Elevator-Shaft Stacking for Continuous Elongated-Item Packaging
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Solution Overview
Problem
Stacking and packaging of elongated items, such as firewood, lumber, pipes, and agricultural products, is challenging due to irregular shapes and sizes, leading to inefficiencies and potential jamming in existing packaging machines.
Innovation Solution
A device with an elevated platform, diverter, and elevator shafts with support structures that form and release stacks of elongated items, utilizing a paddlewheel diverter and chain drives for controlled movement and cyclic stacking into packages.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional packaging machines are used for elongated items, then packaging function is provided, but the machines jam frequently due to irregular shapes and sizes
Solution Approach 1:
The packaging system is divided into multiple independent elevator shafts (first elevator shaft, second elevator shaft) that operate separately. Each shaft can continue packaging items independently even if the other encounters obstructions, segmenting the continuous packaging process to maintain reliability and throughput.
Solution Approach 2:
The support structures within each elevator shaft are made movable rather than fixed, allowing them to adapt dynamically to irregular item shapes and sizes. The support structures can move to accommodate varying item dimensions, preventing jamming and maintaining continuous operation.
2Productivity
If manual stacking of elongated items is used, then flexibility is maintained, but labor intensity is high and efficiency is low
Solution Approach 1:
The elevator shafts automatically stack elongated items without manual intervention. The support structures self-adjust and self-position items within the shafts, and the diverter automatically directs items to the appropriate shaft, eliminating manual labor while maintaining high packaging efficiency.
Solution Approach 2:
Manual mechanical stacking operations are replaced with an automated mechanical system comprising elevator shafts, support structures, and a diverter mechanism. This automated system performs stacking functions that would otherwise require manual labor, significantly improving productivity.
3Adaptability or versatility
If fixed support structures are used in elevator shafts, then structural stability is maintained, but items with irregular shapes cannot be accommodated
Solution Approach 1:
The support structures are designed to be movable rather than fixed, allowing them to change position and configuration dynamically. This enables the structures to adapt to irregular item shapes while maintaining stability during the stacking process through controlled movement rather than rigid fixed positions.
Solution Approach 2:
The support structures can change their positional parameters and configuration based on the items being stacked. By adjusting their position and orientation parameters, the structures accommodate varying item shapes and sizes while maintaining structural stability during operation.
4Productivity
If a single elevator shaft is used, then device complexity is reduced, but continuous packaging operation is interrupted by obstructions
Solution Approach 1:
The packaging system uses multiple elevator shafts (first and second) that operate independently. This segmentation allows continuous packaging operation to continue uninterrupted even when one shaft encounters obstructions, as the other shaft can maintain packaging throughput without interruption.
Solution Approach 2:
The dual elevator shaft configuration ensures continuous packaging operation by providing redundant pathways. While one shaft processes items, the other can continue operating or prepare for the next batch, maintaining continuous useful action and preventing interruptions in overall packaging throughput.
Data Source
AI summary
A device and conveyance system are provided for packaging elongated items such as firewood pieces. The device includes: an elevated structure having an upper platform for receiving the elongated items from a separate conveyor; a paddlewheel diverter located on or above the platform for changing the direction of movement of the elongated items; and one or more elevator shafts having open bottoms. The elevator shafts are located adjacent to the platform and configured for receiving the elongated items after contact with the diverter and for holding the elongated items on support structures while a stack of elongated items is formed. The release of the stack of elongated items from the elevator shafts occurs via the open bottoms of the elevator shafts. The system includes one or more conveyors having features inducing alignment of the elongated items prior to conveyance to the device.