Automated Loading System for Elongated Metal Tubes
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Solution Overview
Problem
Conventional manual loading systems for elongated members into laser cutting machines are hazardous due to the need for human intervention and lack automation in feeding members to the cutting machine, posing safety risks to operators.
Innovation Solution
A system comprising an elevator, pusher arms, and gripper arms that automatically load elongated members onto a conveyor, allowing for safe and efficient handling of various shapes and sizes, including tubes and bars, by moving them from an elevator to a support surface and then to a conveyor for processing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Extent of automation
If manual loading by hand or overhead crane is used, then human intervention is required for each step, but safety risks to operators increase
Solution Approach 1:
The system uses self-service mechanisms where the inclined support surface and pusher arms automatically guide and move the elongated member without requiring human intervention. The member is pushed by its own weight component along the incline, eliminating the need for operators to manually handle or position the member during the loading process.
Solution Approach 2:
The patent replaces manual mechanical handling with an automated mechanical system consisting of the inclined support surface, pusher arms, and conveyor. This substitution eliminates direct human contact with the elongated member during loading, thereby removing the safety risks associated with manual handling while maintaining the mechanical function of transferring the member.
2Ease of operation
If overhead crane with human arrangement is used, then member handling is possible, but human intervention and safety risks remain
Solution Approach 1:
The system eliminates the need for human arrangement of crane supports by using a self-service inclined support surface. The elongated member is automatically guided and positioned on the inclined surface, which then pushes it into the conveyor support, removing all human intervention from the handling process while maintaining ease of operation.
Solution Approach 2:
The patent extracts and removes the overhead crane and human operator from the loading system entirely. The function previously performed by the crane and human operator is replaced by the inclined support surface and pusher arms, which automatically complete the member transfer without requiring external mechanical assistance or human presence.
3Object-affected harmful factors
If automated elevator and pusher arms are used, then safety is improved, but device complexity increases
Solution Approach 1:
The loading system is segmented into distinct functional components: the elevator for vertical transport, the inclined support surface for guiding, the pusher arms for horizontal movement, and the conveyor for final delivery. Each component performs a specific function with minimal complexity, and the segmentation allows for independent optimization and maintenance while collectively achieving safe automated loading.
Solution Approach 2:
The inclined support surface creates a gradual transition in potential energy from the elevated conveyor position to the lower support position. This equipotential gradient naturally guides the elongated member downward and into the conveyor support through gravity, eliminating the need for complex active control systems while maintaining safe automated operation.
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 enhances safety by automating the loading process, reducing human intervention and enabling efficient handling of different elongated member shapes and sizes, thereby improving operational safety and efficiency in material processing systems.
Implementation Method 1
the elevator being movable in an upward direction to lift each elongated member carried thereon to a predetermined height
Implementation Method 2
the second side of the second support surface that is distal to the elevator being raised relative to the first side so that the second support surface is inclined upwardly and outwardly
Data Source
AI summary
A system for loading elongated members, such as metal tubes and bars, onto a conveyor for later processing features an elevator, pusher arms, a support surface provided at a predetermined height, and gripper arms. The elevator acts to lift a topmost layer of the members, which are typically arranged in a stack thereon, to a predetermined height so that the pusher arms may transfer the members forming the topmost layer onto the support surface at this height. The pusher arms push these members across the support surface by engaging the member farthest from the support surface until the respective elongated member passes over a distal side of the support surface and onto the gripper arms arranged at a height of this side. The gripper arms lower that member to an unloading location below the support surface where an empty support cradle of the conveyor is arranged for receiving same.