Adapter Pallet for Large Format Sheet Stacking
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Solution Overview
Problem
In the production of large stacks from large-format sheets, the stack receiving table cannot be moved vertically to the level of the feed plane due to structural limitations, such as feeder towers, preventing even stacking and causing sheets to buckle or jam.
Innovation Solution
An adapter pallet, significantly taller than conventional pallets, is used initially to bridge the vertical distance, allowing the stack receiving table to reach the feed level, with sensors and alignment devices ensuring precise positioning and separation of sheets for even stacking, before being replaced by a conventional pallet for continuous production.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If the stack receiving table is moved vertically to the level of the feed plane, then even stacking of sheets is achieved, but structural limitations (feeder towers) prevent the table from reaching the feed level
Solution Approach 1:
An adapter pallet with extended height is introduced as an intermediary element between the stack receiving table and the feed conveyor. This adapter pallet raises the stacking surface to match the feed level, enabling even stacking without requiring the receiving table itself to reach the feed plane. The adapter pallet acts as a mediator that compensates for the structural height limitation of the receiving table.
2Ease of manufacture
If a conventional pallet is used from the beginning, then device simplicity is maintained, but sheets buckle and jam due to insufficient vertical distance bridging
Solution Approach 1:
The adapter pallet is used preliminarily at the beginning of the stacking process to bridge the vertical gap and enable proper sheet stacking. Once the stacking process is established and the first stack is formed, the adapter pallet is removed and replaced with a conventional pallet for continuous production. This preliminary action allows the system to overcome the initial height mismatch problem.
3Manufacturing precision
If the adapter pallet is used initially, then even stacking is enabled, but additional device complexity is introduced
Solution Approach 1:
The adapter pallet is used temporarily only for the initial stacking operation and then discarded (removed and replaced with a conventional pallet). This approach minimizes the long-term device complexity by using the specialized adapter pallet only when necessary, rather than permanently incorporating it into the system.
Data Source
Figure 1~2
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Figure 5~6
AI summary
The invention relates to a method for producing large stacks of large-format sheets. In order to bridge a vertical distance between a feeding level of the sheets and a floor level, a stacking platform is designed as a stack-accommodating table (2) that can be moved vertically up and down. A pallet (10) is placed on the stack-accommodating table (2), on which pallet the sheets are stacked to formed stacks. The accommodating table is moved into an upper end position by means of a lifting device, and the sheets are continuously fed to the pallet. The stack-accommodating table is continuously lowered together with the pallet during the continuous feeding in order to ensure uniform stack formation. When the desired stack height is reached, the stack-changing device (11) moves between two sheets and completely separates said two sheets from each other. The subsequent stack is formed on the top side of the insertion bottom. The insertion bottom is continuously lowered, while the accommodating table moves into a lower end position of the accommodating table at the height of the floor region and the pallet is transported away together with the formed stack. Then the stack-accommodating table is moved to the height of the stack-changing device together with a new, empty pallet and the stack-changing device moves back into the initial position thereof horizontally and thus unloads the stack being formed onto the empty pallet. Thereafter the pallet, or rather the stack-accommodating table, is continuously lowered again until the desired stack height is reached and the stack-changing device moves between two sheets again in order to separate the stacks. The method is characterized in that an adapter pallet (1) is used once at the start of the continuous stack formation.