Side-Loader Product Stacking With One Robot and Layered Filling
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Solution Overview
Problem
Existing side-loader packaging machines for confectionary products, particularly in the ice-cream industry, require complex and expensive systems with multiple robots and advanced software to arrange products in bulking conveyors due to high production rates, making them inefficient and costly.
Innovation Solution
A method using a single picking robot to convey confectionary products one by one, transferring them to bulking conveyors with compartments, where the robot collects and positions products based on sensor detection to ensure rapid and reliable filling without hesitation, allowing variable speed operation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If multiple robots are used to arrange products in compartments, then productivity is improved, but device complexity and cost increase
Solution Approach 1:
Multiple robot functions are merged into a single picking robot that can perform picking, positioning, and product release operations. The robot integrates the capabilities of multiple separate robots while working in coordination with the pocket conveyor system to achieve high productivity with reduced complexity.
Solution Approach 2:
The picking robot dynamically adjusts its operation by moving between different positions (picking position and release position) and by controlling the timing of product release based on compartment filling requirements. This dynamic operation allows one robot to perform functions that previously required multiple robots.
2Manufacturing precision
If multiple robots and advanced software are used, then manufacturing precision is improved, but ease of manufacture deteriorates
Solution Approach 1:
The pocket conveyor system automatically provides products to the picking robot in an organized sequence, and the robot autonomously manages the picking and releasing operations. The system self-regulates the product flow and positioning without requiring complex external control software, simplifying manufacturing while maintaining precision.
3Productivity
If products are arranged rapidly in compartments, then productivity is improved, but reliability deteriorates due to waiting time
Solution Approach 1:
The pocket conveyor prepares and positions products in advance at the picking position before the robot needs them. This preliminary arrangement ensures that products are ready for immediate picking, eliminating waiting time and ensuring continuous reliable operation while maintaining high productivity.
Solution Approach 2:
The system uses sensor feedback to detect when compartments are ready to receive products and when the picking robot should release products. This feedback mechanism ensures that products are released at the optimal moment, preventing delays and ensuring reliable continuous operation at high speed.
Data Source
AI summary
1. Method of preparing confectionary products for packaging in a side-loader packaging machine, where the confectionary products are conveyed one by one on a first pocket conveyor, and where a picking robot is arranged for picking up a predetermined number of ice cream products from said first pocket conveyor and transferring the confectionary products to a bulking conveyor, said bulking conveyor having compartments suitable to accommodate a predetermined number of confectionary products in one or more layers in each compartment, where the picking robot can be in a first position above one or more compartments to be filled, and a second position above the pocket conveyor, where a) in a first step the picking robot, pick up a predetermined number of confectionary products corresponding to the number of confectionary products in a first layer from the pocket conveyor and thereafter positions the picking robot above one or more empty compartments on the bulking conveyor; b) in a further step determine that a further predetermined number of confectionary products corresponding to the total number of confectionary products needed for filling all consecutive layers are available on the pocket conveyor, ready to be picked up; c) releases the picked up confectionary products into the one or more compartment, and d) the picking robot moves to pick up the further predetermined number of confectionary products from the pocket conveyor, and e) transfers the further predetermined number of products to the compartment creating a further layer of confectionary products, and f) repeat steps d) and e)) until the desired number of layers are arranged in the compartment, whereafter g) repeat steps a) to f).