Robotic Mail Tray Sleeving System With Adaptive Gripper
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Solution Overview
Problem
Current automated mail tray sleeving systems face challenges in handling multiple sizes efficiently, have low throughput, and require human intervention for replenishing sleeve blanks, which limits their effectiveness in reducing labor and increasing operational efficiency.
Innovation Solution
A robotic mail tray sleeving system that uses a conveyor, sleeve blank presentment device, and a robotic arm with an end-of-arm tool to automatically open and position sleeves, allowing for continuous operation without human intervention, and can handle multiple sizes of mail trays by using a tray induction system with paddles and sensors to guide trays into open sleeves.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If a single vertical stack of sleeve blanks is used, then the system structure is simple, but the throughput is limited and requires stopping to replenish sleeves
Solution Approach 1:
The system divides the sleeve supply into multiple horizontal positions within a magazine, allowing multiple sleeves to be accessed simultaneously. The robotic arm can service multiple positions in sequence without stopping the overall operation, segmenting the replenishment task into discrete accessible locations.
Solution Approach 2:
Sleeves are pre-loaded into the magazine in horizontal stacks before operation begins. This preliminary preparation allows the robotic arm to simply retrieve pre-positioned sleeves rather than handling loose blanks, reducing the time and complexity of the sleeving operation.
2Adaptability or versatility
If two systems are used in parallel to handle multiple tray sizes, then all tray sizes can be accommodated, but the capital investment increases significantly
Solution Approach 1:
The robotic arm is designed with adaptive grippers and positioning capabilities that allow it to handle multiple tray sizes with a single system. The end effector can adjust its configuration to accommodate different tray dimensions, making one system perform the function of what would traditionally require multiple dedicated systems.
Solution Approach 2:
The system employs dynamic adjustment mechanisms in the robotic arm and positioning system that allow real-time adaptation to different tray sizes. The robotic controller can modify motion paths, gripper forces, and positioning parameters based on the specific tray being processed, enabling versatility without requiring multiple fixed systems.
3Reliability
If the system stops to replenish sleeve blanks, then the supply is maintained, but the overall throughput is reduced
Solution Approach 1:
The magazine design allows the robotic arm to retrieve sleeves from multiple horizontal positions without interrupting the continuous flow of trays. As the robotic arm services one position, trays continue to move through the system, and the arm can quickly move to the next position, maintaining continuous productive action rather than stopping the entire system.
Solution Approach 2:
The magazine acts as an intermediary buffer between the sleeve supply and the sleeving operation. It stores multiple sleeves in advance and allows the robotic arm to retrieve them sequentially, decoupling the replenishment need from the production flow and eliminating the need to stop the main system for restocking.
4Loss of substance
If used sleeves are reused, then costs are reduced, but the sleeves become creased and torn making automatic handling difficult
Solution Approach 1:
The system replaces manual inspection and handling of worn sleeves with a robotic arm equipped with sensors and adaptive grippers. The robotic system can detect the condition of sleeves and adjust its handling approach accordingly, using force control and position feedback to manage creased or slightly damaged sleeves without requiring perfect condition.
Solution Approach 2:
The robotic system can modify handling parameters such as gripper force, extraction speed, and positioning precision based on the condition of individual sleeves. This adaptive parameter adjustment allows the system to accommodate variations in sleeve condition from reuse while maintaining reliable automatic operation.
Data Source
AI summary
A novel method and apparatus for placing trays into sleeves is provided. The apparatus includes a conveyor system for transporting a mail tray, a sleeve blank presentment device and a robotic arm. The robotic arm is provided with an end of arm tool which retains and opens a sleeve blank. A tray induction system including a plurality of paddles configured to guide a tray into an open sleeve blank is also provided.