Packaging Line Robot Exchange With Automatic Disconnect and Refit
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Solution Overview
Problem
Current packaging line operations require significant downtime and manual effort for robot replacement, as they need to be shut down entirely for manual disconnection and reconnection of data and energy connections, which is time-consuming and prone to errors.
Innovation Solution
A method for partially automatic robot replacement on packaging lines, where the old robot's mechanical and power connections are automatically released, and the new robot is automatically connected, allowing for unmanned removal and lowering to working height, with the use of a delivery device and assembly device for precise positioning and fixing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of repair
If manual robot replacement is performed by operators, then the robot can be replaced with a new unit, but the entire packaging line must be shut down resulting in long downtimes
Solution Approach 1:
The packaging line is divided into modular sections with individual robot stations that can be serviced independently. Each robot is mounted on a separate support structure with isolated mechanical and energy connections, allowing one robot to be replaced without affecting other stations or shutting down the entire line.
Solution Approach 2:
The mechanical fixation, energy connection, and data connection are automatically released before the robot is physically removed. This preliminary automatic disconnection prepares the system for quick robot exchange without requiring manual intervention during the actual replacement process.
2Ease of repair
If manual robot replacement is performed by operators, then the robot can be replaced, but trained personnel are required and the process is time-consuming
Solution Approach 1:
The system performs self-service through automatic release mechanisms that handle mechanical fixation, energy disconnection, and data connection termination without human intervention. The robot can be exchanged by simply detaching and attaching mechanical components, eliminating the need for trained operators to perform complex disconnection procedures.
Solution Approach 2:
Manual mechanical operations for releasing connections are replaced by an automatic release device that uses actuators and control systems to perform the disconnection functions. This substitution of manual mechanical actions with automated mechanisms simplifies the replacement process and reduces operational complexity.
3Ease of repair
If manual robot replacement is performed, then the robot can be replaced, but the process contains potential sources of error
Solution Approach 1:
The automatic release device incorporates sensors and control feedback mechanisms that monitor the status of mechanical fixations, energy connections, and data connections during the release process. This feedback ensures that each connection is properly released and reconnected, preventing errors that could occur during manual operations.
Solution Approach 2:
Manual mechanical operations are replaced by automated actuators and release devices that precisely control the disconnection and reconnection processes. This automation eliminates human error in tightening torques, connection alignment, and procedural steps, significantly improving the reliability of the replacement process.
Data Source
Figure 1a
Figure 1b~1b1
Figure 1c~1c1
AI summary
In order to be able to replace a defective unit, in particular a robot (7), quickly and with as little manpower as possible, preferably without manpower, in a packaging line (1) with several robots (7), especially during the ongoing operation of the packaging line (1), the unit to be replaced is automatically disconnected from the energy and data supply as well as the purely mechanical connections and removed from the packaging line (1), preferably transversely to the direction of travel (10') of the packaging line (1), and the new unit is automatically moved in, positioned and mechanically fixed in the opposite direction and the energy and data supply is automatically connected.