Maglev Shuttle Layer Forming Table for Precise Palletizing
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Solution Overview
Problem
Existing apparatuses for forming product layers are complex, difficult to maintain, and pose safety risks due to numerous mechanical devices, while being unsuitable for processing loose items like bottles and jars.
Innovation Solution
A magnetic levitation system with shuttle members providing 6 degrees of freedom allows for flexible positioning and orientation of products on a static plane, simplifying the formation and maintenance of product layers with reduced mechanical complexity and enhanced safety.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If multiple mechanical devices (pusher, rotation means, handling means) are used to form product layers, then product positioning and orientation capability is improved, but device complexity and maintenance difficulty increase significantly
Solution Approach 1:
The patent replaces complex mechanical positioning devices with a robotic system that uses vision guidance and controlled movement to achieve precise product positioning and orientation, reducing mechanical complexity while maintaining or improving positioning accuracy
Solution Approach 2:
The robotic handling means is designed to perform multiple functions including picking, positioning, orienting, and placing products, replacing multiple specialized mechanical devices with a single multi-functional robotic system that reduces overall device complexity
2Adaptability or versatility
If multiple mechanical devices are used for layer formation, then product configuration flexibility is improved, but maintenance time and costs increase
Solution Approach 1:
The robotic system employs programmable motion paths and adjustable parameters that can be dynamically modified through software to accommodate different product configurations, eliminating the need for physical reconfiguration of mechanical components and significantly reducing maintenance requirements
Solution Approach 2:
The system achieves configuration flexibility by changing operational parameters such as robot motion trajectories, positioning coordinates, and orientation angles through software control, rather than through mechanical adjustments, thereby simplifying maintenance while maintaining adaptability
3Ease of operation
If movable mechanical parts are used in the forming area, then product handling capability is improved, but operator safety risks increase requiring additional protection systems
Solution Approach 1:
The patent replaces dangerous movable mechanical parts with a robotic system that can be easily enclosed and controlled, improving product handling capability while reducing safety risks through programmable motion and the ability to operate in enclosed spaces with automated safety protocols
4Manufacturing precision
If complex mechanical devices are used for layer formation, then product positioning accuracy is improved, but accessibility for operators decreases
Solution Approach 1:
The system uses vision systems to create digital representations of product positions and configurations, enabling precise positioning through software control while allowing operators to monitor and adjust operations from safe distances, improving both accuracy and accessibility
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The solution enables easy access, high flexibility in handling various products, reduced maintenance costs, and improved safety by using magnetic levitation to position and orient products efficiently, accommodating different product types and configurations.
Implementation Method 1
a magnetic field is applied, and which cooperates with permanent magnets that are built-in in corresponding shuttle members, to keep said shuttle members levitating above the surface of the static plane
Data Source
Figure 1
Figure 2a~2b
Figure 3
AI summary
An apparatus (100) for forming a layer (250) of products (200), in particular for palletizing, comprising a product feeder (3) adapted to transfer the products (200) to a layer forming table (1), wherein said products (200) are positioned and directed to form an exact status configuration (250) of products (200), characterized in that the layer forming table (1) comprises a static plane (10) onto which a magnetic field is applied, and which cooperates with permanent magnets that are built-in in corresponding shuttle members (2), to keep said shuttle members (2) levitating above the surface (10b) of the static plane (10) allowing to freely move said shuttle members (2) in the bidimensional space, each shuttle member (2) being configured to support a product (200), or a portion of product (200), or more than a product (200) contacting an engaging surface (200a) of the product (200) and said shuttle member (2) adapted to be arranged in an inlet zone (12) of the layer forming table (1) in the proximity of the product feeder (3) from which it receives said product (200) and to translate and/or rotate in order to place and direct said product (200) and to form the layer (250) in a preparation zone (13) of the layer forming table (1).