Vertical Tray Registration for Continuous Robot Part Supply
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Solution Overview
Problem
Current robotic systems require human intervention to supply and manage parts, limiting their operation to specific reach planes and preventing continuous, unattended 24-hour operation due to the need for manual part placement and removal, which reduces efficiency and increases labor costs.
Innovation Solution
A part registration system with a tray support rack and vertically adjustable tray support shelf, along with a tray transfer arrangement and autonomous motorized cart, allows for the automatic positioning of parts within the optimal reach plane of a robotic arm, enabling continuous operation and maximizing part storage capacity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If parts are stored in vertical stacks with multiple trays, then part storage capacity is improved, but the robot can only access one layer at a time requiring tray movement between load and unload positions
Solution Approach 1:
The system transitions from horizontal tray arrangement to vertical stacking configuration, utilizing the vertical dimension to increase storage capacity. Multiple trays are stacked vertically with the robot arm capable of accessing different vertical levels, transforming the single-plane limitation into a multi-level storage solution that maintains continuous operation capability.
2Device complexity
If a fixed plane is used for part storage, then the system structure is simplified, but the robot reach is limited to a small number of shelves
Solution Approach 1:
The system introduces vertical adjustability to the tray support shelf, transforming it from a fixed position to a dynamically adjustable component. The shelf can be repositioned vertically to accommodate different part heights and optimize robot reach, allowing the same structure to adapt to various storage configurations and maximize the number of accessible shelves without increasing overall system complexity.
3Stability of the object's composition
If trays are fixed to sliding drawers, then tray stability is improved, but the robot is prevented from delivering parts to different levels on the same cart
Solution Approach 1:
The system separates the tray support function from the drawer sliding mechanism. Trays are supported on vertically adjustable shelves that are independent of horizontal drawer movements. This segmentation allows trays to remain stable on adjustable shelves while enabling the robot to access and deliver parts to different vertical levels on the same cart without the trays being constrained by sliding drawer mechanics.
4Manufacturing precision
If human operators manually position and replace parts, then part placement precision is improved, but continuous 24-hour operation is prevented
Solution Approach 1:
The system implements automated part management where the robot arm independently performs part retrieval, positioning, and tray replacement operations. The vertically adjustable shelf system works in conjunction with the robot to automatically maintain optimal part positions without human intervention, enabling continuous 24-hour operation while preserving placement precision through robotic control and consistent mechanical positioning.
Data Source
AI summary
A part registration system for registering one or more parts relative to a robot having a robotic arm that defines a plane of optimal reach at a vertical position is provided. The part registration system includes a tray support rack, a tray support shelf and a tray transfer arrangement. The tray support rack is configured to support a plurality of trays for holding one or more parts. The tray support rack has a plurality of tray support regions in which one or more trays may be supported. The plurality of tray support regions are at different vertical positions. The tray support shelf is vertically adjustable relative to the tray support rack. The tray transfer arrangement transfers the trays between the tray support rack and the tray support shelf. Methods are also provided.