Robotic Kitting Machine Synchronization for Arbitrary Item Retrieval
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Solution Overview
Problem
Existing kitting processes are largely human labor intensive due to challenges in automating the retrieval and packaging of arbitrary quantities of items of varying sizes, fragilities, and consistencies using robotic arms.
Innovation Solution
A kitting machine system that integrates robotically controlled units with modular kitting system modules (KSMs), robotic arms, and retractable box restraints to automate the location, selection, and packaging of items, with the ability to request human intervention when automated operation is not feasible.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If robotic arms are used to automate kitting operations, then productivity and labor cost reduction are improved, but device complexity and difficulty of handling arbitrary items worsen
Solution Approach 1:
The robotic arm is divided into multiple independently controllable segments or modules, each capable of performing specific functions such as gripping, positioning, or manipulating items. This segmentation allows the system to handle diverse items more effectively while maintaining manageable complexity through modular architecture.
Solution Approach 2:
The robotic arm is designed with universal capabilities to handle arbitrary quantities of items with varying sizes, shapes, and fragilities through programmable control. The system can adapt to different kitting requirements by executing different instruction sets, eliminating the need for dedicated hardware for each item type.
2Adaptability or versatility
If robotic arms are programmed to handle arbitrary items, then adaptability is improved, but ease of operation and programming complexity worsen
Solution Approach 1:
The robotic arm incorporates sensors and feedback mechanisms that enable it to automatically detect item characteristics such as size, shape, and fragility. The system self-adjusts its gripping force and manipulation strategies based on real-time sensor data, reducing the need for complex pre-programming and making operation more intuitive.
Solution Approach 2:
The system uses continuous feedback from sensors monitoring item position, grip force, and manipulation success to dynamically adjust its operation. This closed-loop control allows the robotic arm to adapt to arbitrary items in real-time, simplifying operation by eliminating the need for exhaustive pre-programming of all possible item variations.
3Reliability
If human intervention is integrated into automated kitting, then reliability is improved, but extent of automation worsens
Solution Approach 1:
The system introduces an intermediary control layer that coordinates between fully automated robotic operations and human intervention. This intermediary layer manages task allocation, allowing the robotic arm to handle routine operations autonomously while seamlessly transitioning to human operators when complex or unpredictable tasks arise, maintaining high automation levels while ensuring reliability.
Data Source
AI summary
A kitting machine is disclosed. In various embodiments, the machine includes an actuator configured to move a surface or receptacle to a position associated with item retrieval; and a controller configured to control operation of the actuator to position an item in the position associated with item retrieval, in a manner that is synchronized at least in part with operation of a robotic retrieval device configured to retrieve the item from the position associated with item retrieval.