The invention relates to a pusher assembly, and in particular to a pusher arrangement being configured to remove one or more misaligned containers. Also, the invention relates to a method for removing one or more misaligned packaging containers from a misalignment location.
Individual packaging containers, such as liquid food packaging containers, are typically produced from a carton-based material and filled using a filling machine. When the filled, formed, and sealed packaging containers are unloaded from the filling machine they are typically transferred to a cardboard packer in which a predetermined number of packaging containers are stacked in a packing pattern and placed in a case made from a cardboard blank, or to a wrapping machine or similar equipment that encloses groups of packaging containers.
During these operations there is a need to move the packaging containers from one location to another. For example, packaging containers need to be moved from the filling machine (or any conveyor associated thereto) to the cardboard packer (or any conveyor associated thereto).
In order to move packages from one area to another within industrial machine equipment, a robot arm can be used. The robot arm may be programmed to move in three or four dimensions. At the distal end of the robot arm, a gripper is arranged providing an interface between the machine and the packaging container.
In these fast-paced manufacturing environments there will be failures and due to e.g. damaged cardboard blanks, packages falling, misalignment etc. The time to restore the production line is called Mean Time to Restore, MTTR and is crucial. Robotic solutions to restore a production line exist. However, these are typically time consuming due to difficulties in accurately removing the cause of the fault. In other production environments, an operator is alerted and has to manually interact with the production line in order to get it up and running after a failure. Apart from being costly and time consuming, having operator interaction may increase the risk of contamination when handling food products.
The restoration of the production line consequently has to be fast and without human interaction and there is thus a need for an improvement to a gripper unit solving or at least mitigating the abovementioned problems.
An object of the present invention is to provide a new type of machine interface termination which is improved over prior art and which eliminates or at least mitigates the drawbacks discussed above. More specifically, an object of the invention is to provide a pusher assembly configured to remove one or more misaligned packaging containers restoring a manufacturing line to a working state. These objects are achieved by the technique set forth in the appended independent claims with preferred embodiments defined in the dependent claims related thereto.
According to a first aspect, a pusher assembly is presented. The pusher assembly is configured to remove one or more misaligned packaging containers and comprises a gripper unit comprising at least one vacuum suction cup. The gripper unit is connected to the robotic arm. The pusher assembly further comprises a pusher arrangement comprising an interface plate, one or more extension means and a pusher plate. The pusher plate is arranged distanced from the interface plate by said one or more extension means. The interface plate is releasably attached to the gripper unit by means of said at least one vacuum suction cup.
In one variant of the pusher assembly, the pusher plate is configured in a meshed structure. This reduces the weight of the pusher plate thereby reducing the total weight of the pusher arrangement and moves a center of mass of the pusher arrangement closer to the interface plate with a reduction in torque at the gripper unit of the pusher assembly as a result.
In another variant of the pusher assembly, the pusher plate is substantially parallel to the interface plate. This enables the pusher assembly to push the one or more packaging container(s) in a substantially radial direction relative to the robotic arm thereby pushing them far from the robotic arm.
In yet another variant of the pusher, the pusher plate is substantially centered relative to the interface plate in at least one of a horizontal axis or a vertical axis. Having the pusher plate centered in such a manner is beneficial since it makes the pusher assembly easier to control since it can present a reduced front view making it easier to steer at tight locations.
In a further variant of the pusher, the pusher plate is connected to the interface plate by two extension means. One of the extension means is arranged in a substantially v-shaped form having its fulcrum at the interface plate. This arrangement presents a stable and robust design that is capable of exerting a pushing force at many points of the pusher plate without bending or skewing.
In a second aspect, a pusher arrangement comprising an interface plate, one or more extension means and a pusher plate, is provided. The pusher plate is arranged remote from the interface plate by said one or more extension means. The interface plate is configured to be releasably attached to a robotic arm and a gripper unit by means of at least one vacuum suction cup of the gripper unit.
In one variant of the pusher arrangement, the pusher arrangement is the pusher arrangement of the pusher assembly or any of its variants as presented above.
In a third aspect, a method for removing one or more misaligned packaging container(s) from a misalignment location is presented. The method comprises connecting a pusher arrangement to a robotic arm thereby forming a gripper assembly and moving the robotic arm to position a pusher plate of the pusher arrangement proximate to the misalignment location. The method further comprises moving the robotic arm along the misalignment location to push, by means of the pusher arrangement, said one or more misaligned packaging container away from the misalignment location.
In one variant of the method, the misalignment location is at a secondary package. This is beneficial since it allows the secondary package to be quickly cleared in a single action without human interaction.
