Functional Trays for Automated Packaging Tasks
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Solution Overview
Problem
Conveyor systems in electronic marketplaces and fulfillment networks lack versatility in handling different types of items and packaging processes, as they are limited by fixed functionalities and require manual intervention for various tasks such as envelope opening, item pushing, and wrapping.
Innovation Solution
The introduction of functional trays that can be removably attached to conveyors, equipped with mechanisms for envelope opening, item pushing, and wrapping, allowing for customizable functionality based on the type of items and processing needs, enabling efficient and automated packaging processes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If fixed-functional conveyor systems are used, then the system structure is simple and reliable, but the adaptability to different packaging tasks is poor and manual labor is required
Solution Approach 1:
The conveyor system is divided into modular functional trays that can be independently attached and detached. Each tray performs a specific packaging function (envelope opening, item pushing, wrapping), allowing the system to be segmented into interchangeable functional units that can be reconfigured based on different packaging tasks.
Solution Approach 2:
The functional trays are designed with universal attachment mechanisms that allow the same tray structure to perform multiple different packaging functions by simply changing the attached functional module. This enables one base structure to serve multiple purposes across different packaging scenarios.
2Productivity
If manual intervention is used for packaging tasks, then the system complexity is low, but the processing speed and accuracy are reduced
Solution Approach 1:
The functional trays are designed to perform packaging tasks automatically without requiring manual intervention. The trays self-propel items through the packaging process using integrated mechanisms (envelope openers, pushers, wrappers) that operate autonomously as items pass through the conveyor system.
Solution Approach 2:
The functional trays prepare items for subsequent packaging steps in advance. For example, envelopes are opened beforehand, items are positioned and pushed into place, and wrapping is applied proactively as items move through the conveyor, eliminating the need for manual intervention at each step.
3Adaptability or versatility
If customizable functional trays are implemented, then the versatility for different items is improved, but the tray exchange and configuration complexity increases
Solution Approach 1:
The functional trays are segmented into standardized base units with interchangeable functional modules. This segmentation allows operators to easily attach and detach different functional components onto the same base tray, simplifying the exchange process while maintaining versatility for handling different item types.
Solution Approach 2:
The functional trays incorporate dynamic attachment mechanisms that allow for quick connection and disconnection of functional modules. This dynamic design enables rapid reconfiguration of the conveyor system to handle different item types without complex assembly procedures.
Data Source
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AI summary
A conveyor system is provided including a conveyor and a plurality of functional trays that are removably attachable to the conveyor. Each tray includes a plate having first and second dimensions that are orthogonal to each other, and the plate includes a coupler configured to be removably attached to the conveyor with the second dimension of the plate being in parallel with a moving direction of the conveyor. The plurality of functional trays include one or more of an envelope-opening mechanism, an item-pushing mechanism, an envelope-closing mechanism, an item-wrapping mechanism, and a tray-height-adjustment mechanism. For example, the item-pushing mechanism includes a pusher slidably coupled to the plate, and a linear actuator configured to move the pusher relative to the plate along the first dimension so as to push an item off the functional tray.