Stackable Part Trays for Low-Payload Robotic Processing
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Solution Overview
Problem
Existing robotic part transfer systems are limited by high cost, complexity, and capacity constraints, particularly in handling high-mix manufacturing, due to the need for high-payload robots and complex programming in existing systems like fixed table, drawer, and conveyor systems.
Innovation Solution
A tray system comprising identical trays with alignment features and stacking posts, allowing for efficient stacking and configuration, along with a docking station and supports for precise positioning, enables a low-cost, simple, and high-capacity robotic part processing system that can handle parts of various dimensions with a small footprint.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If existing tray systems require a very large, high payload robot to lift entire trays of processed workpieces, then the robot can handle the trays, but the cost of the robot increases significantly
Solution Approach 1:
The system divides the workpiece handling into separate trays for raw workpieces and processed workpieces. The robot only needs to lift individual workpieces from one tray and place them into the other tray, rather than lifting entire heavy trays. This segmentation of the handling function reduces the payload requirement and associated cost.
Solution Approach 2:
The tray system acts as an intermediary structure that provides stable support for both raw and processed workpieces. The trays serve as intermediate holding structures, allowing the robot to transfer workpieces without directly supporting the weight of complete trays filled with heavy workpieces.
2Quantity of substance
If drawer systems are used to increase the number of parts presented to the robot, then part capacity increases, but the cost and complexity of the system increases substantially
Solution Approach 1:
The system merges the functions of multiple drawers into a single tray structure. Instead of having separate drawers with complex slides and bearings, the patent uses simple stacked trays that provide equivalent part storage capacity without the mechanical complexity of drawer mechanisms.
Solution Approach 2:
The tray system uses simple, inexpensive tray structures rather than expensive, complex drawer assemblies. The trays are basic containers without mechanical components, making them much cheaper to manufacture and replace if needed, while still providing the required part storage capacity.
3Quantity of substance
If drawer systems are used to increase part capacity, then more parts can be stored, but the programming complexity and calibration required increases substantially
Solution Approach 1:
The tray system uses identical, standardized trays for both raw workpiece storage and processed workpiece storage. This universality simplifies programming because the robot only needs to learn one tray geometry and positioning scheme, rather than programming different drawer configurations and calibration procedures.
Solution Approach 2:
The system changes the parameter of tray positioning from complex drawer slide positions to simple, fixed tray locations on the support structure. This parameter simplification reduces the calibration and programming complexity while maintaining adequate part storage capacity.
4Measurement precision
If fixed table systems are used to present workpieces to the robot, then workpieces can be arranged in a known configuration, but the table capacity is limited by the size of the table
Solution Approach 1:
The system transitions from a two-dimensional fixed table surface to a three-dimensional stacked tray configuration. By adding the vertical dimension with multiple stacked trays, the system dramatically increases the total workpiece capacity while maintaining precise positioning and configuration on each individual tray level.
Data Source
AI summary
A tray system for robotic part processing is provided, comprising: a plurality of substantially identical trays, each including a base having an upper surface and a lower surface, a frame connected to the upper surface of the base and defining a plurality of pockets for receiving workpieces, and a plurality of spacers, each spacer including an alignment feature on the upper surface or the lower surface of the base, and at least one stacking post on another of the upper surface or the lower surface of the base of each of the plurality of trays, each stacking post including one end having a centering tip and another end configured to mate with another stacking post; wherein the trays are configured to be stacked in alignment with one another by placing the plurality of alignment features of one tray into engagement with the plurality of spacers of another tray.