Article Sorting and Nesting Device Using Gravity Rack
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Solution Overview
Problem
Existing article nesting machines, such as the Cameron Flooring Nester, occupy large floor space and face challenges in reliably scooping and un-scooping boards, leading to inefficiencies in the nesting process.
Innovation Solution
A compact article sorting and nesting device with a rack assembly and sensor system that successively supplies and collects articles based on detected length, width, and color, using a controller to efficiently arrange boards into rows and layers, reducing the need for multiple scoops and optimizing space usage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Extent of automation
If a chain conveyor with multiple scoops is used to sort and nest boards, then the nesting process can be automated, but the machine occupies a large amount of floor space
Solution Approach 1:
The patent transitions from a horizontal chain conveyor layout to a vertical rack assembly layout. Boards are fed vertically through the rack structure, utilizing the vertical dimension for board storage and manipulation. This dimensional change allows the same nesting functionality to be achieved in a more compact horizontal footprint, directly resolving the contradiction between automation and floor space occupation.
2Extent of automation
If multiple scoops are used to collect and arrange boards, then automated row formation is achieved, but the scooping and un-scooping process becomes difficult to reliably achieve
Solution Approach 1:
The patent extracts the scooping mechanism entirely from the system, replacing it with a gate-based board release system. Individual boards are retained on rack shelves by gates and released one at a time through controlled gate opening. This eliminates the complex scooping and un-scooping operations that caused reliability issues, while maintaining automated row formation through controlled board dispensing.
Solution Approach 2:
The patent replaces the mechanical scooping system with a simpler gate-based retention and release system. Instead of using scoops to lift and transfer boards, the system uses gravity-fed board delivery with gates that control board release timing. This mechanical substitution reduces complexity and improves reliability while achieving the same automated sorting and nesting function.
3Adaptability or versatility
If hand nesting is used to create bundles, then flexibility in board selection is maintained, but labor intensity and time consumption increase
Solution Approach 1:
The patent implements a system where the machine automatically performs board selection and nesting operations based on programmed parameters. The controller automatically determines which boards to select from the rack, opens the appropriate gates, and assembles rows and bundles according to specified length requirements. This self-service automation maintains flexibility in board selection through programmable logic while dramatically increasing nesting speed and productivity.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The device achieves a more compact and efficient nesting process by minimizing space requirements and improving the reliability of board selection and arrangement, enhancing the overall efficiency of the bundling operation.
Implementation Method 1
laser time-of-flight distance sensors
Data Source
AI summary
An article sorting nesting device includes an article delivery device, a rack assembly and a collection device under operation by a controller to transport, sort and nest random articles into a particular configuration. The rack assembly is arranged at an angle and incrementally displaced relative to the delivery device to position empty shelves adjacent the delivery device to successively receive the articles by gravity. The controller controls which articles from the shelves are delivered in sequence to a collection device based on a sensed length, width or color of each article. The collection device collects the selected sequential articles and arranges them in the particular configuration.