Robotic Bag Stacking Between Bin Posts
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Solution Overview
Problem
Manual stacking of bags into bins with posts is inefficient and often requires expensive robotic arms to reach over the posts, leading to potential product damage and increased costs.
Innovation Solution
A packaging system that includes an open bag detection subsystem to ensure bags are sealed before stacking, using a robotic arm that maneuvers between posts and employs a shrink wrap dispenser to raise the bin height, allowing for efficient stacking without the need for a tall robotic arm.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a tall robotic arm is used to reach over the posts and place bags at the bottom of the bin, then the bags can be stacked efficiently, but the equipment cost increases significantly
Solution Approach 1:
The bin is divided into multiple levels by the posts, creating separate stacking zones. The robotic arm stacks bags on the floor level first, then uses the posts as support structures to create additional stacking levels above, eliminating the need for a single tall reaching motion
Solution Approach 2:
Instead of stacking vertically by reaching over posts, the system uses the posts as horizontal support structures to create multiple stacking levels. Bags are stacked in layers above the posts, transforming the stacking approach from vertical reaching to multi-level horizontal support utilization
2Productivity
If a robotic arm is used to stack bags, then labor costs are reduced, but the risk of product damage increases due to potential dropping
Solution Approach 1:
The system implements detection and verification steps before the final stacking action. The optical sensors detect bag presence and proper placement, and the system verifies bag orientation and position before releasing, preventing drops and damage
Solution Approach 2:
The system uses optical sensors to continuously monitor bag placement and provide feedback to the control system. If a bag is not properly positioned or oriented, the system detects this and adjusts the stacking operation to prevent damage
3Device complexity
If manual stacking is used, then equipment costs are reduced, but labor time and inefficiency increase
Solution Approach 1:
The system uses the bin's own posts as structural support for stacking bags, eliminating the need for additional expensive equipment. The posts serve dual purposes as both bin structural elements and stacking support structures
Solution Approach 2:
The posts serve multiple functions: they provide structural support for the bin, act as support structures for stacked bags, and create defined stacking zones. This multi-functionality eliminates the need for separate support structures or taller equipment
Data Source
AI summary
A product stacking system may include an open bag detection subsystem and a product stacking subsystem. The open bag detection subsystem may agitate bags to cause product to be displaced out of open bags and determine if a bag is open by comparing a weight of the bag after the agitation to a target threshold. The product stacking subsystem may include a robotic arm and a controller that moves the robotic arm between posts of a bin based on an orientation of the bin. A turntable rotates the bin and can operate as an additional axis of movement of the robot.