Separating Full and Half-Size Boxes via Speed Variation
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Solution Overview
Problem
Current methods for separating full-sized and half-sized foldable plastic boxes from a mixed stack are inefficient, requiring large space and low performance, often relying on faulty machine-readable markings or sensors, and lack the ability to accurately recognize and separate box sizes during processing.
Innovation Solution
A device with a single removal station and transfer and deflection system using laterally gripping conveyor belts to recognize and separate full and half-size boxes, utilizing speed changes and sensors like light barriers or cameras to accurately position boxes for separate stacking, with vertically pivotable conveyor belts for efficient space use.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Extent of automation
If machine-readable markings or sensors are used to detect crate sizes, then automatic separation is enabled, but detection accuracy deteriorates due to wear or loss of markings
Solution Approach 1:
The patent replaces the optical/electronic detection system (sensors reading machine-readable markings) with a mechanical detection system. The conveying element has a first conveying speed for full-size crates and a second conveying speed for half-size crates, allowing size-based separation through mechanical speed variation rather than optical detection. This eliminates reliance on wear-prone markings.
Solution Approach 2:
The patent changes the conveying speed parameter dynamically based on crate size. The conveying element switches between a first conveying speed and a second conveying speed, creating different time intervals between successive crates of different sizes. This parameter change enables reliable size differentiation without depending on the condition of machine-readable markings.
2Extent of automation
If systems with sensors or machine-readable marking detection are used, then automatic identification is achieved, but system complexity increases
Solution Approach 1:
The patent simplifies the system by replacing complex optical sensors and machine-readable marking systems with a mechanical conveying speed variation system. The control unit simply manages speed changes of the conveying element, eliminating the need for complex detection infrastructure while maintaining automatic identification capability.
3Manufacturing precision
If separate stacking systems for full-size and half-size crates are implemented, then stacking precision is improved, but space requirement increases
Solution Approach 1:
The patent combines the detection, separation, and stacking functions into a single integrated system. The conveying element serves both as the transport mechanism and the separation mechanism through speed variation, and the single stacking device receives both crate types. This merging eliminates the need for separate detection systems and multiple stacking devices, reducing space requirements while maintaining stacking precision.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
Enables high-performance, reliable, and space-efficient separation and stacking of full and half-size boxes, ensuring accurate size recognition and direct transfer to specific processing machines, reducing manual intervention and maintenance.
Implementation Method 1
The distance between two crates of half size can be measured in different ways immediately after the two conveyor belts, e.g. by means of a light barrier
Data Source
Figure 1A~1E
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AI summary
Device for separately stacking full-size (2x) and half-size (2y) collapsible boxes, comprising a pair of removal conveyors (3) for removing the full-size (2x) and half-size (2y) collapsible boxes from the top of a single stack, the pair of removal conveyors being pivotably mounted (3a) to grasp the boxes (2x, 2y) and lift them vertically from the top of the stack (3v), and further comprising a transfer and deflection device (C) and a light barrier (4), a color recognition sensor or a camera, wherein the boxes (2x, 2y) grasped between the removal conveyors (3) are moved (2a) from the removal conveyors (3) towards the transfer and deflection device (C) after being lifted (3v), the device being configured such thatthat the movement (2a) takes place at a first speed (V1) for a time (t1) which is required to cover a distance equal to or slightly greater than the short side of a half-size box (2y), followed by a movement at a speed (V2) which is lower than the first (V1) to cover a distance which is slightly greater than the short side of a half-size box (2y), which, due to the difference in transport speed, causes a gap between the two boxes (2y) during the transfer to the transfer and deflection device (C), which is detected by means of the light barrier (4), by means of a color recognition sensor or by means of a camera, which control the transfer and deflection device (C) for the movement (5a) of the boxes (2x, 2y) to the specific stacking devices or the specific processing machines.