Bar Feed Transfer Layout for Fast Format Changeovers
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Solution Overview
Problem
Existing systems for feeding bars to user machines, such as bending and welding machines, are inefficient and require complex robotic pick-up devices or roller transport systems, which are costly, non-versatile, and prone to machine downtimes during format changes.
Innovation Solution
An automated apparatus comprising a support plane, a bar feed zone, a transfer device, and containing and translation units, which allows for the efficient movement and storage of bars of varying diameters and lengths, enabling quick and orderly feeding to user machines while minimizing operator intervention and reducing machine downtimes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If robotic automated pick-up devices are used to feed bars, then bars can be picked up and delivered to the feed station, but the system becomes very complex in design, has high costs, and requires demanding technical management
Solution Approach 1:
The patent replaces complex robotic gripping mechanisms with a simplified mechanical system consisting of a bridge crane, roller transport device, and feed station. Instead of using robotic arms with sophisticated gripping means, the invention uses a crane to lower bars onto a roller conveyor that automatically transports them to the feed station, eliminating the need for complex automated gripping and positioning mechanisms.
Solution Approach 2:
The patent extracts the gripping function from the feed station system and relocates it to the bar storage and loading area. The bridge crane handles the picking up and positioning of bars at the storage location, while the feed station focuses solely on receiving and feeding bars, thereby simplifying the feed station design and reducing overall system complexity.
2Ease of manufacture
If roller transport devices are used to supply bars, then bars can be transported to the feed station, but the devices are not very versatile for changing the format of the bars and must be fed by a bridge crane or automated pick-up device
Solution Approach 1:
The patent creates a versatile system where the bridge crane serves multiple functions: it can pick up bars of different formats from various storage locations, position them accurately on the roller transport device, and adapt to different bar types (different lengths, diameters, and weights). The roller transport device itself is designed to accommodate various bar formats through adjustable roller spacing and configurable transport paths, allowing the same equipment to handle diverse bar specifications without requiring format-specific machinery.
3Manufacturing precision
If dedicated structures and operators are used to transfer bars from warehouse to feed surface, then bars can be positioned correctly, but the procedure becomes extremely complex and causes machine downtimes during bar type changes
Solution Approach 1:
The patent implements preliminary positioning and organization of bars at the storage area before they are needed at the feed station. Bars are pre-grouped by type and kept ready on the roller transport device or in accessible storage locations. When a format change is required, the bridge crane can quickly switch between pre-prepared bar groups without requiring complex repositioning operations at the feed station, thereby minimizing machine downtime while maintaining positioning accuracy.
4Quantity of substance
If bridge crane is used to feed bars, then bars can be supplied to the feed station, but the system requires human operators to guide and position bars, increasing operational complexity and safety risks
Solution Approach 1:
The patent designs the system so that the bridge crane operator works from a centralized control position and simply releases bars onto the roller transport device at predetermined locations. The roller transport device then automatically takes over, conveying bars to the feed station without requiring operator intervention. The system self-regulates the bar feeding process through automated sensors and control mechanisms that monitor bar presence, positioning, and feed rate, minimizing the operator's role to oversight and exception handling only.
Data Source
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AI summary
Apparatus to feed bars (B) to one or more user machines located downstream, said apparatus comprising a support plane (11), a bar feed zone (12) located in proximity to one bar supply end (13) of said support plane (11), wherein said support plane (11) comprises a unit (14) to move said bars (B) in a direction of movement (Z) from and toward said bar feed zone (12).