Dynamic Container Stack for Component Sorting
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Solution Overview
Problem
Existing sorting systems for handling components of different types in production lines require a large amount of space and increased access times as the number of types increases, and they are inefficient when the frequency or number of types is unknown or variable, often necessitating redundant containers and long travel distances for handling devices.
Innovation Solution
A method involving a transport device that successively picks up and classifies components, storing them in a clipboard until filled to a predetermined percentage, then transfers the most frequent type to a container from a stack, allowing for dynamic allocation of containers without predefining their number or type, enabling efficient and space-saving sorting across multiple types.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If multiple trays or drawers are used to sort different types of components in parallel, then the sorting capacity for multiple types is improved, but the space required and access times increase significantly
Solution Approach 1:
The patent transitions from a horizontal arrangement of multiple trays/drawers to a vertical stack configuration. Containers are stacked vertically with the handling system accessing them from the top, converting horizontal space requirements into vertical space utilization. This dimensional change allows sorting multiple component types without proportionally increasing the floor space occupied by the sorting system.
Solution Approach 2:
The stackable containers serve multiple functions: they act as both the sorting destination and the storage medium, and can be dynamically reassigned to different component types. The same physical container can be used for different types across different time periods, eliminating the need for dedicated containers for each type and reducing the total number of containers required.
2Adaptability or versatility
If the number of trays or drawers is increased to handle more component types, then the sorting versatility is improved, but the access times and travel distances increase
Solution Approach 1:
By organizing containers vertically in a stack rather than horizontally in a row, the patent reduces the horizontal travel distance the handling system must cover. The vertical arrangement allows the handling system to access containers by moving vertically within a compact space, significantly reducing travel time compared to traversing a long horizontal array of trays.
Solution Approach 2:
The system dynamically assigns containers to different component types based on current sorting needs rather than having fixed assignments. The container stack can be reconfigured by moving containers in and out of the active sorting position, allowing the system to adapt to varying component type frequencies and minimize access time for commonly sorted types.
3Reliability
If redundant trays or drawers are provided to ensure sufficient capacity for each component type, then the sorting reliability is improved, but the space required and system complexity increase
Solution Approach 1:
The patent employs a fleet of identical, interchangeable containers that can be assigned to any component type. Rather than having dedicated containers for each type (which would require complex tracking and management), the system uses a pool of universal containers that are dynamically assigned based on current sorting demands. This reduces the total number of containers needed while maintaining sufficient capacity for all types.
Solution Approach 2:
The system automatically manages container assignment and reassignment based on real-time sorting requirements. When a container becomes full, the system autonomously selects another container from the stack for the same component type, eliminating the need for manual intervention or complex pre-planning of container allocation.
4Ease of manufacture
If a fixed number of containers is allocated for each component type, then the sorting process is simplified, but the adaptability to varying component frequencies and types is reduced
Solution Approach 1:
The system implements dynamic container allocation where the assignment of containers to component types changes based on real-time sorting needs. The container stack allows containers to be moved in and out of the active sorting position, enabling the system to adapt to varying frequencies of different component types without requiring pre-configured fixed allocations for each type.
Solution Approach 2:
Empty containers are pre-stacked and ready for immediate assignment to component types as needed. Rather than allocating specific containers to specific types in advance, the system prepares a pool of ready-to-use containers that can be quickly assigned to any type based on current sorting demands, combining preparation with flexibility.
Data Source
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AI summary
The invention relates to a method for sorting components for handling systems (100a, 100b) of different types into stackable containers (10), comprising the following steps: a. Successively picking up and classifying the type of components (100a, 100b) delivered in any order by a transport device (30) and depositing the components (100a, 100b) in an intermediate storage area (20) at assigned storage positions (20a); b. After the intermediate storage area (20) has been filled to a predefinable percentage p, removing those components (100a, 100b) that correspond to the type most frequently present in the intermediate storage area (20) into an associated container (10), wherein the container (10) is selected from a selection access area (3b) of a container stack (3); c. Repeating steps a. and b. until a container (10) of one type is filled; d.Moving the filled container (10) into a storage area (3c) of the container stack (3) and moving an empty container (10) from a storage area (3a) of the container stack (3) into the selection access area (3b) of the container stack (3); e. Repeating steps a. to d. until all delivered components (100a, 100b) have been placed in containers (10) assigned to their type, with each full container (10) moved into the storage area (3c) being loaded into the storage area (3a) of the container stack (3).