外文文獻一個復雜紙盒的包裝機器人

A complex carton packaging robot

Venketesh N. Dubey

British School of Design, engineering and computers, Bournemouth University, Poole

Jian of S. Dai

King's College London, University of London, London

Objective - To demonstrate t第一文庫網he feasibility of the design of a complex geometry multifunctional tray packaging machine can be folded

Design / methodology / approach - The study to study various geometric shapes tray, the tray is divided into the appropriate type and machine operation can be achieved; processing tray and mechanical modeling and simulation, and the final design and Ultimately allows the conceptualization of the design and development of packaging machine.

The findings - This multi-functional packaging machine has proved to be possible. Just this versatile packaging machine miniaturization, and investment in order to promote their development, this machine can become a reality.

Limitations of the study factors / - The purpose of this study is to prove that the principle of such a packaging machine, but the practical application need to consider the sensor gives a compact, portable system.

Creative / value - This design is unique, and has been shown to complex shapes can be folded carton.

Keywords: robotics Packaging Automation.

Abstract

Product packaging is one of the key industrial areas, the primary interest in automation. The circulation of any product to the hands of consumers need some form of packaging, food, gifts, or medical supplies. Therefore, the continued demand for high-speed product packaging. For cyclical consumer goods and gifts, this requirement is greatly increased. They require innovative packaging design and attractive in order to attract potential customers. Usually these products look beautiful, complex shape of the tray delivery. If you use the manual method for packaging, not only the workers are tedious and complicated to operate, but also time-consuming and monotonous.

For simple carton packaging, by dedicated machines arranged along the conveyor belt, has received implementation. These machines can only handle a fixed type tray, any shape and structural changes is difficult to be incorporated into the system. In most cases, they are more than 40 kinds of changes needed to adapt the same type but of different sizes tray, which means that each particular type of tray needs a packaging production line. Conversion from one type to another type of paper folding assembly line will be the increase in capital spending. Because of the costs associated with these constraints and convert production lines, packaging flexibility will be lost.

Therefore, as a complement to the manual production lines are introduced in order to adapt to the production of different types of carton, so as to solve the problem of the conversion of production lines. They bear about 10% of the work orders, and is used as the assembly line for production of promotional products. However, the problem still exists, administrators and

operators manual production line requires a long learning process, and machine production line, labor injury is due to twisting hand movements. In addition, manual production lines are usually considered to be a seasonal productivity, and specialized machines still need to run for many years, in order to save cost and time. Designers to pursue fantasy and unique carton packaging in response to competitive market the packaging work more difficult. Frequent changes of style and type of carton and small batch tray assembly and packaging lines posed a challenge to do this need to design a flexible machine.

So the responsibility on the packaging industry body, fully programmable and reconfigurable systems helps speed up the conversion process to handle different types of carton. This flexible and highly reconfigurable system development requires a systematic analysis and synthesis of each component, folding cartons and cartons mode and packing boxes, machine, complete assembly operations. One such method (Lu and Akella, 2000) has been published, this method uses fixtures to folding cartons. Although this method is able to complete all folding carton operation, but the implementation is just a simple rectangular box, the fixed automatic device is installed in the specified location. However, for complex geometry tray, tray and folding mechanism into account, in order to achieve flexible packaging production line automation.

In the complex folding carton operation and process analysis, the authors carried out a lot of research, and resorting to graph theory, spiral theory, matrix theory and a spatial structure of said tray; their research carton mobility and analysis its structural shape (Dai and Rees Jones, 1997a, b, c, 1999; Dubey et al. 1999a, b, c; Dubey and Dai, 2001). This article describes the in reconfigurable carton folding machine designed to handle complex geometry cassette.

The needs of the design principle

The project is listed on the wish list of many cosmetics and perfumes suppliers, such as Elizabeth Arden and Calvin Klein, by Unilever Research UK actively considering a number of years. They are willing to support any kind of to be able to use alternative means to achieve the fancy carton packaging process automation ideas. A result, this project is sponsored by a consortium of British and Dutch Unilever, to explore the feasibility of the development of a tray that can handle a variety of shapes and sizes of flexible packaging machine. The study was conducted by manual packaging process, revealing when converted to a complex production from simple carton production, packaging machine has a high flexibility (Dai, 1996). This tray with an irregularly shaped cardboard folded. Since cardboard is broken, it has a certain surface activity can be rotated around the crease lines. These crease lines to facilitate folding, resulting in a shape shift. Figure 1 shows a fancy carton folding process, the cardboard is folded into the shape of a tent. Usually this complex and small batch tray made by hand.

