Automated Item Righting via Image Fingerprint and Rotary Transfer
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Solution Overview
Problem
Manual transfer of items from trays to item processing systems is time-consuming, imprecise, and can result in items being dropped or improperly aligned, leading to processing errors and delays, especially when items are not properly righted during transfer, causing dislodgment, bending, or damage.
Innovation Solution
An automated item processing system comprising a frame, source tray assembly, content transfer system, tray measuring device, and righting detection device, which includes intermediate and output rotary assemblies with movable fingers and a controller to detect tray presence, item quantity, and stack orientation, adjusting finger positions to transfer items efficiently and ensure proper alignment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If manual transfer of items from trays to item processing systems is used, then operator flexibility is maintained, but transfer time increases, precision decreases, and items may be dropped or improperly aligned
Solution Approach 1:
The system uses image capture devices and processing algorithms to automatically detect tray presence, item quantity, and stack orientation without human intervention. The rotary assemblies and finger mechanisms self-adjust based on detected parameters, enabling autonomous operation that improves transfer speed while managing complexity through automation.
Solution Approach 2:
Manual mechanical transfer operations are replaced with an automated system combining image capture devices, processing controllers, and mechanically actuated rotary assemblies with movable fingers. This substitution eliminates manual labor limitations while structured complexity through integrated sensor-actuator control.
2Reliability
If items are not properly righted during transfer, then transfer speed may be maintained, but items become dislodged, bent, or damaged
Solution Approach 1:
The system performs preliminary detection of stack orientation using image capture devices before the transfer operation begins. Based on detected orientation, the rotary assemblies and finger mechanisms pre-adjust to the appropriate configuration, ensuring items are properly righted during transfer without requiring post-transfer correction, thus maintaining both reliability and speed.
Solution Approach 2:
Image capture devices continuously monitor item orientation and stack configuration during transfer. The processing controller receives this feedback and dynamically adjusts finger positions and rotary assembly movements to maintain proper item alignment, preventing dislodgment and damage while adapting to varying item configurations in real-time.
3Manufacturing precision
If automated detection and adjustment mechanisms are added, then transfer precision and item protection improve, but device complexity increases
Solution Approach 1:
The rotary assemblies serve multiple functions: they transfer items between trays, adjust item orientation, and position fingers at varying distances based on detected item parameters. The movable fingers both detect item presence through image capture and physically manipulate items for proper alignment. This multi-functionality reduces the need for separate dedicated components, managing complexity while maintaining high transfer precision.
Solution Approach 2:
The system employs dynamically adjustable finger mechanisms that can move to different positions based on detected item quantity and orientation. Rather than using fixed-position components for each possible scenario, the dynamic finger adjustment allows a single versatile mechanism to handle varying item configurations, improving precision without proportionally increasing component count.
Data Source
AI summary
An automated system for transferring articles from a container. An item transfer system includes a source tray assembly, a translatable and rotatable intermediate rotary assembly, and a translatable and rotatable output rotary assembly. The system is configured to transfer articles from the tray to processing equipment by an automated process including rotationally transferring the articles from the tray to the intermediate rotary assembly and rotationally transferring the articles from the intermediate rotary assembly to the output rotary assembly. The output rotary assembly can move to align with a shelf or other input of the processing equipment and a paddle assembly can slide the items from the output rotary assembly onto the shelf or other input of the processing equipment.