Robotic End Effector for U-Shaped Packing Insert Placement
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Manual bending and insertion of U-shaped packing inserts into shipping containers is labor-intensive and inefficient in high-volume packing operations, which hinders the ability to effectively support goods and rigidify containers for safe stacking and protection.
Innovation Solution
A robotic end-of-arm tool that picks, forms, and places U-shaped packing inserts over goods in shipping containers, utilizing vacuum retrievers and forming arms to bend and position the inserts efficiently and accurately within the container.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If manual bending and insertion of U-shaped packing inserts is used, then flexibility and simplicity are maintained, but labor intensity increases and operational efficiency decreases
Solution Approach 1:
The patent replaces the manual mechanical bending and insertion process with an automated robotic end effector system. The robotic arm equipped with forming arms and vacuum retrievers automatically picks flat packing inserts, forms them into U-shapes, and inserts them into containers, eliminating manual labor while maintaining operational simplicity through programmable automation.
Solution Approach 2:
The packing insert itself is designed to be self-forming through pre-scored fold lines that guide the forming arms. The insert automatically assumes its U-shaped configuration during the robotic forming process without requiring complex tooling or multiple operation steps, enabling the system to serve itself in achieving the final package structure.
2Productivity
If automated robotic end effector is used, then productivity and operational efficiency are improved, but device complexity increases
Solution Approach 1:
The robotic end effector is designed as a multi-functional tool that combines picking, forming, and inserting operations in a single device. The forming arms can bend multiple sides of the packing insert, while vacuum retrievers handle both the insert and container positioning, reducing the need for separate specialized equipment and thereby managing system complexity.
Solution Approach 2:
The end effector system is divided into modular functional components: vacuum retrievers for picking and positioning, forming arms for bending operations, and a robotic arm for movement. This segmentation allows each component to be optimized independently and facilitates easier maintenance and programming, managing overall system complexity through modularity.
3Productivity
If rapid automated placement is implemented, then productivity increases, but precision and accuracy of insert positioning may be compromised
Solution Approach 1:
The robotic system incorporates sensors and control systems that provide real-time feedback on the position and orientation of the packing insert during formation and insertion. This feedback loop allows the robotic arm and forming arms to make micro-adjustments to ensure precise positioning of the U-shaped insert within the container, maintaining accuracy even at high speeds.
Solution Approach 2:
The packing inserts are pre-scored with fold lines that define the exact bending positions and final U-shape geometry. This preliminary preparation of the insert geometry enables the robotic forming arms to achieve precise positioning through simple, repeatable bending motions, maintaining accuracy while enabling rapid automated operation.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
Enables rapid, automatic, and precise placement of U-shaped packing inserts, enhancing container support and protection, thereby ensuring safe stacking and delivery of goods while reducing manual labor and increasing operational efficiency.
Implementation Method 1
The end of arm tool includes a vacuum plenum housing with at least one vacuum retriever extending down from the vacuum plenum housing for engaging and picking the work products
Data Source
AI summary
End of arm tool (10) is used to load goods A and B in two layers in a packing container (8), with a packing insert positioned between the layers. The tool (10) also grasps a packing insert in the form of a flat sheet, bends the ends of the packing sheet downwardly to form an inverted U shape, and then inserts the packing insert in a straddling relationship about the lower layer of goods A, to protect the lower layer of goods from the weight applied by the upper layer of goods B.