Robotic Unscrambler Selective Routing
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Solution Overview
Problem
Existing robotic unscramblers struggle to achieve 100% efficiency in handling and positioning bottle containers with non-symmetric shapes and offset necks, due to the need for additional rotation operations and recirculation of non-processed containers.
Innovation Solution
A robotic unscrambler system that includes a product picking area, a transfer conveyor, and a product unscrambling device with selectively routable carriers and paths, allowing for the unscrambling of containers regardless of their initial orientation, and incorporating buffer areas to manage fluctuations in feed rate.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If handling robots process containers with predetermined side orientation, then processing reliability is improved, but productivity decreases due to recirculation requirements
Solution Approach 1:
The patent applies asymmetry by designing the container carrier with a specific orientation (longitudinal axis alignment) that matches the asymmetric geometry of the containers. The carrier's longitudinal axis is aligned with the container's longitudinal axis, and the carrier's transverse axis is aligned with the container's transverse axis, creating an asymmetric relationship that eliminates the need for recirculation while maintaining reliable processing.
Solution Approach 2:
The patent inverts the traditional approach by allowing containers to be processed in any initial orientation (scrambled state) rather than requiring predetermined side-up orientation. The unscrambling device actively reorients containers to the correct orientation during processing, reversing the conventional logic where containers must arrive pre-oriented.
2Manufacturing precision
If additional rotation operations are performed to correct container orientation, then manufacturing precision is improved, but processing time increases
Solution Approach 1:
The patent applies preliminary action by performing the unscrambling operation (rotating containers to correct orientation) as part of the initial processing sequence rather than as a corrective step later. The unscrambling device is integrated into the processing line and performs orientation correction before containers proceed to subsequent operations, eliminating delays.
Solution Approach 2:
The patent ensures continuity of useful action by designing the unscrambling device to process containers continuously as they move through the system. The selective routing mechanism directs containers to appropriate unscrambling paths without interrupting the overall flow, maintaining continuous processing while achieving precise orientation.
3Adaptability or versatility
If recirculation path is implemented to handle non-processed containers, then adaptability is improved, but device complexity increases
Solution Approach 1:
The patent extracts the unscrambling function from the main processing line by implementing a separate unscrambling device with selective routing. Containers that require orientation correction are diverted to the unscrambling device, processed, and then returned to the main line. This separation eliminates the need for complex recirculation paths while maintaining adaptability.
Solution Approach 2:
The patent introduces an intermediary unscrambling device that acts as a mediator between the scrambled container input and the processing line. The selective routing mechanism serves as an intermediary that directs containers to appropriate paths based on their orientation, simplifying the overall system architecture while maintaining versatility.
4Productivity
If multiple handling robots are arranged on both sides of conveyor, then processing capacity is improved, but energy consumption increases
Solution Approach 1:
The patent applies universality by designing a single unscrambling device that can handle containers of various orientations and types. The selective routing mechanism and carrier design allow the same device to process different container configurations, eliminating the need for multiple specialized handling robots and reducing overall energy consumption.
Solution Approach 2:
The patent changes the parameter of container orientation handling by implementing a system that accepts containers in any initial orientation rather than requiring specific orientations. This parameter change (from fixed orientation requirement to flexible orientation acceptance) reduces the need for multiple energy-consuming handling robots while maintaining high processing capacity.
Data Source
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AI summary
An unscrambler apparatus, comprising: - a product picking area (2) receiving a flow (SCF) of scrambled products (C) handled by handling devices (R1-3) arranged at said product picking area (2), - a transfer conveyor (4) configured to receive scrambled products (C) picked from the product picking area (2) and released at the transfer conveyor (4) by the handling devices, - a product unscrambling device (6) configured to receive products from the transfer conveyor (4) at the product input (12) and comprising a plurality of carriers (16),which can be selectively routed to a first path (P1), a second path (P2), and a third path (P3),wherein: - the first path extends from the product input to the product output (14), a carrier routed to the first path carries a product having a desired orientation to product output thereof, - the second path extends as a transition from a first direction of the products at the product input to a second direction incident to the first direction wherein the second path includes an interchange station (IS) to the third path at the second direction, and wherein a carrier routed to the second path carries a product having an undesired orientation, - the third path extends as a transition from the second direction to a third direction at the product output, whereby a carrier routed to the second path and carrying a product having an undesired orientation is configured to be routed to the third path at the interchange station so to present the product at the product output with the desired orientation.