Load Former with Sliding Cookie Sheet and Front Access

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Solution Overview

Problem

Conventional load formers are inefficient in forming square stacks of paperboard bundles and lack accessibility for operators, as they require manual alignment and do not provide adequate safety measures to prevent accidental contact with moving parts.

Innovation Solution

A load former design with a frame that includes a sliding cookie sheet and a storage space accessible from the front, featuring a horizontal protective cover instead of a front panel, allowing for storage and work area functionality with optional slidable shelves and electrical connections, enhancing operator safety and efficiency.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If a front panel is provided to enclose the load forming area for safety, then operator safety is improved, but accessibility to the cookie sheet and loading zone is worsened

Engineering Contradiction:
Improveoperator safetyVSAvoidaccessibility to loading zone
Core Design Contradiction:
ReliabilityVSEase of operation

Solution Approach 1:

The invention removes the front panel entirely from the load former structure, extracting the enclosing element that was creating the accessibility barrier. The cookie sheet and loading zone are made directly accessible from the front side without any panel obstruction, while safety is maintained through the structural design of the cookie sheet retraction path and stop wall configuration.

Inventive Principle:
Principle #2Taking out (Extraction)

2Reliability

If the cookie sheet retracts completely into the frame for safety, then operator safety is improved, but the loading zone becomes inaccessible and operator efficiency is worsened

Engineering Contradiction:
Improveoperator safetyVSAvoidoperator efficiency
Core Design Contradiction:
ReliabilityVSProductivity

Solution Approach 1:

The cookie sheet is designed with dynamic retraction behavior - it retracts only to a controlled extent defined by the stop wall position rather than completely into the frame. This partial retraction dynamically balances safety (the sheet does not expose dangerous moving parts) with efficiency (the loading zone remains accessible for bundle placement). The stop wall acts as a mechanical limit that maintains this optimal dynamic position.

Inventive Principle:
Principle #15Dynamics

3Adaptability or versatility

If manual alignment of bundles is required to form square stacks, then flexibility in handling different bundle orientations is improved, but operator efficiency and productivity are worsened

Engineering Contradiction:
Improvehandling different bundle orientationsVSAvoidoperator efficiency
Core Design Contradiction:
Adaptability or versatilityVSProductivity

Solution Approach 1:

The load former structure provides self-aligning features through the stop wall and frame geometry that automatically guide bundles into correct orientations for forming square stacks. The mechanical structure itself performs the alignment function that would otherwise require manual operator intervention, thereby increasing productivity while maintaining the ability to handle different bundle types.

Inventive Principle:
Principle #25Self-service

Data Source

PatentUS11932500B2Load former having storage/work area
Publication Date: 2024.03.19 AG STACKER INC
  • US11932500B2 patent drawing
  • US11932500B2 patent drawing
  • US11932500B2 patent drawing

AI summary

A load former includes a frame, a loading zone bounded on a first end by a stop wall having a stop surface lying in a plane and a rear wall at a rear side of the frame, and a cookie sheet slidably supported by the frame for travel along a path perpendicular to the plane. The path includes portions on first and second sides of the plane, and a portion of the cookie sheet in the second portion of the path defines a bottom of the loading zone. A platform extends over the first portion of the path, and a top wall is vertically spaced from the platform to define a storage space between the top wall and the platform. The storage space has a front opening so that it is accessible from the front of the load former.