Packaging Machine Motion Control for Collision-Free Repositioning
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Solution Overview
Problem
In packaging machine systems with independently movable objects, there is a risk of collisions during calibration and re-positioning due to variability in object orientation and volume, leading to complex and resource-intensive customization and maintenance processes.
Innovation Solution
A method and system where movable objects communicate with a control unit to determine and maintain minimum separation distances along a track coordinate system, associating object coordinates with corresponding separation distances in a function to ensure safe movement and avoid collisions by comparing actual separations with predefined minimum distances.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If independently movable objects are used to manipulate packaging containers in high-speed production lines, then throughput is improved, but the risk of collisions between objects increases during calibration and re-positioning procedures
Solution Approach 1:
The system performs preliminary calibration of independently movable objects by determining their actual geometries and orientations before production operations begin. Minimum separation distances are pre-calculated and stored in a lookup table based on these calibrated parameters, ensuring collision-free operation during high-speed throughput without requiring complex real-time calculations
Solution Approach 2:
The control system continuously monitors the positions and orientations of independently movable objects during operation. When objects are re-positioned or recalibrated, the system feedbacks new geometric data to recalculate minimum separation distances and update the lookup table, ensuring the system adapts to any configuration changes while maintaining collision avoidance
2Adaptability or versatility
If manually re-positioning and calibrating independently movable objects is performed, then operational flexibility is improved, but resource consumption and complexity increase
Solution Approach 1:
The system enables self-service calibration by automatically determining the actual geometries and orientations of independently movable objects using sensors and coordinate measurement. The control unit autonomously calculates minimum separation distances and generates updated lookup tables without requiring manual intervention or complex calibration procedures by operators
Solution Approach 2:
The system changes parameters by storing multiple sets of minimum separation distances corresponding to different configurations and locations of independently movable objects in a lookup table. When objects are re-positioned, the system selects appropriate parameter sets from the lookup table based on current positions, enabling operational flexibility without complex real-time calculations
3Reliability
If complex collision avoidance solutions are implemented, then safety is improved, but ease of operation deteriorates
Solution Approach 1:
The system performs preliminary calculation and storage of minimum separation distances in a lookup table based on calibrated object geometries and track locations. During operation, the control unit simply queries the lookup table using current object positions to determine safe separation distances, eliminating complex real-time collision avoidance calculations and simplifying operation while maintaining safety
Solution Approach 2:
The lookup table acts as an intermediary between object configuration data and collision avoidance control. Instead of directly calculating collision risks during operation, the system uses the pre-computed lookup table to translate object positions into safe separation distances, simplifying the control logic and improving ease of operation while maintaining reliable collision avoidance
Data Source
AI summary
A method is disclosed comprising controlling a packaging machine having independently movable objects along a track, moving object volumes of a leading object and a trailing object along a section of a coordinate system, determine a set of minimum separation distances between the object coordinates of the leading and trailing objects over an interval, associating object coordinates of the trailing object and the corresponding minimum separation distances in a first function, and for a selected object coordinate communicated to a selected movable object, determine the corresponding minimum separation distance from the first function, comparing the minimum separation distance from the first function with a resulting separation between said selected object coordinate and an object coordinate of a movable object closest downstream of the selected movable object.