Automated Bin Handler for Rotary Sorters
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Solution Overview
Problem
Manual removal and replacement of bins in sorting units lead to substrate damage and decreased throughput due to potential overloading and delayed bin exchange in rotary sorters.
Innovation Solution
A bin handler with end effectors is integrated into the sorting unit to automate the removal and replacement of bins, allowing for continuous sorting by determining full bins and swapping them with empty ones using a controller-assisted system.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If manual bin removal and replacement is used, then device complexity is reduced, but substrate damage increases and throughput decreases
Solution Approach 1:
The bin handler system operates autonomously to detect full bins and perform exchanges without human intervention. The controller monitors bin fill levels and automatically activates the bin handler mechanism, allowing the system to service itself and eliminate substrate damage caused by manual handling delays
Solution Approach 2:
The patent replaces manual mechanical operations with an automated bin handler mechanism controlled by electronic sensors and controllers. This substitution eliminates the variability and delays inherent in manual bin handling, ensuring consistent and timely bin exchanges that prevent substrate damage
2Device complexity
If manual bin removal and replacement is used, then device complexity is reduced, but productivity decreases
Solution Approach 1:
The automated bin handler enables continuous sorting operations by eliminating downtime associated with manual bin exchanges. The system maintains continuous operation by automatically detecting full bins and replacing them with empty bins without halting the sorting process, thereby maximizing throughput
Solution Approach 2:
The system autonomously manages bin exchanges through integrated sensors and automated handling mechanisms, eliminating the need for operator intervention and associated downtime. This self-service capability ensures uninterrupted sorting operations and maximizes productivity
3Reliability
If automated bin handler is integrated, then substrate damage decreases, but device complexity increases
Solution Approach 1:
The bin handler mechanism serves multiple functions: detecting full bins, removing full bins, positioning empty bins, and loading empty bins. This multi-functionality consolidates what would otherwise require separate systems into a single integrated mechanism, reducing overall system complexity while maintaining substrate damage prevention
Solution Approach 2:
The controller acts as an intermediary that coordinates between sensors detecting bin fill levels and the bin handler mechanism. This centralized control simplifies the system architecture by providing a single point of coordination rather than requiring direct connections between multiple independent components
4Productivity
If automated bin handler is integrated, then productivity increases, but device complexity increases
Solution Approach 1:
The patent combines bin detection, bin removal, bin positioning, and bin loading functions into a single integrated bin handler system. This merging of functions achieves high productivity through automated continuous operation while reducing the complexity that would result from having separate systems for each function
Data Source
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AI summary
In one example, a sorting unit includes a sorting system and a plurality of bins into which substrates are sorted. The sorting unit includes a bin handler having a first end effector for receiving one bin of the plurality of bins, and second end effector for disposing an empty bin in the previous location of the received bin. In one example, a method of operating a sorting unit is also provided.