Lift Unit for Load Former Stack Formation
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Solution Overview
Problem
Conventional load formers require pits or elevated operator platforms to form stacks taller than 48 inches, and their cycle time is inefficient, leading to reduced throughput and difficulty in forming square stacks.
Innovation Solution
A load former with a cookie sheet and platform actuation system that allows for extended and retracted positions, enabling simultaneous operation and increased throughput without the need for pits or elevated platforms, and a lift unit for forming double-height stacks without additional infrastructure.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Length of moving object
If a conventional load former is used to form stacks taller than 48 inches, then the stack height can be increased, but pits or elevated operator platforms are required which increase device complexity and construction cost
Solution Approach 1:
The load former is divided into two separate platforms: a first platform for forming the base layer of bundles and a second platform for forming additional layers. This segmentation allows each platform to operate independently at standard heights, eliminating the need for pits or elevated structures while achieving greater overall stack height through vertical stacking of platforms.
Solution Approach 2:
Instead of increasing stack height by building vertically in a single location (which would require pits or elevated platforms), the solution transitions to a two-dimensional approach by adding a second platform that operates parallel to the first. This allows bundle layers to be formed on both platforms simultaneously and then stacked vertically, achieving height increase without infrastructure modifications.
2Ease of operation
If the support conveyor is lowered by more than the height of the layer of bundles to retract the cookie sheet, then the cookie sheet can be repositioned, but the cycle time increases reducing productivity
Solution Approach 1:
The cookie sheet is repositioned to the second position (over the support conveyor) before the support conveyor is lowered. This preliminary action allows the cookie sheet to be in the correct position for depositing bundles before the lowering action begins, enabling smoother coordination and reducing the total cycle time required for the retract and reposition operations.
Solution Approach 2:
The system uses coordinated dynamic movement where the cookie sheet position and support conveyor height are adjusted in a synchronized sequence. The cookie sheet moves to the second position while the support conveyor is at its initial height, then the support conveyor lowers as the cookie sheet deposits bundles, creating an efficient dynamic cycle that minimizes idle time.
3Reliability
If the operator is idle during cookie sheet retraction and support conveyor lowering, then the mechanical operations can be completed, but time is lost reducing throughput
Solution Approach 1:
The operator continues to perform useful actions throughout the mechanical cycle by preparing the next layer of bundles on the cookie sheet while it is in the second position over the support conveyor. This continuous useful action eliminates operator idle time, as the operator is always engaged in bundle preparation rather than waiting for mechanical operations to complete.
Solution Approach 2:
The operator prepares bundles for the next layer in advance while the current layer is being deposited and the mechanical systems are cycling. This preliminary preparation ensures that when the cookie sheet returns to the first position, the operator can immediately begin placing the pre-prepared bundles, maintaining continuous productivity without idle time.
4Adaptability or versatility
If bundles are arranged manually on the cookie sheet, then flexibility in arrangement is maintained, but the process is inefficient and difficult to form square stacks
Solution Approach 1:
The bundle arrangement process is segmented into two phases: initial manual placement on the cookie sheet for flexibility, followed by automated deposition onto the support conveyor for efficiency. The cookie sheet acts as a temporary organizing surface where bundles can be arranged flexibly, then transferred as a unit to the support conveyor, combining manual adaptability with automated efficiency.
Data Source
AI summary
A load former includes a frame including a stop wall, a cookie sheet having a top surface parallel to a plane and being movable between an extended position a retracted position relative to the stop wall, and a first platform shiftable between raised and lowered positions relative to the plane. The first platform is positioned relative to the frame such that when the cookie sheet is in the extended position a first portion of the cookie sheet directly overlies the upper surface of the platform and when the cookie sheet in the retracted position no portion of the cookie sheet directly overlies the platform. Also a lift having a lift support and a second platform, the lift being movable relative to the plane and the lift platform begin extendable and retractable relative to the first platform.