Offline Buffering Foam Cans Using Staggered Robotic Gripping
Solution Overview
Problem
Existing foam can production systems face issues with manual handling leading to accumulation, difficulty in gripping, and potential explosions due to component reactions, as well as bottlenecks in the production process when problems arise, affecting all steps.
Innovation Solution
A system with stepwise oriented stands and a robotic arm for offline buffering, where foam cans are securely coupled and gripped, allowing for safe storage and decoupling, reducing the risk of knocking over and enabling independent handling of each production step.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If foam cans are manually transferred between production steps, then flexibility in handling is improved, but accumulation of cans occurs and safety risks increase
Solution Approach 1:
The patent replaces manual mechanical handling with an automated robotic arm system that uses vision guidance and automated coupling mechanisms. The robotic arm equipped with adaptive grippers transfers foam cans between production steps, eliminating manual intervention while maintaining operational flexibility through programmable control.
Solution Approach 2:
The patent introduces an automated transfer system with coupling means as an intermediary between production steps. This intermediary system includes a robotic arm with specialized end-effectors that interface with standardized coupling mechanisms on foam cans, providing a safe and controlled transfer process that prevents accumulation and accidental knocking over.
2Quantity of substance
If foam cans are accumulated at the end of a production step, then buffering capacity is improved, but difficulty in gripping and stability decrease
Solution Approach 1:
The patent arranges foam cans in a three-dimensional stacked configuration on the conveyor belt, utilizing vertical space to create buffering capacity. Multiple layers of cans are stacked with proper spacing and support structures, allowing large quantities to be buffered without increasing horizontal footprint and maintaining accessibility for robotic gripping.
Solution Approach 2:
The patent employs automated coupling means and robotic end-effectors as intermediaries that interface with standardized features on foam cans. The coupling mechanisms provide reliable gripping points even when cans are stacked or accumulated, enabling the robotic system to handle large quantities without difficulty through programmable pick-and-place operations.
3Productivity
If foam cans are knocked over during handling, then handling speed is improved, but safety risks and production disruptions increase
Solution Approach 1:
The patent replaces manual handling with a controlled robotic system that uses vision guidance, force sensing, and programmable motion paths. The robotic arm with adaptive grippers maintains precise control over foam can manipulation, ensuring safe handling speeds while preventing knocking over through automated stability monitoring and gentle placement algorithms.
Solution Approach 2:
The patent implements preliminary protective measures including standardized coupling means on foam cans, controlled acceleration and deceleration profiles in the robotic system, and monitoring mechanisms that detect potential knocking over risks before they occur. These preliminary anti-actions prevent safety incidents while maintaining efficient handling speeds.
4Difficulty of detecting and measuring
If a problem occurs in a production step, then problem detection is improved, but all other steps are affected
Solution Approach 1:
The patent divides the production system into independent modular steps with automated transfer mechanisms between them. Each production step can be isolated and stopped independently without affecting others, as the robotic transfer system can pause or redirect foam cans. This segmentation enables localized problem detection and resolution while maintaining continuity in unaffected sections.
Solution Approach 2:
The patent uses the automated robotic transfer system as an intermediary buffer between production steps. When a problem occurs in one step, the robotic system can temporarily store foam cans in its buffer capacity or redirect them, preventing the problem from propagating to other steps. This intermediary capability decouples the production steps and maintains overall productivity.
Data Source
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AI summary
System for offline buffering of foam cans comprising at least one entrance and at least one exit; at least one conveyor belt (7, 8), wherein the conveyor belt (7, 8) connects the entrance to the exit; at least one buffer zone (3) placed next to the conveyor belt (7, 8), suitable for receiving the foam cans to be buffered; and a robot (5) comprising a robotic arm, wherein the conveyor belt (7, 8) and the buffer zone (3) are within reach of the robotic arm, the buffer zone (3) comprising at least one stand, the stand comprising several rows, the rows being staggered, and the stand with the rows facing the conveyor belt (7, 8).