Layer Formation Table Robot Nesting
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Solution Overview
Problem
Existing conveyor-based systems for batch processing are cumbersome, space-intensive, power-intensive, and lack flexibility in configuring the number of articles abreast, failing to efficiently convert single or double file feeds into multiple rows and requiring complex overhead mechanisms.
Innovation Solution
A multi-axis programmable robot with an end-of-arm tooling system that forms and transfers rows of articles onto a layer formation table, allowing for the creation of multiple rows in side-by-side contact with voids for nesting, using clamping tools to lock articles between guides and enabling flexible configuration and efficient transfer.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If prior art conveyor-based batch processing systems are used, then articles can be grouped for batch processing, but the systems become cumbersome and require space on each side of the conveyor and above the conveyor
Solution Approach 1:
The patent merges the batch processing function with the conveyor structure by integrating a robot system that operates within the conveyor's existing footprint. The robot system combines grouping, transfer, and configuration functions into a single integrated unit that utilizes the conveyor's space rather than requiring additional space on sides or above the conveyor.
Solution Approach 2:
The patent transitions from traditional overhead or side-mounted batch processing mechanisms to a robot-based system that operates in the horizontal plane within the conveyor's footprint. This dimensional shift allows the system to achieve batch processing without vertical or lateral space expansion.
2Adaptability or versatility
If prior art batch processing devices are used, then articles can be grouped, but they are material-intensive and thus expensive
Solution Approach 1:
The robot system performs self-service by using its own end-effectors and positioning capabilities to group and transfer articles without requiring additional external materials or complex mechanical assemblies. The system repositions articles using controlled robot movements rather than material-intensive mechanisms.
3Adaptability or versatility
If prior art batch processing systems are used, then articles can be processed in batches, but they are power-intensive because they run continuously
Solution Approach 1:
The robot system operates with periodic action, moving between loading, grouping, and transferring articles in discrete cycles rather than continuous operation. The robot can be positioned to perform batch operations periodically, reducing overall power consumption compared to continuously running conveyor-based batch processing systems.
4Productivity
If prior art transfer mechanisms are used, then articles can be transferred, but the systems are complicated including assemblies extending transversely that are vertically movable
Solution Approach 1:
The patent extracts the complex vertical transverse mechanisms from the transfer system and replaces them with a robot-based approach. The robot system eliminates the need for complicated overhead frames and vertically movable assemblies by using programmable positioning and simple end-effector tools for article transfer.
Solution Approach 2:
The patent substitutes complex mechanical transfer mechanisms with a programmable robot system. Instead of using mechanically linked assemblies with cranks and chains, the robot uses electronic control and programmable motion to achieve article transfer, significantly reducing mechanical complexity.
5Productivity
If prior art systems are used, then articles can be transferred in groups, but they do not change configuration of the number of articles abreast
Solution Approach 1:
The robot system provides dynamic configuration capability, allowing the number of articles abreast to be changed by programming the robot's positioning and grouping actions. The system can adaptively configure articles in different patterns and densities based on the specific batch processing requirements, rather than being fixed in a single configuration.
Data Source
AI summary
An apparatus for transferring articles is disclosed herein. The apparatus includes a layer formation table. The apparatus also includes means for supplying articles to the layer formation table. At least one row of the articles is formed at a first end of the layer formation table. The apparatus also includes a programmable robot including an end of arm tool for transferring the at least one row of the articles towards a second end of the layer formation table. The programmable robot is configured to form a plurality of rows of articles on the layer formation table. Each of the rows comprises a plurality of articles in side by side contact creating a void between adjacent articles in each of the rows. The programmable robot is configured to nest the articles of one of the rows in the voids of an adjacent row. The end of arm tool includes a multiplicity of guides which form lanes. The rows of articles fill the lanes. The end of arm tool includes clamping tools which lock the individual rows of articles between the guides.