Synchronized Picking Tooling for Flexible Beverage Packaging
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Solution Overview
Problem
Conventional packaging systems for beverage containers are limited in capacity, flexibility, and efficiency, requiring extensive manual adjustments and occupying large footprints, with a need for multiple machines to handle different configurations, and often result in labor-intensive change-over periods and production rate ramp-ups.
Innovation Solution
An article picking and placing system comprising a first and second picking tooling, with an intermediate transportation unit and a control unit that synchronizes the tooling to form different article configurations, allowing for efficient and flexible picking, orienting, and placing of articles with reduced footprint and minimal treatment steps, without the need for pre-pitching or extensive change parts.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If conventional reciprocating pick and place systems are used, then packaging capacity is limited, but the system requires extensive infeed product laning and collation infrastructure that occupies large packaging hall real estate
Solution Approach 1:
The system segments the packaging hall into functional zones: an infeed area for product arrival, a central processing area with multiple picking tools, and an output area. This segmentation allows efficient use of space by concentrating operations in specific zones rather than requiring continuous lane infrastructure throughout the entire hall.
Solution Approach 2:
The patent introduces vertical movement dimensions through reciprocating picking tools that move between upper and lower positions, and through multi-level packaging configurations. This vertical utilization reduces the horizontal footprint required for packaging operations.
2Adaptability or versatility
If conventional packaging systems are used, then they can handle limited ranges of container types and packaging formats, but switching between configurations requires numerous manual adjustments and extensive change parts
Solution Approach 1:
The packaging system employs universal picking tools with adjustable gripping mechanisms that can accommodate multiple container types and packaging formats without requiring tool changes. The system integrates multiple functions (picking, placing, orienting) into single versatile tools rather than requiring separate specialized equipment for each configuration.
Solution Approach 2:
The system incorporates dynamically adjustable parameters such as variable picking speeds, adjustable gripping forces, and reconfigurable packaging configurations. These dynamic adjustments allow the same equipment to adapt to different product types and packaging formats without manual reconfiguration or part changes.
3Adaptability or versatility
If conventional packaging systems are used, then change-over periods are long and labor demanding, but productivity is reduced during and after each changeover
Solution Approach 1:
The system performs preliminary configuration setup during off-peak times or before production runs, pre-adjusting packaging parameters and verifying tooling positions. This advance preparation eliminates the need for time-consuming manual adjustments during actual production changeovers.
Solution Approach 2:
The patent replaces manual mechanical adjustments with automated control systems that electronically configure packaging parameters. Programmed control eliminates the need for manual tool changes and mechanical reconfiguration, enabling rapid switching between packaging formats through software commands rather than physical adjustments.
4Ease of operation
If pre-pitching is implemented at the infeed, then article handling is simplified, but additional treatment steps are required that increase process complexity and footprint
Solution Approach 1:
The system merges multiple functions (pitching, orienting, picking) into a single integrated processing zone. Rather than separating these operations into distinct treatment steps, the reciprocating picking tools perform all necessary article preparation and handling functions simultaneously during the picking cycle, reducing overall process complexity.
Data Source
AI summary
The present invention provides an article picking and placing system, the system comprising: —a first article picking tooling and a second article picking tooling, and an intermediate transportation unit configured in between an article infeed transportation unit and an article outfeed transportation unit; —a control unit for synchronizing the first and second article picking tooling such that (i) the first article picking tooling picks and/or forms a first configuration of articles from the infeed transportation unit for transfer to the intermediate transportation unit, thereby forming an intermediate configuration on said intermediate transportation unit, and (ii) the second picking tooling picks a second configuration of articles from said intermediate transportation unit for transfer to the outfeed transportation unit, wherein the second and intermediate article configurations are different relative to each other and each different from the first article configuration.