Item Tilting and Robot Placement for Flexible Object Packing
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Solution Overview
Problem
Existing material handling systems, such as conveyors and robotic arms, face limitations in flexibility, precision, and efficiency when handling objects of varying sizes and orientations, leading to sorting errors and inefficient packing.
Innovation Solution
An object handling system comprising an item tilter to orient objects and a robot handler, guided by a software module that analyzes object characteristics and provides instructions for placement, utilizing machine learning and databases to optimize orientation and positioning.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If conventional conveyors and robotic arms are used for material handling, then automation is achieved, but flexibility and precision are limited when handling objects of varying sizes and orientations
Solution Approach 1:
The system employs dynamic routing mechanisms that can change the path of objects based on their characteristics. The routing system is not fixed but can be reconfigured to handle different object sizes, shapes, and orientations, allowing the conveyor system to adapt to varying material handling requirements without requiring multiple dedicated conveyor lines
Solution Approach 2:
The item manipulator is designed to perform multiple functions including tilting, rotating, and positioning objects of various types. This single multi-functional device replaces what would traditionally require multiple specialized devices, achieving versatility in handling different object characteristics while maintaining system simplicity
2Reliability
If robotic arms are programmed for narrowly defined tasks, then reliability and accuracy are improved, but adaptability to varying object characteristics deteriorates
Solution Approach 1:
The system incorporates sensors and vision systems that detect object characteristics such as size, shape, and orientation. This feedback information is used by the control system to automatically adjust the manipulation parameters, ensuring accurate and reliable handling adapted to each specific object without requiring manual reprogramming
Solution Approach 2:
The robotic system automatically determines the appropriate manipulation strategy based on detected object characteristics. The system self-adjusts its parameters and selects suitable manipulation techniques without external intervention, maintaining both accuracy and adaptability across varying task requirements
3Device complexity
If conveyors operate along a fixed path, then system simplicity is maintained, but routing flexibility deteriorates
Solution Approach 1:
The item manipulator serves as an intermediary device between conveyor sections, enabling flexible routing decisions. Objects can be tilted, rotated, or diverted at the manipulator station, allowing the system to change material flow direction without requiring complex branching conveyor mechanisms throughout the entire system
4Productivity
If pushers are used for high-speed sorting, then productivity increases, but positioning precision deteriorates leading to sorting errors
Solution Approach 1:
The system performs preliminary positioning and orientation of objects using the item manipulator before the actual sorting action. Objects are pre-oriented to the correct angle and position, and pre-positioned on the conveyor path, which enables high-speed pusher operation without sacrificing sorting accuracy since the difficult positioning work has already been completed
Data Source
AI summary
Provided is an object handling system that may include: an item tilter configured to orient an object; a robot handler configured to place the object into a destination container; and a software module configured instruct the robot handler to move the object to the destination container. Another object handling system may include: an item tilter configured to orient an object; and a software module configured to (i) analyze an orientation of the object and (ii) provide instructions to the item tilter to orient the object to a desired orientation. A method of packing a destination container with an object may include: providing the object to an item tilter; rotating the object, using the item tilter, to a desired orientation; and moving the object into the destination container.