Packaging Line Robot Changeover With Automated Coupling

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Solution Overview

Problem

Existing packaging lines require manual disconnection and reconnection of robots, leading to high downtime and potential errors due to the need for trained personnel and line shutdown during unit changes.

Innovation Solution

A method for automatically releasing and reconnecting mechanical, energy, and data connections of units like robots, allowing for partially automated replacement without shutting down the entire line, using a delivery device to maneuver units to a transfer position and a transfer device to move them to an assembly position for exact positioning and fixing.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Adaptability or versatility

If manual disconnection and reconnection of robots is performed, then unit changes can be made, but downtime increases and errors may occur

Engineering Contradiction:

Improveunit change capabilityVSAvoiddowntime

Core Design Contradiction:

Adaptability or versatilityVSLoss of time

Solution Approach 1:

The robot system is divided into modular components that can be independently disconnected and reconnected. The mechanical fastening, energy connections, and data connections are separated into distinct coupling devices, allowing systematic and rapid replacement without affecting the entire system.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Coupling devices serve as intermediary mechanisms between the robot and the packaging line. These devices automatically manage the disconnection and reconnection processes, acting as mediators that enable rapid unit changes while maintaining system integrity and minimizing downtime.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Adaptability or versatility

If manual disconnection and reconnection is performed, then unit changes can be made, but operation complexity increases due to trained personnel requirements

Engineering Contradiction:

Improveunit change capabilityVSAvoidoperation complexity

Core Design Contradiction:

Adaptability or versatilityVSDevice complexity

Solution Approach 1:

The coupling devices are designed to perform the disconnection and reconnection operations automatically without requiring manual intervention. The system serves itself by automatically managing the mechanical, energy, and data connections during robot replacement, eliminating the need for trained personnel to perform complex manual operations.

Inventive Principle:

Principle #25Self-service

Solution Approach 2:

Manual mechanical operations are replaced with automated coupling devices that manage the connection and disconnection processes. The automated systems substitute for human operators, reducing operation complexity while maintaining the ability to perform unit changes.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

3Adaptability or versatility

If manual disconnection and reconnection is performed, then unit changes can be made, but errors may occur during the process

Engineering Contradiction:

Improveunit change capabilityVSAvoiderror rate

Core Design Contradiction:

Adaptability or versatilityVSReliability

Solution Approach 1:

The coupling devices incorporate feedback mechanisms that monitor the connection status of mechanical, energy, and data connections. This feedback ensures that each connection is properly established or disconnected, providing verification that prevents errors during robot replacement operations.

Inventive Principle:

Principle #23Feedback

Solution Approach 2:

The automated coupling devices act as reliable intermediaries that manage the connection processes, reducing the risk of human error. By automating the disconnection and reconnection operations, the system eliminates manual mistakes while ensuring proper establishment of all connections.

Inventive Principle:

Principle #24Intermediary (Mediator)

4Reliability

If line shutdown is performed during unit changes, then safety is improved, but productivity decreases

Engineering Contradiction:

ImprovesafetyVSAvoiddowntime

Core Design Contradiction:

ReliabilityVSProductivity

Solution Approach 1:

The coupling devices are pre-configured to enable rapid disconnection and reconnection operations. By preparing the mechanical, energy, and data coupling mechanisms in advance, the system can perform unit changes quickly without requiring complete line shutdown, thus maintaining productivity while ensuring safe operations.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The system transitions from static line shutdown to dynamic unit replacement. The automated coupling devices enable the packaging line to maintain operation during robot changes, creating a dynamic system where unit changes occur without stopping the entire production line, thereby maintaining productivity.

Inventive Principle:

Principle #15Dynamics

Data Source

PatentUS12534257B2Process for changing a unit on a packaging line and packaging lines designed for this purpose packaging line

Publication Date: 2026.01.27 GERHARD SCHUBERT GMBH

AI summary

In a packaging line (1) comprising a plurality of robots (7), in order to be able to replace a faulty unit, in particular robot (7), quickly and with minimal, preferably no manpower, in particular during running operation of the packaging line (1), the unit to be changed is automatically decoupled from the power and data feeds and from the purely mechanical connections and is removed from the packaging line (1), preferably transversely to the throughput direction (10′) of the packaging line (1), and the new unit is automatically introduced in the opposite direction, is positioned, and is mechanically fixed, and the energy and data supplies are automatically coupled.