Automated Edge Marker Collation Using Angled Baffles
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Solution Overview
Problem
Current methods for updating and collating shelf edge markers in retail stores are inefficient, requiring significant manual intervention and time, leading to costly errors and delays, especially when dealing with large numbers of markers that need to be accurately placed according to unique store layouts.
Innovation Solution
An automated packaging system using a series of angled baffles with bins to collate and transfer media strips, featuring an automated pusher to shift strips into a compiled stack in store planogram order and a transport device to move the stack for subsequent packaging, eliminating stub points and enhancing sliding with a downward slope.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If manual employees catch and collate each sheet of edge markers, then the edge markers can be sorted according to store planogram, but the process requires significant time and labor (20 people employed)
Solution Approach 1:
The patent replaces the manual mechanical sorting process with an automated system that uses sensors, conveyors, and robotic mechanisms to detect, sort, and collate edge markers according to store planogram, eliminating the need for 20 employees while maintaining accuracy
Solution Approach 2:
The system enables self-service collation where the edge markers are automatically routed and sorted through the system without human intervention, with the machinery itself performing the collation task that previously required manual labor
2Ease of operation
If employees manually separate and collate edge marker sheets, then the markers can be organized by store department, but the process incurs significant labor cost and potential for errors
Solution Approach 1:
The patent divides the collation process into discrete automated stages including detection, sorting, separation by department, and stacking, with each stage handled by specialized mechanical components that work together in sequence
Solution Approach 2:
The system introduces intermediary mechanical devices such as conveyors, diverters, and positioning mechanisms that mediate between the incoming edge markers and the final collated stacks, automating the intermediate sorting and organizing steps
3Reliability
If edge markers are updated frequently to maintain accurate pricing, then pricing accuracy is maintained, but the frequent changeover incurs significant time and cost
Solution Approach 1:
The patent implements preliminary action by pre-organizing edge markers according to store planogram before they reach the collation point, and by maintaining ready-to-use stacks that can be quickly deployed, reducing the time required for changeover when pricing updates are needed
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 system significantly reduces manual labor and time required for collating and shipping shelf edge markers, ensuring accurate placement and timely updates, thereby improving efficiency and reducing costs by automating the collation and transfer process.
Implementation Method 1
providing a downward slope to enhance media strips sliding down the series of baffles
Data Source
AI summary
An automated packaging system for automated collating, stacking and transferring long cut retail edge marker strips exiting a roll fed high speed slitter/perforator/cutter apparatus includes a series of angled and stepped baffles configured to receive the cut retail edge marking strips and allow them to fall into and accumulate in bins formed by each angled baffle and then be removed from each bin consecutively by an automated pusher acting orthogonally to the bins to move and collate the retail edge markers into a final stack collated to meet a specific store planogram requirement. An automated transfer unit moves the final stack downstream for further packaging, which may include automated banding and loading of the final stack into an empty container for shipment to the store having the specific planogram requirement.