Single-Robot Cardboard Blank Application on Container Lines
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Solution Overview
Problem
Existing systems for applying cardboard packaging blanks, particularly those forming carrying handles, to containers are complex and costly, often failing to achieve desired throughput and integration with production lines in the beverage industry.
Innovation Solution
A system utilizing a single application robot to individually pick up and apply cardboard packaging blanks from a stationary removal magazine, optimizing the process to enhance throughput and efficiency by eliminating intermediate handling steps and incorporating synchronized control with a container conveyor.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If multiple devices or systems are used for applying secondary packaging, then the application process can be completed, but the device complexity and operational cost increase significantly
Solution Approach 1:
The patent combines the separation function and application function into a single robot system. The robot performs both tasks using its gripper device, eliminating the need for separate separation devices and application devices that would otherwise be required. This merging reduces overall system complexity while maintaining complete functionality for packaging blank application.
Solution Approach 2:
The robot is designed as a multi-functional device that can both separate packaging blanks from the magazine and apply them to containers. The gripper device serves multiple purposes: grasping blanks during separation, holding them during transport, and positioning them during application. This universal approach replaces multiple specialized devices with one versatile robot system.
2Manufacturing precision
If multiple handling steps are used to transfer packaging blanks, then the blanks can be properly positioned, but the production throughput decreases
Solution Approach 1:
The robot performs separation, grasping, and application in one continuous motion cycle without intermediate placement or release of the packaging blank. The gripper maintains continuous control of the blank from the magazine through the application point, eliminating idle transfer steps and maximizing production throughput while ensuring precise positioning.
Solution Approach 2:
The robot separates and grasps the packaging blank in advance during the same work cycle before application, preparing it for immediate placement. This preliminary action ensures the blank is ready for precise positioning and application without requiring separate preparation steps, thereby maintaining both accuracy and speed.
3Productivity
If a complex system is used to achieve desired throughput, then production speed can be maintained, but the operational cost increases
Solution Approach 1:
The robot system serves itself by performing both separation and application functions without requiring external coordination with separate devices. The integrated system manages its own work cycle, gripping and positioning blanks autonomously, which simplifies operation and reduces the need for complex control systems and multiple operators, thereby lowering operational costs while maintaining high production speed.
4Reliability
If separate devices are used for separation and application, then each function can be optimized, but the overall system integration with production lines becomes difficult
Solution Approach 1:
The robot provides a universal platform that can be adapted to different production line configurations. By consolidating separation and application into one device, the system becomes easier to integrate with various container types and conveyor systems, improving adaptability while maintaining the functional optimization of both separation and application through the robot's programmable control and gripper design.
Data Source
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Figure 3A~4
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AI summary
The invention relates to a system (1) for applying cardboard packaging blanks (100) to containers (2). The system comprises at least one container conveyor (3) for conveying the containers (2) in a conveying direction (FR) and at least one application robot (4, 4') for applying the packaging blanks (100) to the containers (2) conveyed by the container conveyor (3). Furthermore, the system (1) comprises at least one stationary removal magazine (5, 5') with at least one removal magazine shaft (5.1, 5.2) for the packaging blanks (100) and at least one provision device (10) for providing and feeding packaging blanks (100) to the removal magazine (5, 5'). The application robot (4, 4') has at least one gripping device (6) and is designed to separate and apply the packaging blanks (100) in one work cycle.In this case, the application robot (4, 4') picks up a single packaging blank (100) from the removal magazine shaft (5.1, 5.2) of the removal magazine (5, 5') in a respective work cycle by means of its gripping device (6) and applies the picked up packaging blank (100) to the containers (2) in the same work cycle.