Vacuum-Grip Tray Insertion for Pliable Produce Packing
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
The existing process of manually packing filled produce trays into boxes is labor-intensive, slow, and prone to repetitive stress injuries, and automation efforts have been hindered by the difficulty in fitting trays into boxes due to their pliability and susceptibility to tearing, as well as the risk of bruising the produce.
Innovation Solution
A produce packing system utilizing a produce information sensor, linear actuator assembly, and end effector with a vacuum mechanism to automate the process, ensuring precise placement of filled trays into transport containers without bruising the produce, by using height parameter data and retractable infeed belts with justifiers for alignment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If manual packing is used, then flexibility in handling pliable trays is maintained, but labor intensity increases and packing speed decreases
Solution Approach 1:
The patent replaces manual mechanical handling with an automated end effector system that uses vacuum suction to grip trays. The end effector incorporates a vacuum generator and suction cup that can securely hold pliable trays without requiring manual dexterity, thereby maintaining flexibility while dramatically increasing packing speed and reducing labor intensity.
Solution Approach 2:
The patent introduces an intermediary device (the end effector with vacuum mechanism) between the robotic arm and the tray. This intermediary component is specifically designed to handle the pliable nature of trays through vacuum suction, allowing automated handling while preserving the flexibility needed for these soft, deformable containers.
2Productivity
If trays are inserted on top of existing trays, then packing efficiency is improved, but produce bruising occurs due to dropping
Solution Approach 1:
The patent implements beforehand cushioning by using the vacuum suction mechanism to securely hold each tray during the insertion process. The end effector maintains continuous vacuum grip on the tray being inserted, preventing it from dropping onto the tray below. This prior cushioning through vacuum support eliminates the harmful impact that would otherwise cause produce bruising while maintaining efficient vertical stacking.
3Extent of automation
If automation is implemented without vacuum mechanism, then labor intensity is reduced, but tray control and positioning accuracy deteriorate
Solution Approach 1:
The patent replaces simple mechanical gripping with a vacuum-based suction system controlled by a vacuum generator. This allows the automated end effector to precisely control tray position and orientation through regulated vacuum pressure, maintaining high positioning accuracy while achieving full automation. The vacuum mechanism provides gentle yet firm control over the pliable trays throughout the insertion process.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The system efficiently automates the packing process, reducing labor intensity and bruising risks while accommodating trays that are larger than the box dimensions, ensuring accurate and rapid tray placement.
Implementation Method 1
an end effector with a vacuum mechanism to automate the process
Data Source
AI summary
An apparatus for packing a plurality of filled produce trays into a transport container, such as a box or a carton, without bruising the produce in the process. The produce packing system includes an infeed belt, produce information sensors and a processing assembly. The processing assembly receives information from the produce information sensors to calculate a container packing position. Using this information, the produce packing system clamps onto a filled produce tray from an infeed belt and moves the filled produce tray downward into a transport container at a predetermined height to place the filled produce tray into the transport container.