In another variant, the misalignment is outside of a work-space of the robotic arm. Since the pusher arrangement extends the reach of the robotic arm, areas that would normally not be reached without manual intervention can be cleared.
In a further variant, the step of connecting the pusher arrangement to the robotic arm comprises moving the robotic arm to an idle location of the pusher arrangement. Having the robotic arm pick up the pusher arrangement from an idle location is beneficial since allows the gripper arrangement it may be securely stored at the idle location when not used by the robotic arm.
In yet another variant of the method, it comprises disconnecting the pusher arrangement from the robotic arm. This is beneficial since it frees the robotic arm for normal operation, when for instance misaligned packaging containers have been removed from the misalignment location by means of the pusher arrangement.
In one variant of the method, before the step of disconnecting the pusher arrangement, the robotic arm is returned to the idle location of the pusher arrangement. This is beneficial since it frees the robotic arm for normal operation, when for instance misaligned packaging containers have been removed from the misalignment location by means of the pusher arrangement. It also allows the gripper arrangement to be securely stored at the idle location when not used by the robotic arm.
In a further variant of the method, the pusher arrangement is the pusher arrangement of any aspects or variants previously presented and/or wherein the pusher assembly is the pusher assembly any aspects or variants previously presented.
In a fourth aspect, a non-transitory computer-readable storage medium is presented. The medium stores one or more software programs configured for execution by one or more processors. The one or more software programs comprises instructions for performing the method according to any aspects or variants previously presented.
Embodiments of the invention will be described in the following; references being made to the appended diagrammatical drawings which illustrate non-limiting examples of how the inventive concept can be reduced into practice.
ac are perspective views of a pusher arrangement according to embodiments of the invention;
Hereinafter, certain embodiments will be described more fully with reference to the accompanying drawings. The invention may, however, be embodied in many different forms and should not be construed as only limited to the embodiments set forth herein; rather, these embodiments are provided by way of example so that this disclosure will be thorough and complete and fully convey the scope of the invention to those skilled in the art, such as is defined in the appended claims.
Starting from
The robotic arm assembly 5 is arranged in a machine environment exemplified, such as between a filling machine and secondary package 40 or other type of equipment. The term “secondary package” should be construed as packaging intended to contain one or more packaging containers filled with a product. One non-limiting example is the production line 1 of
The robotic arm assembly 5 is configured to operate at very high speed; from an idle position, it must be capable of performing the following motion sequence: arranging the gripper unit 10 in close proximity to the approaching packaging container 20, activating the gripper unit 10 in order to attach the packaging container 20 to the gripper unit 10, moving the gripper unit 10 and the attached packaging container 20 to the desired position, releasing the packaging container 20 by deactivating the gripper unit 10, and to return to the idle position.
A controller 50 is therefore provided and connected to the gripper unit 10 in order to control activation and deactivation of the gripper unit 10. In some embodiments, the controller 50 is also in communication with the robotic arm 5.
The controller 50 preferably comprises a non-transitory computer-readable storage medium, storing one or more programs configured for execution by one or more processors, the one or more programs comprising instructions for controlling the gripper unit 10.
The gripper unit 10 may be any suitable gripping means for engaging with the planar panel 21 of a packaging container 20. In one embodiment, the gripper unit 10 is realized as a device capable of exerting a controllable suction or vacuum at the planar panel 21 of a packaging container 20. The control of the suction/vacuum may be in a straightforward on/off manner meaning the vacuum suction is activated and deactivated. In the coming sections, a comparably more advanced embodiment of the gripper unit 10 will be disclosed, as it should be emphasized that this comparably more advanced gripper unit is not mandatory for implementing the disclosed invention.
Now turning to
The gripper unit 10 comprises a housing 11 and a vacuum distribution unit 12. The vacuum distribution unit 12 is moveable in relation to the housing 11 and comprises at least one suction cup 13. In the shown example, the vacuum distribution unit 12 comprises two spaced apart suction cups 13 for attaching to the packaging container 20 by applying vacuum, and one control suction cup 14.
All suction cups 13, 14 are preferably activated simultaneously. This is particularly the case when the suction cups 13, 14 share common air. By activation of the control suction cups 13, 14, the vacuum distribution unit 12 is moved towards the housing 11, in the direction indicated by the block arrows in
In the active position, as shown in
The gripper unit 10 is used to collate individual packaging containers 20 while they are in motion, necessitating the activation of the suction cups 13. The vacuum operated suction cups 13 need to engage with the packaging containers that they are picking in order to attain a seal, and therefore a robust grip.
Should the suction cup 13 stand out from of the housing 11 (and ready to contact a packaging container), it would possibly impede the collection of the packaging container. Thus, the gripper unit 10 described herein is configured to retract the suction cups 13, leaving a “clean” housing surface that does not impede packaging container movement.
