Planar Motor Pick-and-Place Conveyors for Faster Product Transfer
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Solution Overview
Problem
Current pick and place systems face challenges in managing trade-offs between size and number of manipulators, leading to increased complexity and cost, especially when handling varying product volumes and sizes, which affects operation speed.
Innovation Solution
Incorporating planar motors as either the infeed or outfeed conveyor, synchronizing the movement of the shuttle with the product trajectory to minimize the pick and place distance, thereby reducing the size and transfer time of the manipulator.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the number of manipulators is increased to handle high volume of smaller products, then the operation speed is improved, but the device complexity and automation cost increase
Solution Approach 1:
The patent replaces the traditional mechanical conveyor system with a planar motor system that uses electromagnetic fields to levitate and propel shuttles. This substitution eliminates the need for complex mechanical transmissions, gears, and belts, thereby reducing device complexity while maintaining high operation speeds for handling small products
2Weight of moving object
If larger manipulators are used for heavier products, then the handling capability is improved, but the operation speed decreases due to higher inertia
Solution Approach 1:
The planar motor system replaces traditional mechanical manipulators with electromagnetic propulsion. The shuttles are levitated above the stator surface using electromagnetic fields, eliminating mechanical contact and friction. This allows the system to handle heavy products without the inertia limitations of mechanical manipulators, maintaining high acceleration and operation speeds
Solution Approach 2:
The system employs dynamic control of multiple shuttles that can independently adjust their positions, speeds, and trajectories. The control system optimizes the movement of shuttles based on product weight and destination requirements, enabling heavy products to be transported efficiently while maintaining overall system speed
3Adaptability or versatility
If the pick and place distance is increased to accommodate larger workspace, then the adaptability is improved, but the manipulator size and cost increase
Solution Approach 1:
The patent transitions from traditional linear conveyor arrangements to a two-dimensional planar motor workspace. Multiple shuttles operate simultaneously on the same stator surface, utilizing the planar dimension to increase workspace capacity without requiring longer manipulator arms or larger physical distances
4Productivity
If the number of manipulators is increased to maximize pick range, then the productivity is improved, but the automation cost increases
Solution Approach 1:
The patent merges the functions of multiple traditional manipulators into a single planar motor system with multiple shuttles. The shuttles share common infrastructure (stator, control system, power supply) while providing distributed picking coverage. This consolidation reduces the total number of independent manipulator systems needed while maintaining or expanding pick range
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This approach reduces the size of the manipulator required, decreases transfer time, and increases the operation speed of the pick and place system, enhancing flexibility for various applications.
Implementation Method 1
at least the infeed conveyor or the outfeed conveyor is designed as a planar motor comprising at least one shuttle, which at least one shuttle is moveable in a transfer zone of the pick and place system
Implementation Method 2
a planar motor has a stator which forms a movement plane above an active surface of the stator. One or more movable devices, so-called shuttles, can be moved mainly in two dimensions in the movement plane formed by the stator, whilst levitating above the active surface of the stator
Data Source
Figure 1~2
Figure 3~4
AI summary
To provide an improved pick and place system (1), wherein the required pick and place distance and the size of the manipulator (2) is minimized and operation speed of the pick and place system (1) is increased, the outfeed conveyor (4) is designed as planar motor (8), wherein the outfeed planar motor (48) is designed to synchronize the movement of the shuttle (10) of the outfeed planar motor (48) in the transfer zone (5) to an infeed movement trajectory (Ti) of the at least one product (6) in the transfer zone (5) at least when the manipulator (2) picks the at least one product (6) off the infeed conveyor (3), or that the infeed conveyor (3) is designed as planar motor (8), wherein the infeed planar motor (38) is designed to synchronize the movement of the shuttle (10) of the infeed planar motor (38) in the transfer zone (5) to an outfeed movement trajectory (To) of the at least one product (6) in the transfer zone (5) at least when the manipulator (2) picks the at least one product (6) off the shuttle (10) of the infeed planar motor (38).