Automated Container Lifting Assembly for Tray Separation

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Solution Overview

Problem

Existing automated object processing systems face challenges in efficiently and automatically managing the use of trays for boxes, particularly due to the need for manual labor to remove boxes from trays, which can be heavy, improperly closed, and lack graspable features.

Innovation Solution

A container assembly processing system that includes a container lifting assembly for lifting containers vertically from carriers on a conveyor system, allowing for automated separation and reassembly of container assemblies, including carriers, containers, and collars.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If manual labor is used to remove containers from carriers, then flexibility and adaptability are maintained, but productivity decreases and labor costs increase

Engineering Contradiction:

Improveprocessing efficiencyVSAvoidautomation level

Core Design Contradiction:

ProductivityVSExtent of automation

Solution Approach 1:

The container's own structural features (flaps, edges, or surfaces) are utilized by the lifting mechanism to automatically lift and separate the container from the carrier, eliminating the need for external manual intervention while maintaining system simplicity

Inventive Principle:

Principle #25Self-service

Solution Approach 2:

Manual mechanical operations are replaced with an automated lifting mechanism that uses vertical lifting motion to separate containers from carriers, enabling continuous automated processing without manual labor

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

2Reliability

If containers are made heavy-duty and secure, then reliability and containment improve, but ease of operation deteriorates due to weight and lack of graspable features

Engineering Contradiction:

Improvecontainer securityVSAvoidhandling difficulty

Core Design Contradiction:

ReliabilityVSEase of operation

Solution Approach 1:

The lifting mechanism acts as an intermediary between the container and the external environment, providing a grasping interface that interacts with specific container features (flaps, edges, or surfaces) to enable automated handling without requiring manual grasping of the container itself

Inventive Principle:

Principle #24Intermediary (Mediator)

3Stability of the object's composition

If containers are tightly secured on carriers, then stability during transport improves, but ease of operation worsens due to difficulty in separation

Engineering Contradiction:

Improvecontainer-carrier stabilityVSAvoidseparation difficulty

Core Design Contradiction:

Stability of the object's compositionVSEase of operation

Solution Approach 1:

The separation process is achieved through vertical segmentation - the lifting mechanism applies upward force to the container while the carrier remains stationary or moves horizontally, creating a clear separation plane that divides the container-carrier system into independent components

Inventive Principle:

Principle #1Segmentation

Data Source

PatentUS12297000B2Automated processing of container assembly systems and methods

Publication Date: 2025.05.13 BERKSHIRE GREY OPERATING CO INC

AI summary

A container assembly processing system is disclosed that includes a container lifting assembly for lifting a container vertically from a carrier on a conveyor system.