Case Manipulator Swing Plate Paddle Arm Orientation Control
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Solution Overview
Problem
Palletizing systems face inefficiencies due to the frequent mishandling of boxes delivered in incorrect orientations, leading to production slowdowns and safety concerns, as existing systems struggle to ensure accurate and precise positioning of cases according to pre-determined patterns.
Innovation Solution
A case manipulator apparatus that receives cases from an infeed conveyor, manipulates them to the correct orientation, and positions them on a row build platform according to a pre-determined build menu, allowing for sequential operation to form complete rows without operator intervention, utilizing a swing plate and paddle arm mechanism controlled by a microprocessor.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If cases are delivered to the palletizer without orientation verification, then the palletizing operation can proceed quickly, but cases may be positioned in incorrect orientations causing production slowdowns and safety issues
Solution Approach 1:
The system performs preliminary verification of case orientation on the infeed conveyor before cases reach the palletizing position. Sensors detect case orientation early in the process, allowing the system to prepare for corrective actions (rotation or rejection) before the case needs to be positioned, thus preventing production slowdowns while maintaining accuracy
Solution Approach 2:
The system uses sensors to continuously monitor case orientation on the infeed conveyor and provides feedback to the control system. This real-time feedback enables the system to identify incorrectly oriented cases and trigger appropriate corrective actions, ensuring both high throughput and accurate orientation positioning
2Manufacturing precision
If operator intervention is used to correct case orientation, then cases can be manually positioned correctly, but production efficiency decreases and safety concerns arise
Solution Approach 1:
The system automatically detects incorrectly oriented cases using sensors and performs corrective actions through automated mechanisms (rotation devices or rejection systems). The palletizer self-corrects orientation issues without requiring operator intervention, maintaining both high precision and productivity while eliminating safety concerns associated with manual handling
3Productivity
If cases are positioned without precise spacing control, then the palletizing operation is faster, but the stack stability and pattern accuracy are compromised
Solution Approach 1:
The system pre-calculates the required spacing and positioning for each case based on the predetermined pattern and box dimensions. Before cases are positioned, the control system prepares the row build conveyor and layer head with the correct spacing parameters, enabling fast automated positioning that maintains precise spacing accuracy
Solution Approach 2:
The system replaces manual measurement and positioning mechanisms with automated sensor-based detection and computer-controlled positioning. Sensors measure case positions and dimensions, and the control system automatically adjusts spacing and positioning, achieving both high speed and precise spacing control without mechanical measurement steps
Data Source
AI summary
A case manipulator receives cases from an infeed conveyer and manipulates individual cases or groups of cases and transfers the manipulated cases to a row accumulator platform in a desired and pre-determined orientation and positioned on the accumulator platform to a desired and pre-determined location. The manipulation of individual cases, or groups of cases, is continued in a sequential operation until a complete row is formed on the accumulator platform according to a pre-determined build menu. The case manipulator includes a swing plate pivotal on a first axis and a paddle arm that is attached to the swing plate and pivotal on a second axis that is transverse to the first axis. The invention allows the palletizer to have the next case in a row transferred from the infeed conveyer to the row-build staging area while the case manipulator is operating on an already-delivered case.