Tray Nesting Device for Fruit Packing Line Alignment
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Solution Overview
Problem
Conventional fruit tray handling systems are inefficient due to misalignment and friction issues between trays and crates, leading to improper deposition of trays into packing crates.
Innovation Solution
A produce packing system with a multi-layer conveying arrangement that includes a first loading track with a tray guide and a second loading track with a crate caddy, allowing filled trays to be accurately nested into crates using a controlled and measured process, ensuring proper alignment and alignment without skewing or misalignment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If trays are delivered into packing crates by gravity sliding from an inclined conveyor, then the system is simple in structure, but the trays fail to be properly deposited due to misalignment and friction between trays and crates
Solution Approach 1:
A positioning device acts as an intermediary between the inclined conveyor and the packing crate. This device includes a positioning member that engages with the tray and a positioning surface on the crate, mediating the transfer to ensure precise alignment and eliminate friction-related misalignment issues during the gravity-fed deposition process
Solution Approach 2:
The positioning device performs preliminary positioning actions before the tray actually contacts the crate. By pre-aligning the tray with the crate's receiving surface through the positioning member, the system ensures proper orientation and location are established in advance, preventing misalignment during the gravity slide
2Manufacturing precision
If the upper and lower conveyors move at substantially the same speed to coordinate positioning, then tray and crate positioning is attempted, but the system still fails due to difficulty in coordinating the conveyors
Solution Approach 1:
The positioning device serves as a coordination intermediary that decouples the conveyor speed synchronization requirement. Instead of requiring the upper and lower conveyors to move at matching speeds, the positioning member acts as a buffer that accommodates speed differences while maintaining precise tray-to-crate alignment through mechanical engagement
Solution Approach 2:
The positioning device introduces dynamic adjustment capability to the rigid conveyor synchronization requirement. The positioning member can move and adjust its engagement point dynamically to accommodate variations in tray and crate positioning, allowing the conveyors to operate at different speeds while maintaining coordination through the flexible positioning mechanism
3Extent of automation
If filled trays are delivered to a loading station for insertion into crates, then automated tray nesting is achieved, but the system becomes complex with multiple conveying lines and tracks
Solution Approach 1:
The positioning device employs a nested structure where the positioning member is received within a receiving structure on the crate. This nesting arrangement allows the automated positioning and tray insertion functions to be integrated within the existing crate structure, reducing the need for separate complex conveying mechanisms while maintaining high automation levels
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 enables reliable and efficient tray nesting into crates, reducing packing, stacking, and palletizing issues, and lowering overall costs by ensuring accurate and automated tray placement.
Implementation Method 1
a platform having an incline relative to the track, wherein the pre-determined track underlies the platform and the track has a direction of travel that is parallel to an inclined edge of the platform such that a produce tray may be transferred down the inclined platform toward the crate caddy
Data Source
AI summary
The present invention provides devices, systems and methods for reliably inserting packing trays into packing crates. Thus, the present invention solves the problems of conventional packaging lines by providing a positioning device for depositing packing trays into packing crates. Particularly, the present invention can be incorporated into existing fruit and vegetable packing lines.