Robotic De-palletizer and Magazine Loader for Carton Supply
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Solution Overview
Problem
The manual process of removing half-slotted cases (HSC) from pallets and loading them into magazine feeding machinery is inefficient, leading to potential assembly line shutdowns due to inadequate supply and misalignment issues.
Innovation Solution
A robotic de-palletizer and magazine-loader system that uses conveyors and end-of-arm tools (EOATs) to automate the removal of HSC from pallets, orient, and load cartons into the magazine, ensuring precise placement and maintaining a consistent supply.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If manual pallet-emptying and magazine-loading is used, then operational flexibility is maintained, but productivity is low and assembly line downtime increases
Solution Approach 1:
The patent replaces manual mechanical operations with an automated robotic system comprising a robot arm, end-of-arm tooling, and control system. The robot automatically performs pallet-emptying and magazine-loading operations, eliminating manual labor while significantly increasing loading speed and productivity.
Solution Approach 2:
The system enables self-service automation where the robotic apparatus independently performs the complete sequence of operations: approaching the pallet, grasping HSCs, transporting them, unloading into magazines, and returning for the next cycle without human intervention, thereby achieving continuous high-speed operation.
2Productivity
If rapid HSC removal is not maintained, then adequate supply in magazine is insufficient, but increasing speed may cause misalignment and jamming
Solution Approach 1:
The control system monitors the magazine supply level and adjusts the robotic operation accordingly. When the magazine approaches capacity or misalignment is detected, the system automatically slows down or pauses operations to prevent jamming, ensuring both high supply rate and precise alignment are maintained dynamically.
Solution Approach 2:
The robotic system dynamically adjusts its operation speed and positioning based on real-time conditions. The robot can accelerate during normal loading and automatically decelerate or pause when the magazine is nearly full or when alignment precision is required, optimizing both productivity and precision throughout the operation cycle.
3Reliability
If manual loading is used, then equipment complexity is low, but reliability is reduced due to human error and downtime
Solution Approach 1:
The robotic system performs multiple functions within a single integrated apparatus: it grasps HSCs from pallets, transports them across the workspace, unloads them into magazines, and returns for the next cycle. This multi-functionality increases reliability by eliminating human error while the modular design keeps system complexity manageable.
Solution Approach 2:
The end-of-arm tooling acts as an intermediary between the robot arm and the HSCs, providing a standardized interface for grasping and releasing cases. This intermediary component simplifies the overall system complexity by creating a universal interface while enhancing reliability through consistent, precise manipulation of HSCs throughout the operation.
Data Source
AI summary
Examples of a robotic de-palletizer and a robotic magazine loader are described herein. The robotic de-palletizer is configured to remove cases (e.g. HSC (half slotted cases) filled with product (e.g. disassembled cartons)) and to place the HSC on one or more conveyors. The conveyor(s) move the full HSC from the “de-palletizing” area to a magazine-loading area for processing by a robotic magazine loader. In one example of the robotic magazine loader, HSC containing unassembled cartons are removed from the conveyor. The contents of the HSC are added to a magazine feeding a carton assembling and filling machinery and the empty HSC is conveyed to a discard location.