Discharge Box With Replaceable Pallet For Automated Bulk Handling
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing containers for shipping and dispensing bulk solid materials are prone to damage, leading to costly replacements, and often require integrated pallets that wear out and render the entire container unusable.
Innovation Solution
A discharge box with a conical shaped lower surface, a displaceable cone valve, a removable pallet, and a polyethylene enclosure with a top opening, allowing for automated dispensing without human intervention, featuring replaceable components and a low-maintenance design.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If conventional containers with integrated pallets are used, then the container structure is simple, but the entire container must be discarded when the pallet wears out
Solution Approach 1:
The container system is divided into separate components: the enclosure and the pallet are distinct replaceable parts. The pallet can be removed and replaced independently from the enclosure, allowing the enclosure to be reused while only the worn pallet is discarded. This segmentation resolves the contradiction by making the container system more reliable through component replacement rather than complete disposal.
Solution Approach 2:
The pallet is designed as a consumable component that can be discarded when worn, while the enclosure is recovered and reused. This principle allows the system to maintain reliability by replacing only the necessary component (pallet) rather than discarding the entire container, thus improving overall container reusability.
2Ease of manufacture
If conventional containers with integrated pallets are used, then the structure is unified, but maintenance cost increases due to complete replacement
Solution Approach 1:
By segmenting the container into enclosure and pallet components, the system allows selective replacement of only the worn pallet rather than replacing the entire container. This reduces maintenance costs while maintaining structural functionality, as the durable enclosure can be reused multiple times with different pallets.
Solution Approach 2:
The pallet is designed as a cheaper, replaceable component with shorter service life compared to the enclosure. When the pallet wears out, it can be replaced with a new, inexpensive pallet rather than replacing the entire expensive enclosure, thus reducing overall maintenance costs.
3Device complexity
If manual handling is used, then automation complexity is low, but productivity is reduced
Solution Approach 1:
The container design enables automated handling through self-aligning features and standardized interfaces. The enclosure and pallet are designed to work together with automated dispensing mechanisms, allowing the system to serve itself without manual intervention. This increases productivity while keeping automation complexity manageable through simple, standardized components.
4Strength
If durable materials are used throughout the container, then container strength increases, but weight increases
Solution Approach 1:
The container is segmented into the enclosure and pallet, allowing different material selections for each component based on functional requirements. The enclosure can use durable materials for strength and protection, while the pallet can use lighter materials since it is replaceable and has different functional demands. This segmentation optimizes the weight-strength balance of the overall system.
Data Source
AI summary
A discharge box capable of transporting and then dispensing a high bulk density of solid product with substantially no human intervention. The discharge box includes separable/replaceable components allowing for a low cost, low maintenance, and long-term package and includes a tamper-evidence site window, and desiccant pockets, in a lid portion.