Dynamic Dual Bin Collation System Eliminates Pusher Reset
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Solution Overview
Problem
Existing auto-collation systems with static angled bins and one-direction pushers are inefficient due to the need for frequent reset and vibration issues, leading to media jams and increased costs in signage changeovers for retail stores.
Innovation Solution
A dynamic dual bin position collation system that eliminates the need for pusher reset by allowing bidirectional collation and pushing media to two banders, utilizing rotatable bins and a bidirectional pusher for increased productivity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a one-direction pusher system is used with static angled bins, then media can be collated into a single bander, but the system requires frequent reset which reduces productivity and causes vibration issues leading to media jams
Solution Approach 1:
The bin system transitions from static to dynamic by allowing bins to rotate between different positions. The bins can swing from a receiving position to a discharge position, enabling the pusher to continuously move media without resetting. This dynamic configuration resolves the contradiction by maintaining productivity while eliminating reset time losses.
Solution Approach 2:
The system adds a rotational dimension to the bin positions, allowing media to be collated in one direction while bins rotate to different discharge locations. This dimensional change enables continuous operation without pusher reset, as the bins themselves provide the directional change needed for dual bander output.
2Device complexity
If a one-direction pusher system is used, then the structure is simpler, but the system experiences vibration and settling issues that cause media jams
Solution Approach 1:
By making the bins dynamic and rotatable rather than static, the system maintains structural simplicity while eliminating the vibration and settling issues. The continuous rotational motion prevents media from settling and jamming, improving reliability without significantly increasing device complexity.
Solution Approach 2:
The bins are pre-positioned in optimal receiving orientations before media arrives, and pre-positioned in discharge orientations before media needs to be pushed. This preliminary positioning prevents vibration and settling issues during the actual pushing operation, maintaining reliability while keeping the pusher structure simple.
3Ease of operation
If static angled bins are used with single bander output, then the system is easier to operate, but productivity is reduced due to mandatory pusher reset after each push
Solution Approach 1:
The dynamic bin rotation system maintains ease of operation through automated positioning while dramatically improving productivity. The bins automatically rotate to receive and discharge media, eliminating the need for manual pusher reset operations. This automation preserves operational simplicity while enabling continuous high-speed collation to multiple banders.
Solution Approach 2:
The bin system gains multi-functionality by being able to discharge to multiple different bander positions through rotation. The same bin structure serves both receiving and discharge functions at different orientations, and can serve multiple banders sequentially without reset, thereby improving productivity while maintaining ease of operation through standardized components.
Data Source
AI summary
A system that eliminates return and reset of a pusher in a media collation system includes the use of bidirectional bins that allow accumulated sets of media in the bins to be collated in first or second directions and pushed to either of two banders rather than being restricted to one bander.