Vertical Rotation Unit for Counter Gravity Casting
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Solution Overview
Problem
Current robotic systems in the sanitary ware sector, particularly in toilet production with ring adhesion, face excessive load and high costs due to the need for larger capacity robots, leading to increased defect rates and reduced productivity, as well as difficulties in fault detection and machine shutdowns during the transfer of semi-finished products.
Innovation Solution
A vertical rotation unit is developed to facilitate counter gravity casting and reduce the load on robots by enabling independent positioning of electric, electronic, and pneumatic systems, allowing for lower capacity robot selection and continuous production despite failures, through a mechanism comprising a rotation head, L-shaped body, fork, and adjustable rear surface for stable product handling.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Force
If a larger capacity robot is used to handle excessive load during semi-finished product transfer, then the robot can handle the load, but the costs increase and the robot usage life decreases
Solution Approach 1:
The system is divided into two separate functional units: a vertical rotation unit that handles the semi-finished product transfer and positioning, and a robot that only performs the lifting and placement operations. This segmentation allows the robot to operate with a smaller, more cost-effective capacity while the vertical rotation unit manages the complex transfer operations.
Solution Approach 2:
The vertical rotation unit acts as an intermediary device between the robot and the semi-finished product. It receives the product from the robot, performs the rotation and positioning operations, and transfers it to the next station, thereby protecting the robot from excessive mechanical stress and reducing its required capacity.
2Extent of automation
If electric, electronic and pneumatic elements are assembled on the robot during transfer, then the system is integrated, but fault detection becomes difficult and machine shutdown occurs
Solution Approach 1:
The electric, electronic, and pneumatic elements are extracted from the robot and relocated to the vertical rotation unit. This separation allows for independent monitoring and maintenance of these elements, making fault detection straightforward and enabling targeted repairs without shutting down the entire system.
Solution Approach 2:
The control system is segmented into separate modules: robot control and vertical rotation unit control. This modular architecture allows for independent troubleshooting and fault isolation, making it easier to identify and resolve issues without affecting the entire production line.
3Productivity
If tool changer apparatus is used during semi-finished transfer, then the production process continues, but excessive load is imparted on the robot
Solution Approach 1:
The tool changer apparatus is extracted from the robot system and integrated into the vertical rotation unit. This allows the tool changing operations to be performed independently by the vertical rotation unit, eliminating the excessive load that would otherwise be imposed on the robot while maintaining continuous production.
4Manufacturing precision
If vertical rotation unit is implemented to enable counter gravity casting, then production defects are prevented, but device complexity increases
Solution Approach 1:
The casting process is inverted by implementing counter-gravity casting, where the mould is positioned above the casting table and the semi-finished product is lifted upward rather than being poured downward. This inversion prevents production defects by eliminating gravitational interference with the casting process, while the vertical rotation unit manages the complexity through a focused, specialized design.
Data Source
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AI summary
The invention is related to a vertical rotation unit (10) developed to be used in the toilet machine with robotic high pressure ring adhesion in the sanitary ware sector. Said vertical rotation unit (10), provides casted semi-finished products flat without formation of any defect by means of making the counter gravity casting possible. Said vertical rotation unit (10) allows for selecting a lower capacity robot by decreasing the total load of the robot and thus it both decreases the costs and extends the lifecycle of the product.