Curved Tier Sheet Dispensing Apparatus for Conveyor Palletizing
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Solution Overview
Problem
Conveyor systems face inefficiencies in palletizing objects due to damaged tier sheets, which cause objects to fall from the perimeter of the arrayed layer, leading to increased time and costs in loading pallets.
Innovation Solution
A tier sheet dispensing apparatus with a convexly curved support surface and a lift mechanism using vacuum pressure to efficiently dispense tier sheets, ensuring the edges and corners angle upward, preventing objects from falling and reducing dispensing time.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a flat tier sheet is used to support objects in a two-dimensional array, then the central portion can maintain object positions, but the damaged edges and corners cannot prevent objects from falling
Solution Approach 1:
The patent applies curvature by forming the tier sheet into an arched or domed shape with a curved surface that bows upward from the center. This curvature causes the edges and corners to be positioned higher than the center, creating a bowl-like structure that prevents objects from rolling or falling off the perimeter, thereby solving the problem of objects falling from damaged edges while maintaining position stability
2Ease of manufacture
If conventional flat tier sheets are used, then manufacturing is simple, but dispensing time is increased due to object falls requiring repositioning
Solution Approach 1:
The patent applies preliminary action by pre-forming the tier sheets into curved or arched shapes during the manufacturing process. This pre-shaping ensures that when the tier sheets are dispensed and placed on objects, the edges and corners are already positioned to prevent object falls, eliminating the need for repositioning operations and thereby increasing palletizing speed without complicating manufacturing
3Reliability
If the conveyor system waits for object falls to be corrected, then object stability is maintained, but the palletizing process time increases
Solution Approach 1:
The curved shape is pre-formed into the tier sheet before dispensing, so that when the tier sheet is placed on the objects, the edges and corners are already at a higher elevation than the center, creating immediate containment for the objects. This eliminates the need for waiting or corrective actions during the palletizing process, maintaining object stability while preserving cycle time
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 apparatus significantly reduces the time and cost associated with palletizing by efficiently dispensing tier sheets, maintaining object stability on damaged tier sheets, and preventing falls, thus enhancing the operational efficiency of conveyor systems.
Implementation Method 1
a lift mechanism that moves vertically over the stack of tier sheets to selectively attach to the top tier sheet in the stack and raise the top tier sheet from the stack
Data Source
AI summary
A tier sheet dispensing apparatus for a conveyor system stores a stack of tier sheets and sequentially dispenses the tier sheets, one at a time, onto the top of a two-dimensionally arrayed layer of objects that is being conveyed on a conveyor system. The tier sheet dispensing apparatus has a curved surface that supports the stack of tier sheets. The curved surface bends the stack of tier sheets in a convex curve that facilitates the removal of a single sheet from the top of the stack. The apparatus also has a lift mechanism that moves vertically over the stack of tier sheets to selectively attach to the top tier sheet in the stack and raise the top tier sheet from the stack. The lift mechanism also moves transversely relative to the stack of tier sheets to position the attached tier sheet over the conveyor for placement of the tier sheet on the layer of objects conveyed by the conveyor.