This paper details the design of a novel robotic system for performing automated container case packing operations. The system has unique design concepts that addressed many real problems generally encountered in bottle packing operations. The efficient automated operation is mainly achieved through the use of dual-arm concept for parallel tasking. While one arm is searching and picking up a group of bottles, the other arm orientates and loads the bottle(s) into the carton box container. The picking arm is equipped with a range sensor that allows a closed-loop system for compensating position errors of the bottles. Two types of grippers are designed for handling a wide range of bottle sizes and assembly layouts providing automation flexibility. In order to achieve a high degree of automation, the picking arm is incorporated with a layer separator removal module. As a result, no human intervention is required when one layer of bottles is finished in the bottle pallet. In the course of developing the system, robotic simulation technology is used for evaluating the design concepts as well as for determining the specifications of the actuators.
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