Robotic Pack Station With Vision-Guided Suction for Flexible Packages
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Solution Overview
Problem
Automated systems face challenges in accurately and efficiently handling large, asymmetrical, deformable, and/or heavy packages with flexible outer packaging, which are prone to weight shifting and deformation, making consistent pick-and-pack processes difficult.
Innovation Solution
A robotic pack station with a robotic arm, image capture system, and industrial control server that controls the robotic arm to accurately retrieve packages from radially disposed pick sites, orient them based on captured images, and place them into shipping containers, using a suction-based end effector to handle flexible packages.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If automated systems use conventional handling methods for flexible packages, then productivity is improved through automation, but manufacturing precision deteriorates due to package deformation and weight shifting
Solution Approach 1:
The patent replaces conventional mechanical gripping systems with a suction-based end effector that uses vacuum pressure to hold flexible packages. This substitution allows for more precise and controlled handling, preventing deformation and weight shifting while maintaining high automation efficiency. The suction cups create a distributed holding force that conforms to the package surface, ensuring accurate placement.
Solution Approach 2:
The patent employs image capture systems and vision guidance to create a digital representation of the package location and orientation. This optical copy is used by the control system to calculate precise pick and place points, enabling the robotic arm to accurately position flexible packages without physical contact during the measurement phase, thereby minimizing deformation.
2Adaptability or versatility
If robotic arms handle large asymmetrical packages, then adaptability is improved for diverse package types, but device complexity increases due to orientation and positioning requirements
Solution Approach 1:
The patent designs a universal robotic cell that can handle multiple package types through a standardized interface. The end effector with adjustable suction cups and the vision system work together to accommodate various sizes, shapes, and orientations of packages. The control system uses a unified algorithm that calculates pick and place points based on image data, providing multi-functionality without requiring separate handling mechanisms for different package types.
Solution Approach 2:
The patent implements preliminary imaging and calculation of pick and place points before the robotic arm executes the transfer. The vision system captures images of the package at the source location, the control system calculates the optimal pick point and target placement point considering package orientation and asymmetry, and then the robotic arm executes the pre-planned motion. This preliminary action simplifies the real-time control complexity by separating measurement, calculation, and execution phases.
3Manufacturing precision
If suction-based end effectors are used for flexible packages, then manufacturing precision is improved by minimizing deformation, but weight of moving object increases due to the end effector mechanism
Solution Approach 1:
The patent uses thin, flexible suction cups that can conform to the surface of flexible packages. These thin-film end effectors provide sufficient vacuum holding force while minimizing the mass of the moving component. The flexible material allows the suction cup to adapt to package surface variations without requiring heavy rigid structures, thus maintaining manufacturing precision while reducing the weight penalty.
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 efficient and accurate transfer of flexible packages into shipping containers, minimizing deformation and weight shifting, and ensuring precise placement within tolerance limits.
Implementation Method 1
the end effector comprises a suction based end effector
Data Source
AI summary
A robotic pack station includes a work cell that includes a robotic arm with an end effector coupled thereto and a plurality of pick sites radially disposed about the robotic arm. Each pick site includes packages arranged in a stack. An image capture system is configured to capture images of the pick sites and a container conveyor is coupled to the work cell and configured to move one or more containers into the work cell. An industrial control server in communication with the robotic arm and with the image capture system is configured to control movement of the robotic arm and actuation of the end effector to transfer selected packages from one of the plurality of pick sites to one of the containers conveyed into the work cell, based on the images.