Cam-Actuated Tote Accumulator Latch for Pneumatic-Free Stacking

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Solution Overview

Problem

Existing tote stacking and unstacking systems rely on pneumatic cylinders, which require compressed air and are prone to imprecision due to friction and wear, leading to challenges in efficiently managing the accumulation and distribution of empty totes in material handling operations.

Innovation Solution

A cam-actuated stack retaining latch system with a holding mechanism and follower mechanism, utilizing electromagnets for precise control, allows for high-precision stacking and unstacking operations without the need for compressed air, ensuring reliable engagement and disengagement of totes.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If pneumatic cylinders are used for tote stacking and unstacking, then the system can perform stacking operations, but the system requires compressed air and is prone to imprecision due to friction and wear

Engineering Contradiction:

Improveprecision of stacking operationVSAvoidrequirement for compressed air system

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The patent replaces the pneumatic cylinder system with an electromechanical system consisting of an electric motor, cam mechanism, and latch. The motor rotates the cam, which through its profile, precisely controls the timing and position of latch engagement and disengagement, eliminating the need for compressed air while improving positioning precision through controlled rotational motion

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The invention extracts and eliminates the pneumatic system (compressed air requirement) from the stacking mechanism, retaining only the essential mechanical functions through an electromechanical alternative that uses electrical power and mechanical linkages to achieve the same stacking and unstacking operations

Inventive Principle:

Principle #2Taking out (Extraction)

2Manufacturing precision

If pneumatic cylinders are used for tote stacking and unstacking, then the system can perform stacking operations, but the system is prone to imprecision due to friction and wear

Engineering Contradiction:

Improveprecision of latch engagementVSAvoidconsistency of operation

Core Design Contradiction:

Manufacturing precisionVSReliability

Solution Approach 1:

The patent replaces the pneumatic cylinder with an electromechanical system where an electric motor provides controlled rotational motion to a cam. The cam's precisely engineered profile ensures consistent and accurate latch engagement timing, eliminating the friction and wear issues associated with pneumatic systems while maintaining high precision through controlled mechanical motion

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The cam mechanism is designed with a specific profile that preliminarily positions the latch at the correct engagement point before actual contact with the tote occurs. This preliminary positioning ensures that the latch engages at the precise moment and location required, improving manufacturing precision through pre-planned motion sequencing

Inventive Principle:

Principle #10Preliminary action

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 efficient and precise control over tote stacking and unstacking, eliminating the need for compressed air and improving reliability, resulting in a more efficient and cost-effective material handling system.

Implementation Method 1

a cam and a respective follower arranged on each of the first and second sides and configured such that, upon lowering of the lifting member by a first distance after the disengagement of the latches, each cam interacts with the respective follower to act on the first and second latches

Methodology Applied

Scientific EffectCam mechanism: Cam

Implementation Method 2

a lifting member configured to engage with a bottom of the lowermost tote and raise the stack of totes to disengage the first and second latches from the lowermost tote

Methodology Applied

Scientific EffectMechanical force: Mechanical Force

Implementation Method 3

each latch interlocks with a mating feature on the next tote, whereby the lowermost tote is separated from the stack of totes

Methodology Applied

Scientific EffectMechanical interlocking: Mechanical Fastener

Data Source

PatentUS11479420B2Automatic tote accumulator with cam-actuated stack retaining latch

Publication Date: 2022.10.25 KORBER SUPPLY CHAIN LLC

AI summary

A tote accumulator includes stack retaining latches that are configured to be acted on by a cam and follower mechanism and additionally by a holding mechanism. The cam and follower mechanism is configured to act on the stack retaining latches when the stack of totes is moved vertically by a lifting member, to move the stack retaining latches into an active dwell wherein the stack retaining latches are engaged with the stack of totes. The holding mechanism is configured to be activated to extend the active dwell after the cam and follower mechanism ceases to act on the stack retaining latches. The active dwell is extended even further by a mechanical interlocking feature between the latches and the totes. In various implementations, the design of the cam and follower arrangement and the activation timing of the holding mechanism may be adapted to execute a stacking or an unstacking operation.