Integrated Bundle Lifter for Automated Metal Sheet Stacking
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Solution Overview
Problem
The existing process of building metal sheet bundles is cumbersome, unsafe, and inefficient, requiring manual intervention and occupying double the floor space with separate bundle builder and lifter machines, which affects productivity and safety.
Innovation Solution
An integrated bundle builder and lifter system that automates the creation of metal sheet bundles with spacers using a roller conveyor and lifting arms, combining the functions of building and lifting into a single unit, utilizing AC motors and screw jacks for actuation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If separate bundle builder and lifter machines are used, then the bundle building and lifting functions are provided, but the floor space requirement doubles
Solution Approach 1:
The patent combines the bundle builder and lifter functions into a single integrated machine. The builder assembly stacks packs into bundles while the lifter assembly simultaneously or sequentially lifts completed bundles onto the overhead crane lifter, eliminating the need for separate discrete machines and reducing floor space requirements.
Solution Approach 2:
The integrated machine performs multiple functions: the builder assembly creates bundles by stacking packs with dunnage insertion, while the lifter assembly lifts completed bundles. This multi-functional design allows one machine to replace what previously required two separate machines, addressing the floor space constraint.
2Device complexity
If manual dunnage insertion is used, then the bundle building process is simpler, but the process becomes cumbersome and unsafe
Solution Approach 1:
The system uses automated mechanisms for dunnage insertion and pack stacking. The builder assembly automatically positions and inserts dunnage between packs without operator intervention, and the stacking process is mechanically controlled, making the system self-sufficient and eliminating unsafe manual operations.
Solution Approach 2:
The patent replaces manual mechanical operations with automated mechanical systems. The dunnage insertion is performed by automated positioning mechanisms, and the stacking is controlled by the builder assembly, eliminating the need for operators to reach inside the machine and improving safety.
3Productivity
If manual bundle building is used, then the equipment requirement is lower, but the productivity and efficiency decrease
Solution Approach 1:
The integrated machine enables continuous operation with the roller conveyor system that continuously feeds packs to the builder assembly. The automated stacking and lifting operations proceed without interruption, maintaining continuous productive action rather than manual batch processing.
Solution Approach 2:
The automated builder and lifter assemblies perform bundle creation and lifting without manual intervention. The system self-manages the complex tasks of dunnage insertion, pack stacking, and bundle lifting, achieving high productivity through automation rather than manual labor.
4Extent of automation
If individual packs are discharged for automated packaging, then the packaging process can be automated, but the crane must handle every single pack which reduces efficiency
Solution Approach 1:
The builder assembly performs preliminary bundling of multiple packs into larger bundles before discharge. By pre-assembling bundles, the system reduces the number of individual items the crane must handle, improving crane efficiency while maintaining automated packaging capability.
Solution Approach 2:
The system transitions from handling individual packs (one-dimensional) to handling bundled packs (multi-dimensional aggregation). By stacking multiple packs vertically into bundles, the system changes the dimensional organization of material, reducing the total number of handling operations required.
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
Enhances productivity, efficiency, and safety by automating the bundle creation and lifting process, reducing manual labor and space requirements, and improving overall throughput.
Implementation Method 1
a roller conveyor assembly positioned above the lift arms and cross beams; wherein a stack of material is moved on the rollers of the conveyor assembly
Implementation Method 2
a stack of material is moved on the rollers of the conveyor assembly
Implementation Method 3
actuator assemblies for actuating the builder and lifter assembly
Implementation Method 4
the lift arms each has a vertical portion and a horizontal portion forming a finger
Implementation Method 5
actuator assemblies for actuating the builder and lifter assembly
Data Source
AI summary
A bundle builder and lifter assembly has a pair of parallel cross beams, and an actuator assembly for actuating the builder and lifter assembly. A pair of lift arms are moved along the parallel cross beams and each has a vertical portion and a horizontal portion forming a finger. The lift arms are also raised and lowered. A conveyor roller assembly is positioned above the lift arms and cross beams, where stacks of material are moved on the rollers of the conveyor assembly. The stacks of material are placed in a stack by the lift arms forming a bundle, which is then removed from the conveyor roller assembly.