Automated Flat Unloading System for Berry Harvesting
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Solution Overview
Problem
The manual handling and unloading of soft and fragile produce, such as berries, from flats is labor-intensive and leads to frequent worker injuries due to repetitive lifting, bending, and turning, resulting in decreased productivity and increased labor costs.
Innovation Solution
A mechanized system that uses a load frame, infeed conveyor, and stack lifter to move and unload entire stacks of flats automatically, employing cradle forks, lifting belts, dumper arms, and ejector arms to handle and dump the produce without operator intervention, allowing for continuous flow and reduced manual labor.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If manual handling of flats is used, then labor flexibility is maintained, but worker injuries increase and productivity decreases
Solution Approach 1:
The system enables self-service automation where the mechanical handler independently performs all operations of picking, placing, and stacking flats without human intervention. The handler autonomously navigates, grasps flats, positions them on conveyors, and stacks them, eliminating the need for manual labor while maintaining continuous operation.
Solution Approach 2:
The patent replaces the manual mechanical system with an automated mechanical handler system. The handler uses mechanical arms, grippers, and conveyors to perform tasks previously done by human workers, substituting human physical labor with automated mechanical components that can operate continuously without injury.
2Productivity
If automated handling system is implemented, then productivity increases, but device complexity increases
Solution Approach 1:
The mechanical handler is designed as a universal system that can handle multiple types of flats and perform various operations including picking, placing, stacking, and sorting. The same basic mechanism can adapt to different container types and production line configurations, reducing the need for multiple specialized devices.
Solution Approach 2:
The automated system is divided into separate functional modules: a picking station, a placing station, a stacking mechanism, and control systems. Each module performs a specific function and can be independently maintained or adjusted, reducing overall system complexity through modular design.
3Ease of manufacture
If manual lifting and turning of flats is required, then equipment cost is reduced, but labor strain increases
Solution Approach 1:
The handler system performs all physically demanding tasks autonomously, including lifting, turning, and positioning flats. The system serves itself by automatically navigating to pickup locations, grasping flats, rotating them as needed, and placing them in designated positions without requiring human physical effort.
Solution Approach 2:
The mechanical handler acts as an intermediary between the flats and the production line, absorbing all the physical strain of handling operations. Instead of workers directly manipulating flats, the handler mediates by using mechanical grippers, conveyors, and positioning mechanisms to transfer and orient flats.
Data Source
AI summary
A produce loading and unloading device and system. The device and system has structures for lifting an entire stack of flats loaded with produce such as berries, moving the stack of flats to a conveyor, and dumping the produce off each flat of the stack, one flat at a time. During the process, the operator of the device doesn't have to lift a single flat of produce. The dumping operation operates continuously, with no pauses to load stacks of flats. Throughput and safety are greatly improved.