Automatic Feeder Stack Alignment via Perforated Belt and Vacuum
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Solution Overview
Problem
Automatic feeders face challenges in efficiently sorting and singulating flimsy articles from bulk stacks, as they often slump or fall out of position, leading to errors like double feeding and damage, due to the thickness of container sidewalls and misalignment with stack guides, and the vacuum and conveyor systems' inefficiencies in handling articles with unbound edges.
Innovation Solution
A system with a perforated drive belt assembly, pivotably attached to a frame, equipped with sensors to detect force and pressure, and a controller to adjust the conveyor's position, ensuring proper alignment and support of the article stack, combined with a vacuum unit for singulation and anti-doubling devices to prevent multiple article pickup.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If articles are provided in bulk containers and unloaded onto a sorting apparatus, then the sorting capacity is increased, but the articles may slump or fall into a position which is not ideal for singulation due to container sidewall thickness
Solution Approach 1:
A stack guide is introduced as an intermediary component between the container and the singulation mechanism. The stack guide receives the stack of articles from the container and properly positions them for singulation, mediating the transition and ensuring correct alignment despite container sidewall thickness variations.
Solution Approach 2:
The system performs preliminary positioning of the stack guide before articles are unloaded. The stack guide is positioned in advance to accommodate the container sidewall thickness, ensuring that when articles are unloaded, they are already in the correct position for singulation.
2Productivity
If the stack of articles is not positioned correctly or slumps in the feeder, then the singulation process continues, but errors such as picking more than one article at a time occur
Solution Approach 1:
Sensors are implemented to detect the position and status of articles in the stack. This feedback information is used to adjust the stack guide position or conveyor operation to maintain proper article positioning, preventing double feeding errors while maintaining high singulation speed.
Solution Approach 2:
The stack guide and conveyor system are configured to prevent slumping before it occurs. By maintaining proper support and positioning of the article stack throughout the feeding process, the system preemptively counteracts the tendency of articles to slump or shift position.
3Productivity
If vacuum and conveyor belts are used to move articles during singulation, then the articles are transported along the feeder, but articles with unbound edges are moved in different directions causing damage
Solution Approach 1:
Different sections of the conveyor system are designed with different characteristics suitable for different article types. Areas handling articles with unbound edges use modified conveyor surfaces or reduced vacuum pressure to prevent edge damage, while other areas maintain standard operation for robust articles.
Solution Approach 2:
The vacuum pressure and conveyor belt speed are dynamically adjusted based on article characteristics. For articles with unbound edges, the system reduces vacuum pressure and modifies transport parameters to prevent damage while maintaining adequate transport functionality.
4Productivity
If the article feeder operates at high speed to match sorter windows, then the feed rate is increased, but damage to articles and double feeding may occur if not synchronized properly
Solution Approach 1:
Sensors detect the presence and position of articles and sorter windows, providing feedback to the control system. This enables real-time synchronization adjustments to maintain high feed rates while preventing double feeding and ensuring articles are delivered to the correct sorter windows.
Solution Approach 2:
The system uses periodic sensing and controlled actuation to synchronize article delivery with sorter window passage. By coordinating the periodic movement of articles with the periodic opening of sorter windows, the system maintains high speed operation with accurate synchronization.
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 the efficiency of singulation and sorting by maintaining stack alignment, reducing damage and double feeding, and ensuring proper contact with the stack guide, thereby improving the feed rate and accuracy of article delivery.
Implementation Method 1
a sensor in proximity to the perforated drive belt assembly, the sensor configured to detect a force exerted on a portion of the perforated drive belt assembly by the stack of articles
Implementation Method 2
feeders use a vacuum to exert a force on articles in the feeder
Data Source
Figure 1
Figure 2A
Figure 2B
AI summary
Embodiments of a system and method for singulating articles in an automatic stack feeder are disclosed. The automatic stack feeder has a plurality of belts (120) and at least one paddle (150, 160), a vacuum powered singulation device (140) and a sorting section (180). The automatic stack feeder receives a stack of flats from a container (190), moves the stack along the belts toward the vacuum powered singulation device, and the stack is singulated and sorted.