Independent Pusher System for Layer Assembly
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Solution Overview
Problem
Existing devices for assembling layers of general cargo are time-consuming and prone to damage and deformation, especially with heavy or fragile items, due to the use of a single slider to move multiple rows of cargo, leading to irregular layer patterns and instability in the stacked cargo.
Innovation Solution
A device with independent feed and pusher systems for each row of cargo, allowing for parallel and opposite movement of rows onto a transfer surface, minimizing direct contact and interference between rows, and using alignment slides to ensure precise alignment and stable stacking.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If a single slider is used to move multiple rows of cargo, then device complexity is reduced, but manufacturing precision and reliability deteriorate due to damage and deformation of heavy or fragile items
Solution Approach 1:
The patent divides the pushing function into multiple independent pushers (first pusher for first row, second pusher for second row) instead of using a single slider. Each pusher independently handles one row of cargo, eliminating the interference and damage caused by multiple rows being pushed simultaneously by a single mechanism. This segmentation resolves the contradiction by accepting increased device complexity to achieve precise cargo alignment and prevent deformation.
Solution Approach 2:
The patent introduces alignment slides that move in a direction perpendicular to the pushing direction, creating a two-dimensional control system. The pushers move cargo in the longitudinal direction while alignment slides adjust position in the transverse direction, enabling precise alignment without compromising cargo integrity. This dimensional approach resolves the contradiction between simple structure and precise alignment.
2Device complexity
If a single slider is used to move multiple rows of cargo, then device complexity is reduced, but productivity deteriorates due to time-consuming serial processing
Solution Approach 1:
The patent segments the cargo handling into multiple independent rows, each with its own feed device and pusher. This allows parallel processing of multiple rows simultaneously, dramatically increasing stacking productivity. The first row and second row are fed and pushed independently at the same time, eliminating the serial processing bottleneck of single-slider systems.
Solution Approach 2:
The patent merges multiple independent feeding and pushing operations into a coordinated system that works simultaneously. Multiple feed devices feed different rows in parallel, and multiple pushers push different rows simultaneously onto the transfer surface, combining the capabilities of multiple independent systems to achieve high-speed parallel processing.
3Ease of operation
If multiple rows of cargo are pushed simultaneously by a single slider, then ease of operation is improved, but reliability deteriorates due to irregular layer patterns and stacking instability
Solution Approach 1:
The patent assigns dedicated pushers to specific rows (first pusher for first row, second pusher for second row), ensuring that each row is pushed with controlled, uniform force. This prevents the irregular layer patterns that occur when a single slider attempts to push multiple rows simultaneously with varying forces, thereby improving layer pattern regularity and stacking reliability.
Solution Approach 2:
The patent introduces alignment slides as intermediary devices between the pushers and the transfer surface. These alignment slides ensure that cargo from different rows is precisely positioned and aligned before being transferred, acting as mediators that guarantee regular layer patterns and stable stacking while maintaining operational simplicity.
4Manufacturing precision
If independent feed and pusher systems are used for each row of cargo, then manufacturing precision is improved, but device complexity increases
Solution Approach 1:
The patent employs movable and adjustable components including alignment slides that can move in transverse directions and pushers that can be positioned at different locations. This dynamic design allows the system to adapt to different cargo types and stacking requirements while maintaining precise alignment, managing the complexity through flexible, reconfigurable components rather than fixed rigid structures.
Data Source
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AI summary
The invention relates to a device (100) for assembling layers of unit loads (220) from at least two rows (211, 212) of unit loads (200a, 200b), preferably for producing at least one stack of unit loads (230) with several layers of unit loads, the device comprising: - a transfer device (150) with a transfer surface (152) for assembling a layer of unit loads (220) from a number of unit loads (200a) of the first row of unit loads (211) and a number of unit loads (200b) of the second row of unit loads (212); - a first feed device (130) for feeding the first row of unit loads (211) to a first feed position (Z1) adjacent to a first side edge (155) of the transfer surface (152); - a sliding device (170) with a first pusher (172) which (172) is designed to push the first row of packaged goods (211) from the first feed position (Z1) to a first transfer position (U1) on the transfer surface (152);- a second feed device (140) for feeding a second row of individual items (212) to a second feed position (Z2), which (Z2) is adjacent to a second side edge (156, 157, 158) of the transfer surface (152) that differs from the first side edge (155); and - a second pusher (174) which (174) is configured to push the second row of individual items (212) from the second feed position (Z2) to a second transfer position (U2) on the transfer surface (152). Furthermore, a method for assembling layers of individual items is specified.