Automated De-stacking System for Refrigerated Environments
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Current material handling systems lack an efficient and automated method for de-stacking individual containers from a nested stack, often requiring manual intervention and being unsuitable for refrigerated environments.
Innovation Solution
An automated de-stacking system comprising a robotic assembly with grabber assemblies, a powered lift, and a conveyor, controlled by a programmable logic controller, which selectively grasps and releases containers, allowing for precise manipulation and operation in refrigerated conditions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If manual intervention is used to de-stack containers, then the system is simpler and easier to operate, but productivity is low and labor intensity is high
Solution Approach 1:
The system uses sensors to automatically detect container presence and position, eliminating the need for manual observation and intervention. The robotic assembly autonomously performs de-stacking operations based on sensor input, achieving self-service operation that increases productivity without proportional increases in complexity
Solution Approach 2:
Manual mechanical operations are replaced with an automated robotic assembly that uses programmable logic controllers and servo mechanisms. This substitution transforms labor-intensive manual work into an automated system that handles container manipulation, significantly improving productivity while keeping the control system manageable through modular design
2Productivity
If automated systems are used for de-stacking, then productivity increases and labor is reduced, but the system complexity increases and operation becomes more difficult
Solution Approach 1:
Sensors provide continuous feedback about container position and presence to the control system. This feedback mechanism allows the automated system to self-regulate and adjust operations automatically, making the system easier to operate as it requires minimal human intervention for monitoring or adjustment while maintaining high productivity
Solution Approach 2:
The robotic assembly is designed with universal capabilities to handle various container types and configurations through programmable operations. The same hardware system can perform multiple de-stacking tasks by changing control parameters, simplifying operation as workers only need to program once and the system handles all variations automatically
3Adaptability or versatility
If conventional material handling systems are used, then the device structure is simpler, but they cannot operate in refrigerated environments
Solution Approach 1:
The system employs sealed enclosures and protective coverings that create isolated environments for mechanical components. These flexible seals and protective films allow the robotic assembly to operate in refrigerated conditions by preventing moisture and temperature extremes from damaging electrical and mechanical parts, achieving environmental adaptability without requiring complete system redesign
Solution Approach 2:
Conventional mechanical systems unsuitable for refrigerated environments are replaced with automated robotic assemblies designed with temperature-resistant components. The substitution includes using sealed motors, protected sensors, and corrosion-resistant materials, which increases structural complexity slightly but enables operation in previously inaccessible refrigerated environments
Data Source
AI summary
An automated system for de-stacking a plurality of stacked objects, the automated system comprising a lift assembly and a grabber assembly. The lift assembly comprises a tower, and a number of electric motors. The tower is configured to rotate about a vertically-extending axis. One of the electric motors is configured to rotate the tower. Another one of the electric motors is configured to raise and lower the grabber assembly. The grabber assembly is configured to move with the tower as the tower rotates and comprises a claw and an electric motor. The claw is configured to grasp the objects individually. The electric motor of the grabber assembly is configured to actuate the claw. The first, second, and third electric motors are configured to operate in a refrigerated environment.