Robot Picking Control for Completing Conveyor Workpiece Groups
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Solution Overview
Problem
Existing robot systems face inefficiencies in workpiece transfer due to potential lack of combination on the second conveyor, leading to waiting and reduced transfer efficiency.
Innovation Solution
A robot system with a controller, situation acquirer, determiner, and instructor that identifies missing workpieces on the first conveyor and prioritizes their transfer to the second conveyor, ensuring complete workpiece groups are formed without decelerating or stopping the conveyors.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If workpieces are picked from the first conveyor in the order they are conveyed, then the transfer process is simple, but there is a possibility of workpieces lacking in combination on the second conveyor, requiring the conveyor to decelerate or stop
Solution Approach 1:
The situation acquirer acquires information about workpieces in advance within a predetermined monitor area before they reach the robot's movable range. The determiner then identifies missing workpieces for combination based on this advance information, allowing the robot to prioritize picking missing workpieces before they fall behind the monitor area, thus preventing combination failures without stopping the conveyor.
2Reliability
If the second conveyor decelerates or stops to wait for workpiece combination, then complete workpiece groups are ensured, but transfer time increases and efficiency decreases
Solution Approach 1:
The situation acquirer continuously monitors the types and positions of workpieces on both conveyors within the predetermined monitor area. The determiner uses this feedback information to identify which workpieces are missing from upcoming combinations. The instructor then directs the robot to prioritize picking these missing workpieces, creating a closed-loop control system that ensures complete workpiece groups without requiring conveyor stops.
3Ease of operation
If the robot picks workpieces in conveyance order, then the picking process is straightforward, but workpiece combination may be incomplete requiring conveyor interruption
Solution Approach 1:
The instructor dynamically adjusts the robot's picking priority based on real-time situation information. When missing workpieces are detected in the monitor area, the robot prioritizes picking those specific workpieces over others, even if it means deviating from strict conveyance order. This dynamic adjustment ensures complete workpiece groups while maintaining high transfer efficiency without requiring conveyor interruptions.
Data Source
Figure 1A~1B
Figure 1C
Figure 2
AI summary
A robot system includes a first conveyor, a second conveyor, a robot, and a controller. The first conveyor conveys a plurality of kinds of workpieces. The second conveyor conveys workpiece groups each including a combination of the workpieces. The controller controls the robot, and includes a situation acquirer, a determiner, and an instructor. The situation acquirer acquires a situation in a predetermined monitor area on the first and second conveyors. The monitor area is set based on a movable range of the robot. Based on the situation, the determiner determines whether one of the workpieces on the first conveyor in the monitor area is a missing workpiece of one of the workpiece groups in the monitor area. The instructor instructs the robot to hold the one workpiece and to transfer the one workpiece from the first conveyor to the second conveyor.