Board Positioner for Pallet Assembly Speed
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Solution Overview
Problem
Current pallet manufacturing methods lack efficiency and reliability in assembly speed, leading to increased production costs due to suboptimal handling and fastening processes.
Innovation Solution
A board positioning system (BPS) that includes a hopper and a movable positioner to align and fasten boards to a pallet, with sensors and controllers monitoring positional movement conditions to ensure precise and efficient board placement and fastening, allowing boards to be advanced and positioned while the positioner is in motion.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If traditional board handling and fastening processes are used in pallet manufacturing, then the assembly process is simpler, but the assembly speed and manufacturing uptime are reduced
Solution Approach 1:
The board is advanced to the queue position in advance while the positioner is in motion, before the positioner engages with the board. This preliminary positioning action enables continuous operation without waiting for the positioner to return, thereby increasing assembly speed while managing system complexity through coordinated timing
Solution Approach 2:
The hopper continues to advance boards to the queue position during the entire cycle, including while the positioner is moving and while fastening is occurring. This continuous supply of boards eliminates idle time and maintains manufacturing uptime, improving productivity without requiring additional complex components
2Productivity
If boards are advanced while the positioner is in motion, then assembly speed is improved, but the reliability of board placement may be compromised
Solution Approach 1:
Sensors monitor the positional movement condition of the board during advancement and provide feedback to the controller. The controller uses this feedback to determine when the board has reached the queue position and is ready for engagement, ensuring reliable placement even while the positioner is in motion. This feedback mechanism maintains reliability while enabling continuous high-speed operation
Solution Approach 2:
The system dynamically coordinates the motion of the positioner with the advancement of boards from the hopper. The timing and speed of board advancement are adjusted based on the positioner's motion state, allowing the system to maintain reliability through adaptive control while achieving improved assembly speed through continuous operation
Data Source
AI summary
Automated assembly of a pallet includes advancement of a subject board from a source location to a queue position. The subject board is moved from the queue position to a fastening position by a positioner. Advancement of the subject board occurs while the positioner is in motion between the queue position and the fastening position.