In fact, the suction cups 13 are controlled to protrude to ensure the suction cups 13 meet the packaging container before the housing 11. The suction cups 13 are retracted by cutting off air supply to vacuum generators (not shown), in order to ensure the suction cups 13 do not interfere with packaging containers 20 being placed.
In the embodiment shown in
During operation, placement of the packaging container will be stable as the suction cups 13 withdraw from the packaging container, into the housing 11, as the vacuum is released. This is achieved by de-activating the control suction cup 14 and the suction cups 13 simultaneously, whereby the vacuum distribution unit 12 is allowed to return to its idle position of
In
From the above, it can be deduced that the gripper unit 10 is adapted to engage with a panel 21 of a packaging container 20 at a predetermined angle. This is the normal mode of operation and works fluently and well until there is a misalignment of the packaging container 20. A misaligned packaging container 20 will be referred to as a misplaced packaging container 20′ and this is comprises all packaging containers 20′ placed in such a way, or in such a location, that they can't be gripped directly by the gripper unit 10.
In
In
Staying with
In
Turning to
The pusher arrangements 100 of
In embodiments of pusher arrangement 100, the pusher plate 120 is presenting a homogenous surface towards packaging containers 20 to be pushed. However, as seen din
It should be mentioned, that although the pusher plates 120 to this point may be interpreted as substantially planar pusher plates 120, there are embodiments a concavely or convexly shaped pusher plate 120 is preferred. Such embodiments may be used where package containers 20 should be either collected (concave pusher plate 120) and pushed to a common location. Alternatively, it may be desirable to have package containers 20 dispersed to the sides of the pusher plate 120, in such cases a convex or perhaps even v-shaped pusher plate 120 may be utilized.
From the above, it is clear that the pusher plate 120 may be formed in any suitable way.
One benefit of forming the pusher plate 120, such that it does not form a homogenous surface is that a weight of the pusher plate is reduced and consequently the force needed to attach the pusher arrangement to the gripper unit 10 can be reduced. Preferably a mass center of the pusher arrangement 100 close to the interface plate 110 in order to reduce torque and one way of shifting the mass center is to reduce the weight of the pusher plate 120.
With reference to
With reference to
Upon initiation, the pusher arrangement 100 is connected 310 to the robotic arm 5. If the robotic arm 5 is provided with a gripper unit 10, this forms a gripper assembly 200 attached to the robotic arm 5. The connection 310 of the pusher arrangement 100 may be achieved by applying a suction force at the interface plate 110 of the pusher arrangement 100. In embodiments of the method 300, wherein the robotic arm 5 is provided with a gripper unit 10, the gripper unit 10 is typically used to connect 310 the pusher arrangement as detailed in previous sections. As mentioned earlier, the pusher arrangement 100 may, before connecting 310 to the robotic arm 5, be located at the idle location 60. In such embodiments, the step of connecting 310 the pusher arrangement 100 to the robotic arm 5 may comprise moving 315 the robotic arm 5 to the idle location 60 of the pusher arrangement 100 before connecting 310 the pusher arrangement 100 to the robotic arm 5.
With the pusher arrangement 100 attached to the robotic arm 5, the robotic arm 5 is moved 320 to position the pusher plate 120 of the pusher arrangement 100 proximate to the misplacement location 30,40.
At the misplacement location, packages to be removed 20′ are pushed 330 away from the misplacement location 30, 40. The pushing 330 is achieved by moving the robotic arm 5 along the misplacement location 30, 40 such that the pusher plate 120 of the pusher arrangement 100 is moved along the misplacement location 30, 40 pushing packages to be removed 20′ away from the misplacement location 30, 40.
Optionally, the method 300 may further comprise the step of disconnecting 340 the pusher arrangement 100 from the robotic arm 5. In embodiments wherein the robotic arm 5 comprises the gripper unit 10, this may be achieved by the gripper unit 10 reducing or removing suction force that is applied to the interface plate 110 of the pusher arrangement. The step of disconnecting 340 the pusher arrangement 100 may in embodiments wherein the pusher arrangement 100 was initially located at the idle location 60, comprise moving 345 or returning 345 the robotic arm 5 to position the pusher arrangement 100 at the idle location 60 prior to disconnecting 340 the pusher arrangement 100.
It should be noted that the method 300 described with reference to
In
Number | Date | Country | Kind |
---|---|---|---|
20162406.1 | Mar 2020 | EP | regional |
Filing Document | Filing Date | Country | Kind |
---|---|---|---|
PCT/EP2021/055559 | 3/5/2021 | WO |