Robotic Case-Packing System for Low-Volume Product Lines
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Solution Overview
Problem
Conventional case-packing systems are unsuitable for low-volume product lines due to high capital costs, often remaining idle and requiring manual handling, as they are not economically viable for continuous operation.
Innovation Solution
A robotic multi-product case-packing system that concurrently accumulates and sequentially packs different products using multiple conveyor lines, a case-packer with multiple magazines, and a robotic arm to select and transfer appropriate case-blanks, ensuring continuous operation by efficiently utilizing machine time.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Extent of automation
If conventional case-packing systems are used for low-volume product lines, then capital costs are high, but the systems remain idle and require manual handling
Solution Approach 1:
The case-packer is designed to handle multiple different products through a control system that receives signals from various conveyors and adjusts packing parameters accordingly. The system can switch between different case types, packing configurations, and products without requiring separate dedicated equipment for each product line, enabling low-volume products to share the same automated packing resource.
Solution Approach 2:
The control system stores packing parameters for multiple products in advance and pre-configures the system based on received signals. When a product is identified on the conveyor, the system has already prepared the appropriate packing parameters, case types, and operational settings, allowing immediate transition without idle time or manual reconfiguration.
2Adaptability or versatility
If conventional case-packing systems operate with low-volume products, then machine time is underutilized, but capital costs remain high
Solution Approach 1:
The system dynamically adjusts its operation based on real-time signals from conveyors and product identification. The control system can switch between different packing modes, case types, and products on-the-fly without requiring physical reconfiguration or stopping the production line, minimizing downtime and maximizing machine utilization across varying product volumes.
Solution Approach 2:
The control system stores and switches between multiple sets of packing parameters including case dimensions, packing patterns, and operational settings. When a product change is detected, the system automatically changes these parameters to match the new product requirements, enabling rapid adaptation without manual intervention or machine idle time.
3Productivity
If multiple products are packed sequentially on a single conveyor, then equipment complexity increases, but production rate decreases
Solution Approach 1:
A single conveyor system is designed to handle multiple product types and deliver them to a universal case-packer that can accommodate different packing configurations. The control system coordinates the conveyor and packer to maintain optimal production rates across all products, avoiding the need for separate dedicated conveyor-packer lines for each product while preserving high productivity.
Data Source
AI summary
A case packing system concurrently accumulates a plurality of different product ensembles and sequentially packs cases thereof, generally by way of (a) concurrently accumulating a plurality of different product ensembles utilizing a plurality of product conveyer lines, each of which is adapted to separately convey distinct products to one or more transfer points; (b) sequentially transferring different accumulated product ensembles from the conveyer lines to a case-packer, the case-packer including a packing section as well as multiple magazines for receiving different case-blanks; (c) controlling transfer of the product ensembles to the case-packer and selection of the appropriate case-blank. Preferably, substantially continuous operation of the case-packer at a production rate higher than an accumulation rate of any individual product conveyer is maintained. A preferred construction employs a 4-axis robotic arm to select KDF cases and shuttle conveyers to transfer product from the conveyers to the case-packer.