Corner Post Application System with Swing Arm
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Solution Overview
Problem
Existing systems for automatically placing corner posts on loads during enveloping processes, such as stretch wrapping or stretch hooding, face inefficiencies and increased costs due to complex motion requirements and limited adaptability to different load heights and sizes.
Innovation Solution
A corner post application system comprising a conveyor subsystem, an enveloping machine, a swing arm, an applicator arm, a corner post gripper, and a controller, which simplifies the motion of the corner post applicator, allows for easy adaptation to multiple corner post heights, and includes sensors for precise alignment and contact detection, enabling efficient and economical placement of corner posts within the space constraints of enveloping machines.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If traditional automatic corner post placement systems are used during stretch wrapping, then corner posts can be positioned on loads, but the system complexity and manufacturing costs increase due to complex motion requirements
Solution Approach 1:
The applicator mechanism is divided into separate functional components: a swing arm assembly for positioning, a linear actuator for approach motion, and a corner post holder for gripping. This segmentation allows each component to perform its specific function with simpler mechanics rather than requiring a single complex mechanism to handle all motions simultaneously.
Solution Approach 2:
The system employs a swing arm that can rotate to different angles to accommodate loads of varying sizes and heights. This dynamic adjustment capability allows the same applicator mechanism to adapt to different load configurations without requiring multiple fixed-position applicators or complex reconfiguration systems.
2Adaptability or versatility
If traditional corner post placement systems are used, then corner posts can be applied to loads, but adaptability to different load heights and sizes is limited
Solution Approach 1:
The swing arm can be rotated to different angular positions, and the linear actuator can extend to different lengths, allowing the corner post applicator to reach various load heights and sizes. This dynamic adjustability provides versatility across different load configurations without requiring multiple specialized applicators.
Solution Approach 2:
The applicator mechanism is designed as a universal system that can handle corner posts of different heights and apply them to loads of various sizes and configurations. The combination of swing arm rotation and linear actuation creates a multi-functional mechanism that replaces what would traditionally require multiple dedicated applicators.
3Manufacturing precision
If complex applicator mechanisms are used for precise corner post placement, then positioning accuracy is improved, but application time increases
Solution Approach 1:
The swing arm is pre-positioned at the appropriate angle based on the load dimensions, and the linear actuator is pre-set to the required extension length. This preliminary positioning ensures that when the corner post application cycle begins, the mechanism is already configured for accurate placement, eliminating the need for complex real-time adjustments during the application process.
Solution Approach 2:
The applicator mechanism performs its positioning and application motions in a continuous, coordinated sequence without idle pauses. The swing arm rotation and linear actuator extension occur simultaneously and continuously, maintaining productive motion throughout the corner post placement process while ensuring precise positioning.
Data Source
AI summary
A corner post application system comprises a conveyor subsystem and an enveloping machine adapted to envelope the plurality of units with a material. The system further includes a swing arm, an applicator arm coupled to the swing arm and adapted to move linearly, a corner post gripper coupled to the applicator arm, and a controller. The controller rotates the swing arm about a vertical axis until a corner post held by the corner post gripper is aligned with adjacent sides that define a corner of the load. The controller thereafter stops rotation of the swing arm and moves the applicator arm linearly toward the corner of the load until the corner post held by the corner post gripper contacts the adjacent sides of the load. A sensor may be included for detecting a corner of the load, with the controller aligning the corner post based on detection by the sensor.