Workpiece Handling Control for Complete Batch Picking
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Solution Overview
Problem
Existing mechanical systems for picking up or taking out workpieces often fail to collect a specified number due to missing or defective items, incomplete conveyance information, or status issues, leading to omissions in the picking or taking process.
Innovation Solution
A controller and mechanical system that includes a decision unit to determine whether a workpiece can be picked up or taken out and a control unit to generate commands for collectively picking up or taking out a specified number of workpieces based on this determination, using conveyance information to adjust for missing or defective items.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a robot picks up workpieces one by one following conveyed workpieces, then the picking process can adapt to individual workpiece positions, but it becomes time-consuming and may fail to pick up the specified number of workpieces due to missing or defective items
Solution Approach 1:
The system performs preliminary actions by pre-acquiring conveyance information about multiple workpieces before the picking operation. The controller stores position information of multiple workpieces in advance and uses this pre-collected data to determine pickup positions, enabling faster execution without sacrificing reliability.
Solution Approach 2:
The picking process is segmented into distinct phases: information acquisition phase (collecting conveyance data), determination phase (calculating pickup positions based on stored data), and execution phase (actual picking). This segmentation allows the system to process multiple workpieces efficiently by preparing information in advance.
2Reliability
If conveyance information is deleted due to defective workpieces or trays, then the system can avoid processing bad items, but it loses track of workpiece positions and may fail to pick up the specified number
Solution Approach 1:
The system cushions against information loss by storing conveyance information of multiple workpieces in advance. When conveyance information for a defective item is deleted, the controller can still retrieve position data from previously stored information about other workpieces, ensuring continuous operation without information gaps.
Solution Approach 2:
The controller performs preliminary information storage by acquiring and storing conveyance data for multiple workpieces before the picking operation begins. This pre-acquisition creates a buffer that protects against information loss due to defective items, allowing the system to maintain complete position data throughout the process.
3Productivity
If the machine collectively picks up multiple workpieces at once, then productivity increases, but the system becomes more complex in managing position calculations and coordination
Solution Approach 1:
The collective picking operation is segmented into independent calculation units, with each workpiece's pickup position determined separately based on its stored conveyance information. This segmentation simplifies the control logic by breaking down the complex multi-workpiece coordination into manageable, independent determination steps.
Solution Approach 2:
The system performs preliminary position calculations by storing conveyance information and determining pickup positions before the actual collective picking execution. This pre-calculation approach simplifies real-time control by eliminating complex coordinate transformations during the picking operation itself.
Data Source
AI summary
This control device is provided with: a determination unit which determines whether or not to allow workpieces being conveyed to be retrieved or whether or not to allow workpieces to be delivered to workpiece containers being conveyed; and a control unit which generates, on the basis of whether or not the retrieval is allowed, a command to collectively retrieve a specified number of workpieces, or generates, on the basis of whether or not the delivery is allowed, a command to collectively deliver a specified number of workpieces, and thereby controls a machine.