Robotic Case Packer Platform with Modular SCARA Stations

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Solution Overview

Problem

Existing robotic case packing systems lack a modular and scalable approach that enhances operational functionality, reduces downtime, and maintains a smaller footprint while ensuring precise and efficient case placement and retention across various case styles, such as wrap around and knock down cases, with limited improvements in case set up, loading, and closure operations.

Innovation Solution

A robotic case packer platform featuring a case conveying apparatus, a case set up station, a case loading station, and a loaded case closure station, utilizing Selective Compliance Assembly Robot Arms (SCARAs) or two-axis Cartesian robots, with end-of-arm tools for secure case handling and closure, and a tool bar for flap manipulation, allowing for adaptable and efficient processing of different case types from non-indexing magazines.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Adaptability or versatility

If conventional case packing machines are used, then case set up, loading and closure operations can be performed, but the machine size increases and operational versatility is limited

Engineering Contradiction:

Improveoperational versatilityVSAvoidmachine footprint

Core Design Contradiction:

Adaptability or versatilityVSArea of stationary object

Solution Approach 1:

The robotic case packing system employs multiple SCARA robots that can perform different operations (case set up, loading, closure) depending on configuration, allowing a single machine to handle various case styles and operations, thereby improving versatility without proportionally increasing footprint

Inventive Principle:

Principle #6Universality (Multi-functionality)

Solution Approach 2:

The system divides case packing operations into distinct functional stations (case set up station, loading station, closure station) that can operate independently and be configured for different case types, enabling versatile operation within a compact integrated footprint

Inventive Principle:

Principle #1Segmentation

2Manufacturing precision

If robotic arms are used for case handling, then precision and speed are improved, but system complexity increases

Engineering Contradiction:

Improvecase placement precisionVSAvoidsystem complexity

Core Design Contradiction:

Manufacturing precisionVSDevice complexity

Solution Approach 1:

The system replaces complex traditional mechanical case handling mechanisms with SCARA robotic arms that offer precise control and programmability, achieving high placement precision while managing complexity through automated control systems

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The SCARA robots utilize programmable motion parameters and end-of-arm tool configurations to adapt to different case styles and operations, maintaining precision across varied tasks without requiring complex mechanical reconfiguration

Inventive Principle:

Principle #35Parameter changes

3Productivity

If multiple operational stations are integrated, then productivity increases, but machine footprint increases

Engineering Contradiction:

Improveoperational efficiencyVSAvoidmachine footprint

Core Design Contradiction:

ProductivityVSArea of stationary object

Solution Approach 1:

The system arranges operational stations in a compact three-dimensional layout with robots operating in vertical and horizontal spaces efficiently, integrating multiple functions within a reduced footprint while maintaining high productivity

Inventive Principle:

Principle #17Another dimension (Dimensionality change)

Solution Approach 2:

Multiple operational stations (case set up, loading, closure) are merged into a single integrated robotic system that shares common infrastructure and control, achieving high productivity without proportionally increasing machine footprint

Inventive Principle:

Principle #5Merging (Combining)

Data Source

PatentUS11505341B1Robotic case packer platform and packing method

Publication Date: 2022.11.22 DOUGLAS MACHINE INC

AI summary

A robotic case packer is provided. The packer includes a case conveying apparatus, a case set up station, a case loading station, downstream of the case set up station, and a loaded case closure station, downstream of the case loading station, the case conveying apparatus receiving and conveying a case blank for case set up, case loading and loaded case closure operations, a process flow path as to case operations delimited by the case conveying apparatus. The case set up station, characterized by a case set up robot operable in a process flow path direction, secures a case blank from a source of case blanks and transfers the blank to the case conveying apparatus. The case loading station, characterized by a case loading robot operable across the process flow path direction, transfers an article group for case loading into a set up case conveyed by the case conveying apparatus. The case closure station, characterized by a loaded case closure robot operable in the process flow path direction, effectuates a compressed sealed closure of a loaded case conveyed by the case conveying apparatus.