Automatic Conversion Station Tray Transfer Mechanism

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Solution Overview

Problem

In warehouse environments, manual handling of items from one tray to another is laborious and time-consuming, especially when dealing with smaller items that can slip or cause tray damage due to lack of structural integrity, necessitating an automated solution for efficient transfer.

Innovation Solution

An automated conversion station with a conversion assembly comprising a paddle assembly, a first tine assembly, and a second tine assembly, where the first tine assembly facilitates item transfer from a first tray to the paddle assembly, and the second tine assembly moves the empty first tray to a second conveyor while the item remains on the paddle assembly, allowing for orientation adjustments and secure transfer without human intervention.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If manual handling is used to transfer items from one tray to another, then flexibility and simplicity are maintained, but labor intensity increases and processing efficiency decreases

Engineering Contradiction:

Improveprocessing efficiencyVSAvoidmanual handling requirement

Core Design Contradiction:

ProductivityVSExtent of automation

Solution Approach 1:

The conversion station performs automatic tray-to-tray transfer without human intervention. The system uses self-contained mechanisms including rotating shafts with tines, paddle assemblies, and clamping devices that automatically grasp items, rotate trays, and complete the transfer operation independently, eliminating the need for manual handling while maintaining continuous operation

Inventive Principle:

Principle #25Self-service

Solution Approach 2:

Manual mechanical handling is replaced with an automated mechanical system comprising electric motors, rotating shafts, and controlled movement mechanisms. The system substitutes human-operated manual transfer with motor-driven rotation of trays and automated positioning mechanisms that complete the transfer operation through controlled mechanical motion

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

2Reliability

If smaller items are handled manually, then direct control is possible, but items may slip or cause tray damage due to lack of structural integrity

Engineering Contradiction:

Improveitem transfer safetyVSAvoidhandling difficulty

Core Design Contradiction:

ReliabilityVSEase of operation

Solution Approach 1:

The conversion station introduces intermediary mechanisms including clamping devices and controlled rotation systems that mediate the transfer of small items. These intermediaries provide stable grasping and controlled movement, preventing items from slipping or causing tray damage by distributing forces evenly throughout the transfer process

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

The system employs dynamic control mechanisms that adjust rotation speeds, clamping forces, and movement sequences to match the specific requirements of different item sizes and tray configurations. This dynamic adjustment ensures reliable handling of small items while preventing damage to trays with varying structural integrity

Inventive Principle:

Principle #15Dynamics

3Manufacturing precision

If tray orientation adjustments are made during transfer, then proper positioning is achieved, but device complexity increases

Engineering Contradiction:

Improvetray positioning accuracyVSAvoidconversion assembly complexity

Core Design Contradiction:

Manufacturing precisionVSDevice complexity

Solution Approach 1:

The conversion station merges multiple functions into integrated components. The rotating shaft assembly combines item grasping, tray rotation, and positioning functions in a single mechanism. The paddle assembly integrates support, transfer, and orientation adjustment capabilities, reducing the number of separate components needed while achieving precise tray positioning

Inventive Principle:

Principle #5Merging (Combining)

Data Source

PatentUS20210101759A1Automatic conversion station

Publication Date: 2021.04.08 INTELLIGRATED HEADQUARTERS LLC

AI summary

A conversion assembly for transferring an item from a first tray to a second tray. The conversion assembly includes a paddle assembly, a first tine assembly comprising one or more tines coupled to a first rotating shaft, and a second tine assembly comprising one or more tines coupled to a second rotating shaft. The first tine assembly is configured to facilitate emptying the item from the first tray onto the paddle assembly and the second tine assembly is configured to facilitate moving the first tray to a second conveyor while the item remains on the paddle assembly. The first tine assembly alters an orientation of the second tray to a position to receive the item from the paddle assembly, and wherein the paddle assembly is configured to move the second tray and the item back onto a first conveyor.