Metal Plate Supply Stacks for Space-Saving Thermal Machine Loading
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Solution Overview
Problem
Existing methods for storing and transferring different types of metal plates to a thermal processing machine are costly, space-consuming, and inefficient, particularly when multiple plate types need to be processed.
Innovation Solution
A method involving the chaotic storage of metal plates in two supply stacks, with each plate identified by type, and a process control system that determines the next plate type needed and rearranges the stacks to facilitate efficient retrieval and transfer to the machining table.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If metal plates of different types are stored separately in individual compartments of a rack, then the correct plate type can be easily retrieved, but the rack becomes expensive and space-consuming
Solution Approach 1:
The system divides plates into different types based on their properties (thickness, material, dimensions) and stores them in separate stacks within a single storage unit. The storage unit is segmented into multiple levels or positions, each capable of holding stacks of specific plate types, allowing efficient retrieval without requiring a large rack with individual compartments for each plate type.
Solution Approach 2:
The patent transitions from a two-dimensional rack structure with individual compartments to a three-dimensional storage system where plates are stacked vertically in multiple layers. The storage unit can hold multiple stacks of different plate types at different heights and positions, utilizing vertical space efficiently to reduce the overall footprint while maintaining easy access to different plate types.
2Adaptability or versatility
If multiple plate types are processed with the same thermal processing machine, then machine versatility is improved, but setup times increase and productivity decreases
Solution Approach 1:
The system performs preliminary sorting and stacking of plates by type before they are needed for processing. The storage unit is pre-organized with stacks of different plate types ready for retrieval. When a processing cycle is initiated, the required plate type is already prepared and can be quickly retrieved without delays for sorting or setup, thus maintaining high machine productivity while processing multiple plate types.
Solution Approach 2:
The system incorporates a control unit that tracks the processing status and plate inventory. Based on feedback from the processing requirements, the control unit can identify which plate type is needed next and ensure it is readily available in the storage unit. This feedback mechanism allows for optimized retrieval sequences and minimizes setup times between different plate type processing, maintaining high productivity across diverse plate types.
3Area of stationary object
If plates are stored in a compact manner, then space efficiency is improved, but access to specific plate types becomes more difficult
Solution Approach 1:
The storage unit is segmented into multiple independent stacks or positions, each dedicated to storing a specific plate type. This segmentation allows compact arrangement of different plate types in vertical stacks within a small footprint, while the organized structure enables quick identification and access to the required plate type without searching through mixed stacks.
Solution Approach 2:
The system employs a dynamic retrieval mechanism where the storage unit can adaptively provide access to different plate types. The control unit can direct the retrieval system to access specific stacks or positions based on the current processing needs, enabling efficient access to compactly stored plates of various types without requiring the entire storage unit to be accessible at once.
Data Source
Figure 1A~1B
Figure 1C~1D
Figure 2A~2B
AI summary
In order to provide a simple, cost-effective and space-saving method for transferring metal plates to the machining table of a thermal processing machine, the following process steps are suggested: (a) Identifying of each plate at least in terms of plate type, (b) Forming a chaotic first supply stack of plates, and storing information regarding plate type and stack position of said plates in the first supply stack in a storage by means of a process control, (c) Forming at least a chaotic second supply stack of plates, and storing information regarding plate type and stack position of said plates in the second supply stack in the storage by means of the process control, (d) Determining the plate type of the plate to be transferred to the machining table as next and selecting the first supply stack or the at least second supply stack for removal of a plate having the determined plate type by means of the process control, and (e) Picking up an upper plate from the selected supply stack by means of a gripper, and (i) transferring said upper plate to the machining table, if said upper plate is a plate of the determined plate type, and updating the plate type and position information in the storage by means of the process control, (ii) or transporting the upper plate of the selected supply stack to the respective other supply stack if the upper plate is not a plate of the determined plate type, updating the plate type and position information in the storage by means of the process control, and repeating process step (e).