The following is a detailed design plan:
Application scenario analysis
Production line loading and unloading: grab the TV from the conveyor belt/tray and place it on the assembly station or packaging line.
Warehouse automation: move the TV from the shelf or AGV to the inspection/packaging area.
Compatibility requirements: need to adapt to different sizes (such as 55~85 inches), weights (15~50kg) and packaging forms (bare machine/with box).
Core design of the robot
End effector (gripper)
Vacuum suction cup group (preferred solution):
Suction cup material: silicone (oil-resistant, non-slip) or polyurethane (high elasticity, suitable for rough packaging box surface).
Layout design: adjustable spacing suction cup array (for example, 6~8 suction cups), width adjustment through slide rails or cylinders, to adapt to different TV sizes.
Safety redundancy: Each suction cup has an independent vacuum sensor. When any suction cup fails, an alarm will be triggered and the action will be suspended.
Auxiliary mechanism (optional):
Lateral clamping arm: a clamping claw wrapped in soft rubber, which gently clamps and fixes the TV from both sides (used for bare machine handling to prevent tilting).
Flipping mechanism: a suction cup group with a rotating axis, which enables the TV to flip 90° (used for quality inspection or double-sided packaging).
Typical workflow (taking the production line as an example)
Loading:
The visual system identifies the position of the TV on the conveyor belt → the robot adjusts the suction cup spacing → vacuum suction grabs → lifts and moves to the assembly station → slowly releases.
Unloading:
Grab the TV from the inspection station → rotate 180° (if the reverse side needs to be packaged) → place it in a packaging box or pallet, and the suction cup is depressurized and detached.
Cost and efficiency optimization
Takt time: After optimizing the path planning, a single loading and unloading cycle can be controlled within 10~15 seconds (efficiency is about 240~360 units/hour).
Low-cost solution:
Replace electric vacuum generator with pneumatic suction cups (suitable for small and medium loads).
Use teach-in programming instead of vision system (suitable for fixed stations).
