Drop Batch Builder for Glass Sheet Organization
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Solution Overview
Problem
Existing methods for organizing glass sheets of different sizes and shapes into batch arrangements on conveyor lines are inefficient and often require manual labor, limiting throughput and efficiency in manufacturing processes like made-to-order production.
Innovation Solution
A drop batch builder system comprising an upper conveyor line and a lower conveyor line, where the upper conveyor line conveys glass sheets along crosswise paths and drops them onto the lower conveyor line without the use of elevators or transport devices, allowing for flexible and automated arrangement of glass sheets into various batch configurations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If manual labor is used to organize glass sheets into batch arrangements, then flexibility in arrangement is achieved, but productivity is reduced
Solution Approach 1:
The system uses automated conveyors and drop mechanisms that self-regulate to place glass sheets in batch arrangements without manual intervention. The upper conveyor automatically drops sheets onto the lower conveyor at controlled intervals, creating batch arrangements through automated timing and positioning rather than human labor.
Solution Approach 2:
The system employs variable speed control on the upper and lower conveyors to dynamically adjust the timing and spacing of glass sheet transfer. By changing conveyor speeds, the system can create different batch arrangements (single batch, double batch, interleaved patterns) automatically, providing flexibility previously requiring manual adjustment.
2Productivity
If automated systems are introduced to increase productivity, then throughput is improved, but device complexity increases
Solution Approach 1:
The system divides the batch building function into two separate conveyor lines (upper and lower) that operate independently but coordinate through controlled dropping. This segmentation allows each conveyor to be simpler in design while the overall system achieves high productivity through their coordinated interaction.
Solution Approach 2:
The upper conveyor is positioned at a higher elevation than the lower conveyor, creating a gravity-assisted drop system. This elevation difference enables automatic sheet transfer without requiring complex lifting mechanisms on the lower conveyor, reducing overall system complexity while maintaining automated operation.
3Productivity
If glass sheets are arranged to fill maximum conveyor area, then productivity increases, but manufacturing precision requirements increase
Solution Approach 1:
The system uses sensors and controllers to monitor the position and timing of glass sheets on both conveyors. This feedback allows the control system to adjust conveyor speeds and drop timing to ensure sheets are positioned accurately in the desired batch arrangements, achieving high area utilization while maintaining positioning precision.
Solution Approach 2:
The system pre-calculates and pre-positions glass sheets on the upper conveyor before dropping them to the lower conveyor. By preparing the arrangement in advance and controlling the drop sequence, the system ensures accurate final positioning while maximizing conveyor area utilization, rather than attempting to position sheets during the transfer moment.
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
Enables efficient and automated organization of glass sheets into diverse batch arrangements, enhancing throughput and reducing manual labor, while ensuring glass sheets are properly aligned and positioned for processing, such as in tempering furnaces.
Implementation Method 1
The upper conveyor has a drop region configured to drop a glass sheet from the upper conveyor line downwardly onto the lower conveyor line
Data Source
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AI summary
A drop batch builder is provided for organizing a plurality of glass sheets into a desired batch arrangement on a conveyor. The drop batch builder includes an upper conveyor line and a lower conveyor line. The upper conveyor has a drop region configured to drop a first glass sheet from the upper conveyor line downwardly onto the lower conveyor line, whereupon the lower conveyor line is configured to convey the first glass sheet along the lower path of substrate travel to the overpass region where the first glass sheet is positioned under the upper conveyor line. Methods of using a drop batch builder are also provided.