Bulk Container Discharge Station With Articulating Arms for Cleaner Loading
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Solution Overview
Problem
Existing bulk bag discharge stations using gantry cranes are bulky, hazardous, and prone to product contamination due to moving parts above the bag during loading, posing safety concerns and contamination risks.
Innovation Solution
A compact bulk container discharge apparatus with articulating arms, a yoke for maintaining container orientation, and synchronized linear drives to lift and empty containers while minimizing stress on the articulation drive, incorporating vibration to facilitate discharge and prevent contamination.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a gantry crane is used to load bulk bags onto the discharge platform, then loading speed and efficiency are improved, but device complexity and safety hazards increase due to bulky structure and moving parts positioned above the bulk bag
Solution Approach 1:
The system divides the loading function into two independent parts: (1) a simple robotic arm for precise bag manipulation and (2) a conveyor system for platform positioning. This segmentation eliminates the need for a complex gantry crane while maintaining high loading efficiency through coordinated operation of the simpler components.
Solution Approach 2:
The patent extracts the hazardous moving parts (gantry crane structure) from the loading system and replaces them with a stationary platform and a compact robotic arm. This removal of the bulky gantry structure eliminates safety hazards while preserving the core loading function through the robotic arm's precise movements.
2Productivity
If a gantry crane is used to load bulk bags, then loading efficiency is improved, but product contamination risk increases due to lubricants and metal grindings falling into the product
Solution Approach 1:
The patent removes the gantry crane structure that positions moving parts above the bulk bag, thereby eliminating the source of contamination (lubricants and metal grindings). The loading function is instead performed by a robotic arm that operates from the side, keeping all moving parts away from the product area.
Solution Approach 2:
The robotic arm serves as an intermediary tool that performs the loading function without requiring overhead moving parts. It manipulates the bulk bag from a safe distance and position, preventing contamination while maintaining loading efficiency through automated precise movements.
3Productivity
If a gantry crane is used for bulk bag loading, then loading capacity is improved, but safety hazards increase due to significant swaying of heavy bulk bags during suspension
Solution Approach 1:
The patent extracts the bulk bag from the gantry crane's suspension system, eliminating the swaying hazard. The robotic arm then handles the bag in a controlled manner from a stable position, maintaining loading capacity while removing the safety risks associated with suspended heavy loads.
Solution Approach 2:
The robotic arm is designed to autonomously handle the bulk bag without requiring suspension from overhead structures. It grasps and manipulates the bag directly, providing stable control throughout the loading process and eliminating the swaying problem inherent in crane-based suspension systems.
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
The solution provides a safe, efficient, and contamination-free discharge process by maintaining container orientation and synchronizing movements to minimize stress, ensuring safe and effective unloading of bulk containers.
Implementation Method 1
The vibrator can be configured to induce mechanical vibration in the platform to facilitate emptying of the bulk container
Implementation Method 2
The at least one articulating arm can be configured to lift a bulk container along a loading path (such as but not limited to an arcuate path) that is at least partially vertical from a lower position to an upper position
Implementation Method 3
The articulation drive is coupled to the base portion and to the at least one articulating arm. The articulation drive is configured to articulate the at least one articulating arm about the first pivot
Implementation Method 4
The yoke can be configured to maintain the bulk container in a level orientation while it is being lifted
Implementation Method 5
The linear drive can be configured to raise and lower the bulk container along a vertical direction after the articulating drive has articulated the at least one articulating arm to the upper position
Implementation Method 6
The vibration isolator can, for example, couple the platform to the base portion to limit vibration from the vibrator from traveling to the base portion
Data Source
AI summary
The disclosure provides a bulk container discharge apparatus and related methods. An illustrative, non-limiting example of such an apparatus includes a base portion, a platform disposed on the base portion, the platform being configured to support a bulk container, and at least one articulating arm. The at least one articulating arm can have a first portion that is pivotally coupled to the base portion at a first pivot. The at least one articulating arm can be configured to lift a bulk container along a loading path (such as but not limited to an arcuate path) that is at least partially vertical from a lower position to an upper position to place the bulk container over the platform when in the articulating arm is in the upper position to facilitate discharging the contents of the bulk container.