The process of fancy folding cartons

The force in manual packaging

Manual packaging process, the side of the folded finger, as shown in Figure 2, along the direction of the arrows around the three axes is folded, while the top and bottom surfaces is folded along a planar direction of the arrows with the palm. The arrows represent the unwinding force is applied with your fingers, flat arrows represent thrust is applied. In the closed intermediate layer, delicate fingers cross the face insert designed gap.

Summarized folding step, the carton in a variety of shapes, and the tray is classified, as shown in Figure 3. It also shows the various operations involved in the carton packaging. In particular, to note that most of the tray must go through three steps, erected, insert [1] and closed. But in addition to the tray outside the tray, in other cases, based on the complexity of the tray shape, the packaging step involves various operations (some of which are described above).

The operations of carton packaging

The design of a mechanical system construction and folding cartons need to consider the following:

● multi-functional. Provide a variety of functions, including dial, fold, squeeze and twist operation.

● flexible. The operating position can be achieved in different ways. ● Control the minimum number of axes. Reduce system complexity.

● reconfigurability. To deal with a variety of different geometries folding carton. ● programmability. Simultaneously, the sequential control of a plurality of axes of motion.

A flexible system that can provide fine motor and operating functions, you need to use the relevant section of the finger-like links. So that the finger is mounted on a movable base, for example, the XY table or the ring guides way, in order to ensure that the system can re-build and handle different shapes and sizes of the tray. The controller architecture should be able to be driven independently of each axis. The design should provide all the operating functions, without making the system becomes complex, thus making it a cost-effective solution.

Packaging machine

The original design based on the above criteria is conceptualized and modeling,

as shown in Figure 4. Manpower to be able to demonstrate a variety of functions is based on manpower flexibility and versatility. The design has four fingers, two of which are three degrees of freedom, two of which are two degrees of freedom. The three degrees of freedom of the joints of the fingers through the bottom of the deflection movement (Y), rely on the remaining two joints for pitch motion (P), thereby forming the YP-P configuration. The two-degree-of-freedom fingers can only be done in a two-dimensional plane pitching motion.

Packaging machine model

The finger is mounted on the guide rail can be moved transversely movable along the slide rail, but the rail itself. The fingers are mounted on the rotating base, these axes can be appropriately adjusted. The two clamp hand propulsive movement in the direction parallel to the finger horizontal rail, as shown in the model. The baffle is attached to the hands of the clamp, and is mounted in the bottom of the joint, when the push operation, they can follow the contour of the tray movement. The tray is placed in the square at the center of the bottom of the base, the base is driven by an electric motor for vertical movement and rotation, so that the carton packaging operations required for any position. The joint of the finger directly through the joint motor drive, the entire system needs to be controlled shaft 14. These considerations are based on a high degree of reconfigurability and control the minimum number of axis.

Fingertip designs special consideration, because they have to perform various operational functions discussed in the previous section. Inspired by the manual packaging process, fingertip design with the tip of the V-groove. According to the needs of the manual packaging, making it the finger "poke" and "squeeze" the force is applied on the cassette. The prongs are used to poke operation, in the extrusion of the V-shaped groove, paperboard, open to plug operation. In addition to providing unstinting effort and squeeze force, Y-shaped portion of the two-degree-of-freedom finger can provide temporary flat cardboard thrust. In the case of a limited degree of freedom, this design can provide many flexible operating functions to handle the different construct different types of tray.

The model provides the machine is running all the necessary motion information (Dubey and Crowder, 2003). Packaging machine parameter model has been developed (Workspace4, 1998), the geometric shape and size changes in the design can be easily incorporated into the model, including the configuration of authentication. This also makes the motion parameters of the machine member can be ascertained prior to processing. Positioning point of contact can be achieved by recording the displacement of the contact point, the connectivity of the finger movement between the carton packaging cartons, carton. The point of contact on the carton can be represented by the geometry of the folding sequence identification (Dubey and Dai, 2001). These contact points used to measure the offset of each finger joint. These displacement data are subjected to the interpolation operation, to generate optimal finger path to minimize the unnecessary finger movement, thus reducing the packaging cycle time. Interpolation of data obtained from the model can be downloaded, to drive the fingers. The current research work is based on the geometric characteristics of the tray and the folding sequence of the entire packaging process can be automated (Dubey et al, 2000), rather than by means of the simulation of the tray.

