Automatic Press Line Packing System with Visual Feedback
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Solution Overview
Problem
Current automatic press production lines face inefficiencies and safety hazards due to manual packing at the line end, which is hindered by position and size uncertainties of parts, and are limited to packing parts with fixed shapes and sizes.
Innovation Solution
An automatic packing system incorporating a servo synchronous belt system, visual system, PLC controller, robot systems, and charging baskets, which adjusts positions and shapes to accurately convey and pack parts of varying sizes and shapes using image acquisition and robotic manipulation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If manual stacking and packing is used at the line end, then flexibility in handling various part shapes and sizes is maintained, but production efficiency is greatly hindered and labor cost increases
Solution Approach 1:
The patent applies dynamics by making the support mechanism adjustable and adaptable. The support table can be adjusted to different positions and angles, and the support blocks can be repositioned to accommodate parts of various shapes and sizes. This dynamic adjustability allows the automated packing system to maintain versatility while achieving high production efficiency through automation.
2Extent of automation
If automated packing is implemented without considering position errors, then automation level is improved, but positioning accuracy deteriorates due to belt conveyor variations and manual inspection randomness
Solution Approach 1:
The patent implements feedback by using a vision system to detect the actual position of parts after they leave the belt conveyor. The detected position information is fed back to the robotic picking system, which then adjusts its picking position accordingly. This closed-loop feedback mechanism compensates for position errors caused by belt conveyor variations and maintains high positioning accuracy while achieving full automation.
3Productivity
If fixed transport frames are used for automatic packing, then packing speed is improved, but adaptability to different part structures deteriorates requiring frame changes
Solution Approach 1:
The patent applies dynamics by replacing fixed transport frames with a dynamic, adjustable support mechanism. The support table and support blocks can be reconfigured for different part types, allowing the system to maintain high packing speed while adapting to various part structures without requiring physical frame changes. This dynamic adaptability eliminates the trade-off between speed and versatility.
4Device complexity
If robotic picking is used without position adjustment capability, then system complexity is reduced, but positioning accuracy deteriorates due to position errors from belt conveyor
Solution Approach 1:
The patent implements feedback by integrating a vision system that detects part positions and provides real-time position information to the robotic picking system. This feedback mechanism allows the robot to automatically adjust its picking position to compensate for belt conveyor variations, maintaining high positioning accuracy without significantly increasing system complexity through the use of standard vision and control technologies.
Data Source
AI summary
An automatic packing system and method at a press line full-part end. Robot systems are respectively arranged at both ends of a servo synchronous belt system, a visual system is connected with a PLC controller, the robot systems are connected with a robot controller, the PLC controller is connected with the robot controller, and a charging baskets are connected with a charging basket change system; and parts are conveyed by the servo synchronous belt system, the visual system acquires position image information of the parts and judges position errors of the parts, the PLC controller transmits the position error information to the robot controller, and the robot controller controls a robot to grab the parts and put the parts in corresponding charging baskets according to the shapes of the parts.