Automated Pallet-Cage Assembly with Robotic Drilling and Bolt Insertion
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Solution Overview
Problem
The automation of coupling metal cages to wood pallets in palletized caged containers is hindered by manufacturing tolerances, material variations, and the generation of drilling residues, which complicates mechanization and creates an unhealthy working environment.
Innovation Solution
A system utilizing cooperative robotic arms to divide tasks into stages, where one arm maps and drills orifices and another arm inserts bolts, allowing for efficient separation of drilling and screwing operations and reducing residue scattering by performing drilling at an earlier stage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Extent of automation
If traditional mechanized drilling and screwing operations are used, then automation is partially achieved, but manufacturing tolerances and material variations prevent complete automation due to inability to adapt to position differences
Solution Approach 1:
The system performs preliminary detection of hole positions on the cage and pallet before drilling. The detection means scans the surfaces to identify actual hole locations, storing this information for subsequent drilling operations. This preliminary action allows the system to adapt to manufacturing tolerances and material variations, enabling complete automation despite position differences between components.
2Extent of automation
If drilling operations are performed mechanically at fixed points, then automation is achieved, but drilling residues scatter across the facility creating an unhealthy and dirty working environment
Solution Approach 1:
The system converts the harmful scattering of drilling residues into a controlled process by using suction means immediately at the drilling location. The suction device captures dust and material strips as they are generated, preventing them from scattering across the facility. This transforms the harmful effect into a controlled local process, maintaining automation while eliminating the dirty working environment.
Solution Approach 2:
The suction means acts as an intermediary between the drilling operation and the surrounding environment. It intercepts drilling residues before they can scatter, channeling them away from the work area. This intermediary device enables the system to maintain automated drilling operations while protecting the working environment from contamination.
3Device complexity
If drilling and screwing operations are performed by the same mechanical system, then device complexity is reduced, but the specialized nature of these tasks makes complete automation difficult
Solution Approach 1:
The system segments the coupling operation into distinct functional units: detection means for identifying hole positions, drilling means for creating orifices, suction means for capturing residues, and screwing means for fastening. Each unit is specialized for its specific task, and they work cooperatively under centralized control. This segmentation enables complete automation of specialized operations while maintaining manageable system complexity through modular design.
Data Source
AI summary
System for the automation by means of robots of the assembly of the pallet and the cage in palletized and caged containers, of the type used in an assembly line, said system being applicable to components of various materials (wood, metal, plastic, etc.)having at least two robotic units intervene, the first one being intended to obtain the entire number of coordinate positions of the drilling performed on the cage-pallet coupling, upon centering and fixing of said coupling by automatic means within the system, said information being transferred to at least a second robotic unit that on the basis of said parameters performs the insertion of the bolts or screws into said drillings, thereby fixing the assembly.