Figure 5 shows a finger trace the point of contact on the tray when the tray is folded. Simulation model for the design and control of the packaging machine provides a lot of valuable information. For example, prior to the dimensions and structure of the simulation model can be used to check the geometry and structure of the machine. By changing the parameters of the basic dimensions of the model, any new mechanical parts geometric information can be obtained directly. Motion data obtained in the folding process of the tray and the track can be used for the finger system control. At present, the analog motion parameters can not be directly integrated into the controller, these data must be input in the form of a data file to the controller. However, this method can be fully checked folding sequence, and then download these data and input to the controller.

Robot folding carton

Testing machine

Three-dimensional information obtained from the model developed by the

packaging machine with three linear motor; two for driving the clamp hands, one for control of the vertical movement of the rotating platform. 10 Japan's Yaskawa Electric high-torque, high-performance motor is used at the joints of the fingers, these motor specifications: size, Φ30 × 30 mm; weight, 70 g; torque, 0.7Nm/22.5rpm; transmission ratio, 80 : 1, harmonic drive; optical encoder, 96 pulse / rev. This means that the fingers can be provided 10cm 7N pressure sufficient to collapse this fancy gift carton. The controller architecture uses four motion control program cards, each card can control up to four axes (Dubey and Crowder, 2003). These cards support the C programming language, motion control, it also has a G-code programming interface for rapid testing and analog processing. The system also uses a pneumatic connection to connect the sucker off switch, the controller can be controlled by the sucker. Turn the dial tray from one location to another location and position (in the future also plans to use the V-shaped groove on the finger), to complete the crawl. This will help to deal with the formation of the carton board, to prevent the slide (Dubey et al, 1999).

In order to establish the function of the packaging system used to build and folding carton, after the same to determine the geometry of the model and packaging machines both data files generated from the model feedback to the controller. Data files running motion data with a single line storage motor coordination, and follow-up to the next stage of the motion control parameters. Therefore, the control program in order to read data, and generates the corresponding interrupt while sending operations command. So, the fingers can be parallel, continuously repeated

movement. Prepared for a variety of operating functions of a subprogram can further enhance the programming capabilities of the controller, so that the modular

structure of the controller can be achieved, and thus better able to adapt to any new carton folding and packaging operation step.

Reconfigurable capacity of the system is one of the key issues of system development. During the system design idea is to use the system to collapse different types of minor changes to the tray. To do this, ensure that the device has developed good graphical model and the basic structure is very important to be assembled. Running machines, data files are included in the main program, when the folding carton operation for the first times in a step-by-step pilot mode to verify that the finger movement. Once the system has completed the preparatory work of the automatic packaging, the system can be built in less than 45 seconds and folding carton (Figure 1). As shown in Figure 1 shows the advanced machine, all the fingers and horizontal push rod are involved in the complex folding operation. Although it is difficult to time the comparison with manual packaging, but we were the same carton test, manual packaging (learning) takes an average of about 60 seconds.

Reconfigurable machine another type of tray can be folded to prove, as shown in Illustration 2. This is a complex shape of the closed tray. The packaging of this carton cardboard to perform various operations, including the allocation of twisting and folding. Reset the machine structure, the whole carton folding process is time-consuming 45s. Modified machine can be modified before the machine (as shown in Figure 1 below) comparable. This indicates a high degree of flexibility in the system and re-designs capabilities.

The running packaging machine

Another carton packaging machine

Discussion and conclusions

This paper proposes a flexible, reconfigurable assembly and packaging systems. The purpose of this study is to design a processing the different geometries tray reconfigurable assembly and packaging systems. The original idea was to develop a system can demonstrate the ability to adapt to different styles and complex shapes carton. The results show that the packaging machine can be folded carton of two completely different shapes. In any case, the folding cycle is approximately 45 seconds. Although this is not an optimal folding time, but using the online data transfer is expected to reduce the cycle time of 30 seconds or less. Although a very flexible carton packaging machine for workshop production, there are still many problems to be solved. However, the purpose of this study is to verify that a fast conversion technology for the packaging industry.

Portion includes optimization finger rail needs to be improved in the future, the use of force feedback touch sensor in order to avoid excessive pressure on the cardboard, and the folding operation will be carried out in a vacuum apparatus. Also recommended that the simulation model combined with the actual machine so that it can be downloaded online data. The XY table available motor drive and control, automatic reconstruction. This state-of-the-art technology will automate the entire packaging process, from the two-dimensional map of the tray, and then determine the kinematic characteristics and generate motion sequences to complete the product packaging. In addition, if small, also plans to be flexible, reconfigurable robot installed on a robot arm to obtain greater flexibility. The system not only for carton folding can also be folded into the paper tray. This will reduce packaging time, also be able to meet the challenges of the changing demand for high-end private product packaging and high flexibility.

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