculating movement sequences based on 3D point clouds and force-torque sensor measurements.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If manual manipulation of flexible primary packaging is used, then ease of operation is maintained, but contamination risk increases and productivity decreases
Solution Approach 1:
The system enables autonomous operation where the robot independently manipulates flexible packaging without human intervention. The force-controlled robot arms automatically adapt to the packaging's physical state, perform opening/closing operations, and maintain sealing integrity through feedback from force-torque sensors, eliminating the need for manual service while ensuring contamination-free handling
Solution Approach 2:
Manual mechanical manipulation is replaced with an automated robotic system that uses force-controlled actuators and sensor feedback. The robot arms with integrated force-torque sensors substitute human hands, providing automated control over manipulation forces while maintaining adaptability to the flexible packaging's varying physical state throughout the process
2Productivity
If automation is introduced for manipulating flexible packaging, then productivity increases and contamination risk decreases, but device complexity increases
Solution Approach 1:
The robotic system is designed with multi-functional capabilities to handle various operations (opening, closing, sealing, manipulating) on flexible packaging using the same robot arms and grippers. The force-controlled system with adaptive impedance control serves multiple functions throughout the packaging process, reducing the need for multiple specialized devices and justifying the automation complexity through versatile application
Solution Approach 2:
The system incorporates force-torque sensors on the robot arms that provide continuous feedback about the physical state of the flexible packaging. This feedback enables real-time adaptation of manipulation forces, allowing the complex automated system to respond dynamically to changing conditions and maintain precise control throughout the handling process
3Ease of operation
If flexible primary packaging is manipulated frequently, then ease of operation is improved, but the packaging stability and physical behavior change
Solution Approach 1:
The robotic system employs dynamic force control with adaptive impedance regulation that adjusts manipulation forces in real-time based on the packaging's current state. The controller continuously adapts the robot's mechanical impedance to match the required interaction level, enabling flexible manipulation while minimizing disruptive forces that could alter the packaging's physical structure or stability
4Manufacturing precision
If force-controlled robot arms are used for manipulation, then manipulation precision is improved, but device complexity and cost increase
Solution Approach 1:
The system performs preliminary characterization of the flexible packaging's physical properties before manipulation begins. The force-controlled robot arms are pre-configured with appropriate impedance parameters and force limits based on the specific packaging type, allowing precise manipulation without requiring complex real-time adjustments during the actual handling operation
Data Source
AI summary
System for automatically manipulating primary packaging in secondary packaging, comprising a robot having at least one robot arm with a clamping gripper installed at a tool centre point, wherein each tool centre point has a force-torque sensor, an image recording module for recording images of at least the upper segment of the primary packaging, comprising at least two stereo cameras for recording 3-D images, and one or more processors for providing a three-dimensional point cloud, controlling the image recording module and controlling the robot on the basis of the analysis of the three-dimensional point cloud and the measurements from the force-torque sensors.