Needle Gripper Automation for Precise Die-Cutter Rubber Placement
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Solution Overview
Problem
The manual rubber coating process of die-cutters is time-consuming, prone to errors, and results in significant material waste due to the need for skilled labor and minimum element length recognition, limiting the ability to optimize the pattern of cutting and creasing rules.
Innovation Solution
An apparatus with a manipulator equipped with a needle gripper and optical recognition system automatically applies ejection rubber elements by aligning and positioning them on a die-cutter using retractable needles and a presser element, ensuring precise optical recognition and minimal material waste.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If manual rubber coating process is used, then skilled labor can ensure proper placement, but the process is time-consuming and results in significant material waste
Solution Approach 1:
The patent replaces the manual mechanical placement process with an automated system that uses optical scanning to detect rubber element positions and a robotic manipulator with adaptive grippers to transfer elements. This substitution eliminates human labor limitations while maintaining placement accuracy through sensor feedback and controlled movement mechanisms.
Solution Approach 2:
The system creates a digital map of the rubber sheet by optically scanning the positions of all rubber elements before transfer. This copying approach allows the automated system to reference the detected positions and accurately reproduce the intended placement pattern on the anvil, ensuring precision without manual intervention.
2Adaptability or versatility
If manual rubber coating process is used, then flexible pattern optimization is possible, but significant material waste occurs due to minimum element length requirements
Solution Approach 1:
The patent implements dynamic element selection where the system can individually choose which rubber elements to transfer based on real-time detection and placement requirements. The adaptive gripper mechanism can adjust its behavior for each element, enabling flexible pattern optimization and minimizing waste by transferring only the necessary elements in optimal configurations.
Solution Approach 2:
The system changes the operational parameters by detecting actual rubber element positions optically and adjusting the transfer process accordingly. This allows the system to work with variable element positions and sizes, optimizing material usage by adapting the placement pattern to the actual rubber sheet configuration rather than requiring fixed minimum element lengths.
3Productivity
If automated system is implemented, then productivity increases, but device complexity increases
Solution Approach 1:
The patent employs a multi-functional integrated system where a single robotic manipulator performs multiple operations: approaching the rubber sheet, detecting element positions, gripping elements with adaptive grippers, transporting them, and placing them on the anvil. This universal approach consolidates multiple functions into one system, increasing productivity while managing complexity through functional integration.
Solution Approach 2:
The system incorporates self-adjustment mechanisms where the adaptive gripper automatically adjusts its grip parameters based on detected rubber element characteristics, and the optical detection system automatically maps element positions without external intervention. This self-service capability reduces the need for complex external control systems while maintaining high productivity.
Data Source
AI summary
An apparatus and a method for automatically applying, without the intervention of an operator, rubber elements on a die-cutter during the manufacturing step thereof, are described. The apparatus comprises a manipulator, preferably a robotic arm, and a needle gripper. The gripper withdraws the water-jet pre-cut rubber elements from a sheet with double-sided adhesive tape, and places them one by one at the point provided for by the working program.