Manipulator Handling Piece Goods for Layer Formation
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Solution Overview
Problem
Existing methods for handling and positioning piece goods in rows for layer formation are inefficient due to high mechanical stresses, complex and expensive equipment, and high computing and control efforts, which affect precision and reliability.
Innovation Solution
A method and device that use a manipulator to grip and separate piece goods from a closed formation, positioning them with defined gaps and orientations to form pre-groupings and layer arrangements, utilizing a control unit for precise movement control and sensor feedback to maintain accuracy and efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If traditional conveyor systems with multiple belts and abrupt speed changes are used to group and position items, then positioning capability is achieved, but mechanical stresses on items increase and processing gentleness decreases
Solution Approach 1:
The patent replaces traditional mechanical conveyor systems with abrupt speed changes and directional shifts with a manipulator-based system. The manipulator gently picks up items from a continuously moving conveyor belt and places them onto a target formation, eliminating the need for abrupt mechanical interventions while maintaining precise positioning control.
Solution Approach 2:
The system segments the handling process into distinct phases: continuous conveyance of items, selective pickup by the manipulator, transport to target position, and gentle placement. This segmentation allows each phase to be optimized independently, with continuous motion reducing mechanical stress and controlled manipulator actions ensuring precision.
2Manufacturing precision
If complex row-forming devices with multiple controllable conveyor sections are used to achieve desired spacing, then positioning accuracy is improved, but device complexity and cost increase
Solution Approach 1:
The patent extracts the spacing and positioning functions from the conveyor system itself and transfers them to a manipulator system. Instead of using multiple controllable conveyor sections to create spacing, a single conveyor belt continuously transports items while the manipulator selectively picks up items at appropriate intervals and places them on the target formation, simplifying the overall device architecture.
Solution Approach 2:
The manipulator serves multiple functions simultaneously: it acts as a positioning device, a spacing mechanism, and a transfer device. This multi-functionality eliminates the need for separate specialized components for each function, reducing device complexity while maintaining or improving positioning accuracy.
3Manufacturing precision
If multiple cycles of conveying, grouping, and positioning are performed to assemble layers, then layer formation is achieved, but processing time increases
Solution Approach 1:
The patent implements continuous conveyance of items on the conveyor belt without interruption. The manipulator continuously operates to pick up items from the moving belt and place them on the target formation, eliminating idle cycles and waiting periods. This continuous operation maintains layer formation quality while significantly reducing total processing time compared to batch-based approaches.
Solution Approach 2:
Items are continuously conveyed and positioned in advance on the conveyor belt before reaching the manipulator. The manipulator is pre-positioned and ready to immediately pick up items when they arrive at the correct location, eliminating delays and ensuring seamless transition from conveyance to positioning actions.
4Productivity
If high-speed operation is implemented to increase productivity, then output rate improves, but positioning precision and reliability may compromise
Solution Approach 1:
The system dynamically adjusts the manipulator's pickup and placement timing based on the continuous motion of the conveyor belt and target formation. By synchronizing the manipulator's operations with the continuous flow of items, the system maintains high-speed operation while ensuring precise positioning through real-time coordination rather than fixed-cycle operation.
Data Source
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AI summary
The invention relates to a method and to an apparatus for handling piece goods (2) which are moved one after another and are transported to a capture area (4) of at least one manipulator (5). In this connection, in a plurality of successive manipulation steps in each case at least one transported piece good (2) is gripped by clamping and/or by force fitting and/or by form fitting by the at least one manipulator (5) out of the closed formation (F), is spatially separated from following piece goods (2) of the closed formation (F), and is brought into a defined relative target position and/or target orientation in relation to the respective following piece goods (2). In particular, in this case the piece goods (2) are brought into respective different target positions and/or target orientations such a way that in each case preliminary groupings and/or layer arrangements for stackable layers of piece goods are formed in each case with a defined number of piece goods (2). During the course of this, within the closed formation (F) gaps (30) are produced in each case between successive groups (1a) of a defined number of piece goods (2), wherein the number of piece goods (2) within the separate group (1a) corresponds to a defined number of piece goods (2) of each preliminary grouping and/or layer arrangement to be formed.