Bagged Product Packaging System

Project Description:  This system is a fully automated self-contained case erecting and packaging system for a bagged food product. 

Operation:  This case erecting/packaging system operates a single UR5e collaborative robot.    The robot retrieves flat cases from a simple (static) horizontal magazine.  The robot then erects the case, and places it into a case filling stage. 

The robot then retrieves the bagged product from a que conveyor (which is continuously supplied from an upstream filling process). 

Mechanical Architecture:  The Card Packaging System is constructed using a two piece powder-coated steel weldment. 

Motion: 

Case Erecting and filling:  1x UR5e 6 Axis collaborative robot with custom End-of-Arm tooling. 

Sensors:  Through beam, ultrasonic, proximity capacitive. 

Vision:  none

Safety:  System is intrinsically safe due to the use of the collaborative robot.     

Primary Challenges and Solutions:

1. Case Erecting:  The desired “unattended time” for the system necessitated that maximum use was made of the robot’s reach for magazine capacity. 

Solution:  A custom End-of-Arm tool and simple horizontal magazine were used to allow the maximum number of cases to be stored in the system. 

2. Product Variability:  The product displayed a high degree of variability in entrapped air (“puffiness”).    This caused the end-of-arm tool to misalign with the product, resulting in dropped or improperly placed product. 

Solution:  A custom docking geometry was developed to enable more precise force feedback on the UR robot.  This helped ensure that the End-of-Arm tool was always firmly engaged on the product prior to lift/placement.